LT106 - LT106S Instruction Manual (New addition).pdf

LOKOTRACK LT106 INSTRUCTION MANUAL 140561-EN

SAFETY INSTRUCTIONS

Safety instructions

Table of Contents INTRODUCTION 1.1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2

Definitions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

GENERAL SAFETY INSTRUCTIONS 2.1

SAFE PRODUCTS AND THE CRUSHING PLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 SAFETY AND YOU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.2.1 Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.2.2 Safety Signs, Labels And Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.2.3 Some General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.2.4 Blasting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 2.2.5 Portable Plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 2.2.6 Mobile Equipment Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2.3 TYPICAL RISKS IN CRUSHING PLANT WORKING ENVIRONMENT . . . . . . . . . . . . . . . 2-7 2.3.1 Typical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2.3.2 Typical Injury Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 2.4 PERSONAL PROTECTIVE EQUIPMENT AND CLOTHING . . . . . . . . . . . . . . . . . . . . . . 2-22 2.4.1 Hearing Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 2.4.2 Eye And Face Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 2.4.3 Respiratory Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 2.4.4 Foot Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 2.4.5 Head Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 2.4.6 Hand Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 2.4.7 Safety Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 2.4.8 Work Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 2.4.9 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 2.4.10 Safety Locks And Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

MACHINE SAFETY 3.1 PROTECTIVE DEVICES AND ACCESSORIES FOR MACHINE SAFETY . . . . . . . . . . . . 3-1 3.1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1.2 Emergency-Stop (E-Stop). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1.3 Safety Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1.4 Additional Warning Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.1.5 Walkways, Service Platforms, Ladders And Railings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.2

Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3

Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.4 At the work-site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3.4.1 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3.4.2 During operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

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Safety instructions

Table of Contents SAFETY DURING MAINTENANCE AND REPAIR 4.1

GENERAL INFORMATION AND SAFETY LOCKOUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 MECHANICAL SAFETY DURING MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . . . . 4-2 4.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.2.2 Fire Safety During Maintenance And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.2.3 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.2.4 Confined Spaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.3 ELECTRICAL SAFETY DURING MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . . . . . 4-4 4.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.3.2 Electrical Fault Situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 4.3.3 Program Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.4

HYDRAULIC SAFETY DURING MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . . . . . 4-6

4.5

GENERAL MAINTENANCE WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

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INTRODUCTION

SECTION

1

1.1 General

This manual, together with specific instruction manuals for individual equipment, has been prepared by Metso Minerals Crushing and Screening Business Line to increase the knowledge and awareness of all persons involved in the operation, supervision, service and maintenance of crushing and screening equipment with regard to safety and operations. A copy of this manual must be provided to and studied by each person entering the machine areas of the Crushing Plant, or otherwise involved in the operation of the Crushing Plant. It is the responsibility of the Owner to always keep this manual and other written instructions either in the Crushing Plant or its vicinity for Operator reference. Knowledge of the machines and the potential hazards they present are essential to a safe workplace. Knowledge of and compliance with all state, provincial, and federal safety laws, safety regulations, and Crushing Plant safety procedures, warnings and instructions also are essential to a safe workplace. Failure to do so can result in serious injury or death. When in doubt - don’t! Never bypass instructions or procedures to save time. Never place foreign items, tools, rods, or any part of your body into an operating machine. Never reach over, around or beyond safety devices. Never operate a machine if safety devices are missing or disabled. Never replace an OEM safety device with a non-OEM device.

Please read this manual carefully. Know its contents. If you have any questions, contact your Metso Minerals representative without delay for advice. Keep in mind that there are different types of risks, hazards and injury types (see Section 2.3 Typical risks in Crusher Plant working environment), which are related to each other. Foresee and prevent such risks and hazards as well as resulting injuries and other consequences from occurring by all available means. Never compromise when the question is about safety! Metso Minerals, as the machinery manufacturer and supplier, regards safety as of the utmost importance, and deems the following as essential prerequisites to the safe operation of the Crushing Plant: – That the Owner makes available this manual, before using the machinery, to each person involved with the operation, supervision, service, or maintenance of the Crushing Plant.

Never service equipment until all potentially moving parts are secured and power has been locked out and tagged out to prevent unexpected movement. The Operator is responsible for using care and common sense at all times. Remember, safety is everyone’s business. You are responsible not only for your safety, but for the safety of those around you.

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– That compliance with and adherence to this manual be mandated and supervised by the Owner. – That all personnel involved in the operation, supervision, service, or maintenance of the Crushing Plant

METSO MINERALS SAFETY INSTRUCTIONS 1-1

SECTION 1 - INTRODUCTION

become familiar with the contents of this manual prior to such involvement. – That every person involved in the operation, supervision, service, or maintenance of the Crushing Plant be properly trained and have adequate professional skills as required for the performance of the respective tasks.

programs. The information may also not include all practices that must be observed, such as insurance requirements or governmental regulations.

– That all visitors to the Crushing Plant be properly informed of applicable safety precautions and risks, and that safety precautions be adequately maintained and in connection with any such visits, including, but not limited to, adherence to this manual. No changes shall be made in the operation of the machinery supplied by Metso Minerals or the contents of this manual without express written approval of Metso Minerals. All operation, service, maintenance, handling, modifications, or other use of Crushing Plant equipment and/or systems is the responsibility of the Owner. Metso Minerals shall not be liable for any injury, death, damage or cost caused by any act or omission on the part of the Owner, Operator or other personnel, agents, contractors, vendors, or others. All applicable safety rules, regulations, standards, instructions, and procedures must be complied with; as must be those of this manual as well as any other instructions, specifications, and recommendations by Metso Minerals.

If you have questions or concerns regarding safety aspects of machinery supplied by Metso Minerals, contact us before using, operating, servicing or repairing the machinery. IMPORTANT! Safe operation of the machine requires alertness and safety-consciousness on the part of all operating personnel. It should be operated only by knowledgeable and trained personnel.

This manual is based upon the safety laws, rules and regulations in effect on the date hereof. The owner and operator bear sole responsibility for complying with any amendments, additions or other changes to safety law, rules or regulations arising subsequent to the date on which this manual was drafted. Although these instructions are intended to be as comprehensive as possible, there may be hazards that cannot be anticipated, hazards associated with a particular work-site or hazards covered by special comany safety

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1.2 Definitions:

“Crushing Plant” means a combination or part of various equipment, components, systems and parts for crushing and/or screening of rock, minerals, recycling or other crushable materials. For the purposes of this manual, the Crushing Plant means also stand-alone crushing or screening equipment as applicable. Throughout this manual, words such as “machine”, “machinery”, “equipment” and “crusher” are used interchangeably to refer to the Crushing Plant and its component parts. “Owner” means the entities or individuals who own or lease the Crushing Plant and/or the entities or individuals who are in charge of operating and/or servicing the Crushing Plant. “Operator” means the individuals who either operate the Crushing Plant or perform actual maintenance, service, repairs, supervision or any other activity on or for it. “This manual” means, as applicable, this general safety instructions, together with any specific instructions for individual equipment, as amended from time to time, provided by or on behalf of Metso Minerals.

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METSO MINERALS SAFETY INSTRUCTIONS 1-3

SECTION 1 - INTRODUCTION

This Page Left Intentionally Blank.

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GENERAL SAFETY INSTRUCTIONS

SECTION

2

GENERAL SAFETY INSTRUCTIONS FOR A CRUSHING PLANT OR PLANT ENVIRONMENT 2.1 SAFE PRODUCTS AND THE CRUSHING PLANT

2.2 SAFETY AND YOU

All machines require human involvement. Like any other heavy machinery, a Crushing Plant has inherent dangers that must be identified, understood and taken into account in order to avoid accidents and injuries. Metso Minerals, as machinery manufacturer and supplier, is committed to promoting safety at the Crushing Plant by providing safety devices and features, and by providing training, services, manuals and instructions.

Safety is everyone's responsibility; safety is your responsibility.

Safety is the concern of all personnel. With your actions, you participate in establishing the safety of the working environment. Metso Minerals products are designed and constructed with safety in mind. The machines incorporate high quality safety features used. To assure safe operation, all personnel must be alert when operating or working on or around the machine. Be aware of real and potential hazards. Only properly trained personnel should operate, supervise, maintain, or service the machine. Personnel must carefully study all aspects of the specific machine, including: – operating instructions – service, trouble-shooting and maintenance instructions – automated features and motions of the machine

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SECTION 2 - GENERAL SAFETY INSTRUCTIONS

– specific safety features and instructions

IMPORTANT!

•

If unsure of any procedure, check the operation manuals and/or contact your supervisor before proceeding.

•

Follow all lockout and safety procedures before entering the machine.

•

Be constantly aware of the location of each worker on or around the machine.

•

Observe all safety instructions.

•

Do not remove or disable any guard, safety device, sign or warning.

2.2.1 Objective

The objective of these instructions is to minimize risks and to avoid or prevent accidents and injuries. Accidents are often caused by carelessness or disregard of important instructions. Knowledge of the machine operation and continuous safety training are necessary for a safe working environment. Safety can be summarized in three main themes: – MACHINE KNOWLEDGE – SAFE OPERATION AND MAINTENANCE – GOOD HOUSEKEEPING

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SECTION 2 - GENERAL SAFETY INSTRUCTIONS

2.2.2 Safety Signs, Labels And Symbols

The following symbol is used in this manual and on the machine to call attention to instructions, which will help prevent machine related injuries.

DANGER

When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.

WARNING CAUTION Sign

Figure 2.1 Alert Symbol

This manual uses the alert symbol, with words such as DANGER, WARNING or CAUTION, to alert you and other Crushing Plant personnel of actions or conditions that pose a potential safety hazard, with an attending risk of personal injury (including death) or property damage. The machine also displays safety signs, labels and tags at appropriate points to show safety risks that may exist.

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Description Immediate hazards or unsafe practices DANGER that will result in severe personal injury or death. Hazards or unsafe practices that could WARNING result in severe personal injury or death Hazards or unsafe practices that could CAUTION result in minor personal injury or equipment damage Figure 2.2 Danger, Warning, Caution Signs And Their Meaning

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SECTION 2 - GENERAL SAFETY INSTRUCTIONS

2.2.3 Some General Safety Instructions

1. Do not remove, cover or disable any installed safety devices, guards, warning signs or tags. They are attached to equipment to warn personnel of possible danger and prevent injury. Use OEM replacements in the event any safety devices, warning signs or tags become damaged or unreadable. Observe all instructions. Keep warnings signs and tags clean, visible and readable. (Warning signs are listed and their locations described in the machine safety instructions.) 2. Make sure that all required walkways, handrails, barriers, safety devices, and guards are in place before starting the machine. Do not use non-OEM walkways, handrails, barriers, safety devices or guards, when such items are available from OEM. 3. Keep the machine itself and the area around the machine clean and clear of obstructions. Be aware of dust, smoke or fog, which may obscure your vision. 4. Wipe up any substance, such as spilled oil, grease, water or ice, which may cause a person to slip or fall. Good housekeeping practices prevent injuries. Be a good housekeeper. Keep the machine environment and walkways clean and free from oil, grease, rags, cables, chains, buckets, rocks and other obstructions. Keep loose parts in a toolbox or return them there promptly. 5. Keep clothing and all parts of the body away from nip points and rotating or moving equipment. Be especially alert to avoid contact with parts that move intermittently. 6. Know the weight limitations of lifting devices and their loads. Never detach a lifting device from a load until the load is stable and secured from unintended movement.

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METSO MINERALS SAFETY INSTRUCTIONS

7. Do not climb or stand on equipment other than in areas, which are designed for that purpose. Do not overreach. 8. Emergency-Stop buttons should be tested on a regular schedule for proper operation, as should electrical interlocks and related limit switches. Safety defects should be repaired prior to continuing operation, and thereafter tested and certified for appropriate operation by skilled personnel. 9. Personal protective equipment and safety uniforms, safety shoes, helmets, safety glasses, heavy gloves, ear protection devices etc. should be used at all times. Safety shoes should be used by all personnel entering into the Crushing Plant. Persons with loose clothing, neck ties, necklaces, unprotected long beard or long hair should not go near the machine. Wrist watches and rings can be dangerous.Rings should be removed or covered with tape. Keep your pockets free of loose objects. 10.Keep all non-operating and non-trained personnel clear of the Crushing Plant at all times. Injury or death may result if this is not done. 11.The equipment at the control panel should be handled with care. Do not place objects on the keyboard, color display or other equipment. All equipment can fail if put in contact with liquids, or excessive heat or excessive humidity. Allow good air flow around the equipment at all times. Keep magnets away from computer components, particularly hard drives and PLC cabinets. 12.A knowledgeable and properly trained Operator familiar with this manual, safety requirements, and automatic operation of the machine should be stationed at the controls whenever the machine is operating.

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SECTION 2 - GENERAL SAFETY INSTRUCTIONS

13.Do not consume any alcoholic beverages or other intoxicants before coming to work or while on the job. Do not operate the Crushing Plant after taking any medicines, tranquilizers or other drugs, which can impair the senses. 14.Familiarize yourself with the safety signs on the Crushing Plant. Never remove or damage any safety signs, nameplates or other safety related warnings, symbols or components. Replace them as necessary with OEM equipment. 15.Do not paint over safety signs, name plates or warnings.

2.2.4 Blasting

The use of the Crusher Plant’s radio control device is strictly forbidden during blasting operations, as it may cause a premature explosion. Move the mobile Crushing Plant far enough away from dangerous area when blasting. Do not store or transport explosives on mobile crushing plant or screening plants.

WARNING:

2.2.5 Portable Plants

Only qualified and properly trained operators and servicemen should operate or service the machine. Everyone else should stay clear of the machine when it is operating, or under service or maintenance!

If the Crushing Plant includes of portable equipment (i.e. crushing and screening equipment mounted on trailers), trailer footing or cribbing is extremely important for safe operation. Your machine must be on as solid and level footing as possible. If the ground is not naturally level, it must be leveled so that the unit will operate safely and effectively. The ground must support the weight of entire unit and keep it from sinking or shifting. Use heavy timber mats as needed. Trailers must be raised so that trailer wheels do not touch the ground. Place jacks at each corner of the trailer or as near the corner as possible and to other suggested support points at mid-frame. All corner jacks must be at an equal distance from each end. Adjust each jack until the unsupported portion of the trailer beams stops vibrating or until vibrations are reduced to a minimum. Lock jacks and adjustable support legs mechanically with locking pins when applicable. Periodically recheck trailer footing for stability.

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SECTION 2 - GENERAL SAFETY INSTRUCTIONS

2.2.6 Mobile Equipment Transportation

Remove all shipping brackets before re-starting the Crushing Plant. Carefully assemble all of the parts previously disassembled. Perform any start up in accordance with the instruction manual.

Use only appropriate transportation and lifting equipment with adequate capacity. Provide a supervisor to direct lifting operations. Follow all disassembly and assembly instructions carefully. Disconnect all external power supplies before moving any part of the equipment.Transport or hoist components and handle any parts in accordance with the instructions and advice provided. Fasten the lifting equipment only to the points meant for lifting. Use only proper means of transport with adequate transporting capacity. Fasten the load carefully. For lifting use only the fastenings shown in instructions. Secure all component parts of the equipment immediately after loading to avoid any accidental shifting. Attach required warning signs to the load.

After the system is running, check all gauges and instruments to see that they are working correctly. Check that all controls function normally and properly. Listen for unusual noises. Shut system down immediately if any component of the system does not operate normally.

When moving your trailer, check bridges before crossing. Make sure they will support the weight of the machine. Check clearances under bridges, for overhead lines or any overhead obstruction. Never travel with near capacity loads. Check local laws, especially on weight limitations. When travelling on the highway make sure all headlights, clearance lights and tail lights are on, as applicable. Use proper traffic warning flags and signs.

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2.3 TYPICAL RISKS IN CRUSHING PLANT WORKING ENVIRONMENT

– sharp edges – high-pressure hydraulic equipment – electrical equipment – automatic functions and unexpected start-ups – toxic and corroding agents – machine inertia – hot surfaces and fires – zinc

Even though every Metso Minerals machine is designed with many safety features, it is impossible to design out all safety risks. There are potential hazards, that must be recognized and avoided. Noise levels may interfere with normal discussion when the machine is operating. By their nature, Crushing Plant and auxiliary equipment can create dust. Crushing itself and some other machine processes may momentarily obstruct the view of some machine parts. In general, high levels of respirable silica and other dust in the air may expose Operator to health risks for lung disease depending upon the length and amount of exposure and type of material being crushed. In addition, there are some risks or hazards which cannot be completely guarded or avoided because of interference with machine operations. Accordingly, working on the Crushing Plant requires constant alertness by all personnel in the area. Accidents happen unexpectedly. Below are some typical hazards and types of accidents that everyone working at, on or around the Crushing Plant should be aware of.

– conveyor belts – dust – noise and vibration – improper work methods – rotating equipment and moving components – ejection of material from the crusher – falling material from conveyors, and from loading, unloading and feeding operations – crushing cavity These typical hazards are discussed more fully in Section 2.3.1 of this chapter. Be aware of these hazards. All personnel working on or around the machine should be properly trained in avoiding these hazards. Typical Injury Types

Typical Hazards

– crushing – slipping, tripping and bumping – falling

– nips, gaps, and pinch points

– cutting

– poor housekeeping

– entanglement

– elevated or narrow working areas

– burns and electrical shocks

– lifting and shifting heavy loads

– respitary organ illnesses

– cranes and mobile cranes

– asphyxiation

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2.3.1 Typical Hazards

ladders and floors. Tidiness provides a safer working environment by preventing or helping reduce tripping, slipping, fire hazards and electrical shocks.

Nips, Gaps, and Pinch Points

Elevated or Narrow Working Location

An ingoing nip is formed by drive devices such as belt and pulley, chain and sprocket or gears. Similarly, a pinch point may be formed by rotating or moving equipment. DANGER:

Nips and gaps are serious hazards in a Crushing Plant. They are usually guarded by nip guards, railings, or location. In all cases, extreme care must be taken to avoid nips, gaps, and pinch points or serious injury or even death may occur.

Crushing Plants are tall structures. The walkways and platforms, designed to be used during machine operation, are furnished with railings to help prevent falling. When working on an elevated surface be aware of machine movements and other activities in the area. Do not run on the walkways. Do not reach over or beyond walkway railings while the machine is running. Do not stand on railings or toe plates.

Poor Housekeeping

There may be narrow access routes for maintenance purposes. Do not use these routes while the machine is operating. Do not enter any close quarters within the Crushing Plant when the machine is operating. Promote good housekeeping. Keep machine environment, walkways, platforms etc. clean and dry and free of debris. Oily or wet machine environment, walkways, platforms, steps and hand rails are slippery. In cold weather, watch out for ice and snow. Wet spots, especially near electrical equipment, are dangerous. Return tools to their proper place after use. Even then extreme caution should be used. Follow established Crushing Plant safety procedures. Clean slippery deposits from walkways,

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Lifting And Shifting Heavy Loads IMPORTANT!

•

When using a crane, always operate within the rated capacity of the crane. The safe rated capacity includes weight of hook, block and any materials handling devices such as cables, slings, spreader bars, etc. Subtract the weight of all these items from the rated capacity to find the true weight of the load that can be handled safely. Always follow the crane manufacturer's operational and safety instructions.

Cranes

Crushing Plants, like any other type of mechanical equipment, require regular periodic maintenance. One of the most flagrant Crushing Plant safety violations is the use of inadequate and unsafe lifting equipment. Although a Crushing Plant is a finely tuned piece of equipment, the internal parts of a Crushing Plant should be assembled and disassembled with crane facilities that have the capability of gently and slowly lifting and lowering the various parts that make up a Crushing Plant. Do not use chain hoists (chain blocks) to assemble or disassemble a Crushing Plant. These lifting devices lack the stability and robustness required in lifting and positioning heavy components. Do not use impact hammer boom or any other equipment which are not designed for lifting, for assembly or disassembly purposes. Affix the load securely to its destination. Never detach a lifting device from a load until the load is stable and secured from unintended movement. When it comes to safety, don't compromise!

IMPORTANT!

The weight indicated in machine plates tells the weight of standard configuration. In many cases the actual weight may differ greatly from that indicated in machine plate due to, e.g., options or ancillary equipment. Always verify the weight of the object you are lifting before attempting to lift it.

•

Mobile cranes

Safe ratings are based on operating the crane on firm, level ground; outriggers must be properly extended and/or lowered whenever required. Avoid fast swings, hoists or sudden braking; these can cause overloads. Do not handle large, heavy loads in strong winds. When moving your crane, check bridges before crossing, make sure they will support the total weight in question. Check clearances under bridges for overhead electrical lines and any overhead obstruction. Be sure your hitcher is clear before starting lift. Make sure the load is securely attached. IMPORTANT!

When using a mobile crane, always operate within the rated capacity of the machine to avoid buckling the boom or tipping.

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Sharp Edges Take the following precautions when lifting heavy loads: – Follow all established Crushing Plant procedures. – Follow all instructions and safety procedures recommended by the crane manufacturer. – Plan the lifting and maintenance procedures in advance. Read and understand specific instructions for proper use of lifting equipment prior to using (e.g instructions of the machine, lifting device and local regulations).

Sharp edges may occur on any metal structures. Equipment damage may uncover or produce unexpected sharp edges. Sharp edges may inflict deep and serious cuts. Wear protective gloves when handling materials, parts, etc. with sharp edges. Repair or guard detected sharp edges immediately.

– Clean the working environment beforehand to prevent slipping and tripping hazards.

High-pressure Equipment - Hydraulic or Air

– Make sure that the crane and other lifting devices such as chains and slings have sufficient capacity and are in good working order. – Do not attempt to ride or sit on moving loads. – Be sure that crane operators, riggers and other personnel have been properly trained. – Rig the load firmly to prevent any unintened movement and assure stable and accurate positioning. – Make sure nobody is below or on the path of the load and that the transfer routes are clear and proper protective clothing and gear are used.

High pressure oil can be dangerous. Relieve all pressure before opening or removing any hydraulic or air pressure lines, valves, fittings, etc. Do not touch pressurized components since the pressure from a pin hole leak is so strong that it can easily penetrate the skin or eyes. Always exercise caution when handling hydraulic devices. Regularly check the condition of hoses, pipes, valves and various connections. Replace them as necessary. Before starting any maintenance work, stop all hydraulic pumps, lock out pump motors, and depressurize the system, bringing all components to a zero energy state. Remember to also depressurize the accumulators through

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the bleed valve for each accumulator. Do not disconnect any hoses until the actuator has been brought to a zero energy state and properly secured. Bleed the hydraulic system regularly to remove entrapped air that may interfere with normal expected machine operation or cause a hazard during maintenance. WARNING!

Poorly tightened or damaged hydraulic components may inject dangerous jets of fluid. Before restarting the machine, be sure that the hydraulic system is ready for operation, and personnel are clear of affected areas. WARNING!

Electrical Equipment

Be especially cautious when working with or near electrical equipment. An electric shock can be fatal. Crushing Plant electrical outlets must be grounded and have ground fault interruption protection. Tools plugged into the outlets must be double insulated. Never expose electrical equipment to mechanical damage or humidity. Protect all electrical equipment from direct contact with water or high humidity. Protect electrical devices that move as part of the machine from dirt and mechanical damage. Regularly check the operability of these devices.

Machine parts may move unintentionally and cause a risk of injury. Before restarting the machine, make sure that all personnel are clear of affected areas where machine movement may occur.

DANGER:

There is a risk of an electric shock, if sufficient precautions are not taken. An electric shock can be fatal. For maintenance work, disconnect all devices from electric and hydraulic power sources and follow Crushing Plant lockout procedures.

The lockout program, locks, tags and the blocking/restraining devices provided are designed for your protection. Your responsibility is to follow the program and use the proper equipment. Remember: – Follow procedures. – Stay alert. – Do not take anything for granted. – Verify lockout. – Each person working on the unit must have his own lock with only 1 key.

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– Tag must identify the work being done and the person(s) who locked and tagged the control. – Locks and tags are changed with each shift that comes on. Work to prevent injury or death. Follow proper procedures at all times!

WARNING:

Machine parts may move unintentionally and cause a risk of injury. Absence of safety functions may cause dangerous machine movements.

Maintenance, repair and installation of electrical equipment must be performed only by qualified personnel who are familiar with the machinery and equipment in question.

Do not tamper with limit switches or other safety devices included in the system.

Automatic Functions and Unexpected Start-ups

DANGER:

If danger zones are not respected during machine operation or maneuvres there is a risk of serious injury or death. Many devices operate automatically, following certain sequences which have been programmed into the logic system (i.e. programmable logic controller, microcontroller, relay system or similar). The danger zone is any area within the confines of moving machine elements, feed material or beneath any objects being lifted. Do not enter these danger zones unless the machine has been properly safeguarded according to the Crushing Plant lockout procedure and manufacturer's instructions.

Unexpected start-ups during maintenance: – Lock out and tag machine controls before performing maintenance or repairs to avoid unexpected start-up. Failure to properly lock out the machine can lead to injury or death. Someone may accidentally start the machine from the control room or an unexpected occurrence may activate a control. For example, a power surge may alter the logic of the control system status causing an unexpected machine movement or sequence.

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Welding Equipment IMPORTANT!

All maintenance personnel who use cutting and/or welding torches should be advised if there are hydraulic components in the immediate area in which they are working.

IMPORTANT!

Weld repairs are to be performed only by qualified personnel. Welders and welder’s helpers must wear protective clothing and equipment. Precautions must be taken when torch cutting and/or welding due to the health hazards posed by many metals. Anyone performing these types of procedures should avoid breathing the fumes. Such procedures should be done outdoors or in a well ventilated area with either a separate clean air supply provided to the mechanic or with local exhaust of fumes. Please refer to EU, OSHA, MSHA or other applicable standards as appropriate. One of the most frequently used tools around the Crushing Plant is the cutting torch. Crushing Plants which are equipped with hydraulic components and/or conveyor belts and/or v-belts should have these components depressurized and adequately covered with flame-proof material so that sparks, weld spatter, etc., cannot reach theses areas. Ruptured high pressure hydraulic lines will quickly vaporize the hydraulic fluid as it reaches the atmosphere. This vaporized fluid can quickly become a mass of flames, resulting in severe burns for personnel in the immediate area. Adequate precautions should be made to avoid contact with these components. Never perform welding or torch cutting activities in the presence of flammable materials. WARNING:

Risk of injury. Fire may break out. Never perform welding or torch cutting activities in the presence of flammable materials.

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Contact Metso Minerals or its authorized representative prior to any welding of major Crushing Plant components such as main frame, adjustment ring, bowl, etc. Performing welding on the Crushing Plant components can be detrimental. Before welding, always verify that material is weldable! Failure to do so may result in weldment failure and present a risk of injury and/or property damage.

Toxic, Corroding and Irritating Agents

Before handling chemicals, carefully read the safety instructions from the supplier of the respective chemical. Hazardous chemicals may be in use. Wear protective clothing, gloves, boots, glasses, and respirator when necessary. Refer to the MSDS (Material Safety Data Sheets) and Crushing Plant procedures for handling of these materials. Avoid prolonged contact with fluids, such as gasoline, diesel fuel, hydraulic oil and cleaning solvents, which may cause skin irritation or other reactions.

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Machine Inertia

Due to the large inertial forces of the Crushing Plant and Crushing Plant components, the machine can not be stopped abruptly. This is potentially hazardous to personnel. All personnel must stay clear of rotating elements and other moving parts until the machine has come to a complete stop. Regularly inspect the structural elements to maintain safe operation. Hot Surfaces and Fires

There are hot surfaces on Crushing Plants. Protective gloves and coveralls help protect against burns. Be aware of hydraulic system, hoses, fittings, and pipes. Regularly inspect and observe high temperature lines, and fluid lines for leaks or damage. On mobile equipment be cautious around the engine because of exhaust gases.

In case of a fire, the machine must be equipped with a fire extinguisher or fire extinguishing system, and marked according to the regulations. Legislation and regulations about suitable equipment may vary by country. Familiarize yourself with applicable standards. Personnel must also be trained properly to be able to use fire extinquishing equipment. A trained person with sufficient fire extinguishing equipment must be present during welding maintenance work. Cold water on hot metal surfaces may cause a violent explosion. Monitoring after welding must be arranged as required by laws and regulations. If no other regulations apply, monitoring time is a minimum of one half hour. Fire Hazards

When in contact with hot temperatures, or when heated themselves, some hydraulic oils may ignite at around 392°F (200°C). Attention must be paid to the condition of hydraulic hoses and couplings. Remove immediately oil spills from floor, walkways, and pits. Fix all sources of oil leaks and clean up spills.

– Do not smoke while refueling, or when handling fuel containers. – Shut off engine when refueling and use extra caution if engine is hot. – When pouring fuel into the tank, ground the funnel or spout against the filler neck to avoid static electric spark.

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– Do not use gasoline or diesel fuel for cleaning parts. Good commercial, nonflammable solvents should be used. – Do not smoke while using flammable cleaning solvents. Whenever possible, use non-flammable cleaning solvents. – Do not let greasy, oily rags accumulate in a poorly ventilated area. Store oily rags and other combustible material in a safe place.

completely eliminated the possibility of workers being accidentally burned due to molten zinc either spilling or exploding when it comes in contact with wet surfaces. When epoxy backings are used, care should also be taken when removing the liners with a cutting torch . Do not use molten zinc as backing material. Use epoxy only according to specific instructions from the manufacturer. Conveyor Belts

– Never use an open flame to check fuel, battery electrolyte or coolant levels, or to look for hydraulic leaks anywhere on the equipment. Use a flashlight. Know where fire extinguishers are kept, how they operate, and for what type of fire. Check regularly, at least monthly, to be sure they are in the working area. – Do not weld or cause open flame in the presence of flammable materials.

WARNING:

Do not use conveyor belts as walkways. Do not climb on them. Always stay clear of any falling or dropping materials or components. Never attempt to stand on, walk on, or step across a conveyor. Never stand below a running conveyor. Do not use loose clothing, neck ties, necklaces or other loose items when near conveyors or other moving or rotating equipment. Emergency pull cords should be used only in case of emergency -do not use them for routine stoppage of conveyor. Never attempt to service the conveyor while it is energized. Keep in mind hazardous nip points.

– In the event of a fire, shut down the Crushing Plant, hydraulic power unit and lubrication system if this can be safely done. Warn other people in the area and commence fire fighting activities according to applicable rules. It is the responsibility of the Owner to maintain proper training and instructions in these respects. Epoxy Versus Zinc

Many Crushing Plants require some type of backing when replacing the crushing members. Epoxy resin backing compounds have almost

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Crushing Plant Dust IMPORTANT!

Metso Minerals highly recommends that dust protective devices such as an appropriate respirator be worn by anyone exposed to airborne dust to prevent its inhalation.

WARNING:

By their nature, Crushing Plant and auxiliary equipment such as chutes, transfer stations, screens, etc. can create dust and, if not contained, the dust can escape into the air. In general, high levels of dust (particularly, respirable silica) in the air can create a hazard of lung disease, depending upon the concentrations of dust, the length of exposure, and the type of material being crushed. Dust protective devices and dust warnings may be required by OSHA, MSHA or local laws.

Breathing dust may be hazardous to the health of anyone working at, on, or around the Crushing Plant. It can cause serious or fatal respiratory diseases including silicosis! It is the responsibility of the Owner and Operator to determine the necessity and adequacy of protective devices and warnings, to provide them, and to ensure that they are used and followed!

The Owner and Operator of the Crushing Plant must identify the material being crushed and ascertain whether respirable dust from the application poses a health hazard to personnel in the vicinity of the Crushing Plant.If the material presents such a hazard the Owner and Operator must take all necessary measures to ensure that personnel are protected from the dust. Such measures include, but are not limited to providing dust collection system, using water spray bars at the feed and discharge points, crusher transfer points and screens and providing adequate personal respiratory protection devices to workers. Crushing with a choke level may also reduce the amount of dust issuing from the Crushing Plant itself. Because the configuration of each rock crushing installation is different, Metso Minerals recommends that the Owner and Operator consult Metso Minerals or a dust consultant about possible alternative means of dust reduction.

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Noise and Vibration

is an increased risk of falling on a vibrating platform. Avoid standing on a vibrating Operator's platform or walkway. Unexpected or excessive vibrations may be a sign of wear and/or maintenance needs. Excessive vibrations associated with a portable crushing or screening plant is frequently caused by improper cribbing.

•

Crushing Plant Noise

Crushing Plant by its very nature is noisy and the auxiliary equipment found at, on or around the Crushing Plant such as chutes, transfer stations, screens, etc., can at times be noisier than the Crushing Plant itself. Typical Crushing Plant noise level while crushing range from 100 - 110 dB measured at 1 m (3ft) from the Crushing Plant.

It is recommeded to regularly monitor vibration levels of machine components including, but not limited to: – bearings – shafts – rollers – structural members (including conveyor frames, walkways, platforms, hoppers, chutes, etc.)

Metso Minerals recommends wearing ear protection at, on and around Crushing Plant, particularly when the noise level exceeds 85dB. It is recommended that the Owner develop a signaling communication system in noisy environments to reduce the risk of accidents. Proper machine maintenance and replacement of worn parts can help reduce noise. The most commonly applied noise reduction procedures are: – use of isolation techniques – equipment enclosures – operator enclosures – silencers Allowable noise levels and exposure limits are regulated by various agencies such as ISO, OSHA, MSHA, etc. Refer to applicable safety regulations for permissible noise exposures, and take steps to ensure compliance with those regulations. •

Vibration

Long term exposure of Operator to vibration may result in detrimental health effects.There

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Improper Work Methods

typically checked with a tachometer. Make sure that any access openings have a protective cover in place at all times except when RPM readings are being taken. Never change sheave combinations without first consulting your Metso Minerals representative. Ejection of Objects from the Crushing Plant

Improper work methods and motions may cause physical injuries. Use suitable tools, cranes or jacks for moving large and heavy objects. Overreaching and improper support for loads may lead to injuries to the back or other parts of the body. If you are unsure of proper work methods, contact your safety director or other person responsible for ensuring the safety at your work place.

Ejected objects from the Crushing Plant may cause bodily injury. For example rock can be thrown several meters (several yards) into the air out of the crushing cavity during operation. Ejected materials may include rock, tramp metal, metal rods and work implements. Do not look into crushing cavity while crusher is in operation. Never attempt to clear jam on feeder, crushing cavity or conveyors when system is energized.

When lifting equipment by hand, protect your back by lifting close to your body and using your legs without twisting. Use hoists whenever possible. Stand clear of hoisted loads and lifting cables. Rotating Equipment and Moving Components

Rotating and moving components provide pinch points, snagging possibilities and other potential hazards. Keep clear of all moving parts until they come to a complete stop. Do not use any body part, tool or other foreign object to attempt to stop, adjust, clear, or clean any area in proximity to moving equipment such as vibrating feeder, conveyor belts, drives or other rotating parts of the crusher. Engaging in such activities can result in severe personal injury, including death. Crushers, designed to operate within a specific RPM range for maximum efficiency, are

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2.3.2 Typical Injury Types

Falling Material from Conveyors, Loading, Unloading and Feeding Operations

Crushing In general, avoid areas where you may be exposed to expected or unexpected machine movements. Crushing injuries typically occur either between two rotating or moving parts, or between a moving component and a stationary object.

Rocks or other objects may fall from conveyors during loading, unloading and feeding operations. Impact of falling material may cause serious bodily injury. To assure safe operation, all personnel must be alert when operating or working at or around the machine. Wear proper protective clothing (including also helmet) and protective devices. Keep all non-operating and non-trained personnel clear of the Crushing Plant at all times.

Keep all body parts, clothing and tools away from areas where they may get trapped, pinched, or crushed, or otherwise come into contact with moving parts on the Crushing Plant. When moving equipment, be sure the path is clear. Horns and lights, where provided, are for your safety to alert you of moving objects. Pay attention to all such devices. Slipping, Tripping, and Bumping

Never walk under any equipment included in loading, feeding, crushing, conveying, discharging or stockpiling material.

Items such as hoses, tools, etc., on walkways and Crushing Plant floors impede movement and create a tripping and slipping hazard. Good housekeeping reduces the risks considerably. Personnel should wear safety shoes that reduce the risk of slipping and provide protection against falling objects or crushing. Hydraulic oil leaked or spilled on the floor must be cleaned up immediately. To help avoid injury, be aware of parts positioned close to the floor level or protruding machine components, changes in elevation of platforms, walkways, and narrow access points. It is recommended that safety shoes be worn at all times. Wear safety helmets and other safety equipment as appropriate.

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Falling

Cutting

Do not reach in or enter: Use only designated access routes designed for the purpose, for example walkways and platforms. Walkways and platforms are furnished with railings designed to meet applicable standards. However, in some work phases, railings or platforms may have to be temporarily shifted aside. In those cases, special caution signs or temporary barriers must be used when working on the machine. Use personal fall protection gear , temporary barriers, interlocks, or other warning devices where appropriate. Never attempt to operate, service, or repair the Crushing Plant without first ensuring proper protection against falling. Guards that are moved aside must be installed immediately after maintenance work and before the machine is returned to operation. Never climb or stand on areas of the Crushing Plant not specifically designated for that purpose. WARNING:

Do not operate any equipment until all guard rails and safety devices have been re-installed or returned to their proper operating condition. Failure to do this could result in serious injury or death.

– the movement paths of cutting equipment – between moving machine components – between moving loads and machine structures Entanglement

To avoid entanglement, avoid wearing loose clothing that could be caught by rotating shafts, conveyors, and other moving parts .and materials. Remove neckties, necklaces, rings, and other jewelry before performing work assignments. Also protect a long beard or hair from entanglement. Do not touch a rotating roller, sheave, pulley, idler or moving conveyor belts with any body part or work implement, as you may become entangled and pulled into a hazardous area. Never attempt to service, repair, or troubleshoot any moving part of the Crushing Plant while it is energized or otherwise capable of movement. WARNING:

KEEP THE AREA CLEAN!

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Keep safety gates, shrouds, guards, and other protective devices in place and in good working condition at all times. Test emergency stop, electrical interlocks, and related limit switches frequently.

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Burns and Electrical Shocks

from the path of ejected materials, also during lifting, assembly and dissassembly operations. Removal of tramp iron jammed between the crushing members is extremely dangerous. Follow the instructions in the instruction manual. Do not look into crushing cavity while crusher is in operation.

Protective gloves and coveralls help protect against burns. Be cautious around and near hydraulic system hoses, fittings and pipes. Regularly inspect and repair leaking or damaged high temperature lines and fluid lines. To avoid electrical shocks: – Power must be shut off and locked out before any servicing or maintenance work is done. Unplug or disconnect all auxiliary motors and equipment. – DO NOT drill blindly into beams, electrical cabinets or other enclosures. Avoid any contact between moisture or other fluid and electrical equipment. Impact from Ejected Materials

There are several hazards related to falling, flying or otherwise ejected materials when the Crushing Plant is being operated or serviced. For example, rock can be thrown several meters (several yards) into air out of crushing cavity during operation. Ejected materials may include rock, tramp metal, metal rods and work implements. Keep the safety grate down during the operation. Wear proper protective clothing (including helmet) and protective devices. Always use properly maintained and approved tools and work methods. Stay clear

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2.4 PERSONAL PROTECTIVE EQUIPMENT AND CLOTHING

appropriate hearing protection of the type and to the extent required by law.

Personal protective equipment and clothing such as foot protection, helmet, hearing protection, dust protective devices, safety glasses or other personal protective clothing and equipment should be worn at all times. All equipment should be maintained in accordance with applicable standards. Respirators, goggles, protective masks, gloves, boots, and other such equipment shall be cleaned and disinfected before being used by another employee. The Owner and Operator are responsible for ensuring that all eye, head, respiratory, and ear protection conforms to applicable standards.

2.4.2 Eye And Face Protection

General requirements should include:

IMPORTANT!

Always use right size of protective equipment.

– The Owner should ensure that personnel for the machine area use appropriate eye or face protection when exposed to eye or face hazards such as flying material, molten metal, liquid chemicals, acids or caustic liquids, chemical gases or vapors. – The Owner should ensure that affected personnel use eye protection that includes side protection from flying objects.

IMPORTANT!

– The Owner should ensure that affected personnel who wear prescription lenses while engaged in operations that involve possible eye hazards wear eye protection that incorporates the prescription in its design, or wear eye protection that can be worn over the prescription lenses without disturbing the proper position of the prescription lenses or the protective lenses.

It is the responsibility of the Owner and Operator to determine the necessity and adequacy of protective devices and warnings, to provide them, and to ensure that they are used and followed.

2.4.1 Hearing Protection

Noise level in the machinery area may exceed 85 dB, and exposure to the machinery area in such circumstances without adequate hearing protection may lead to hearing loss. Therefore, users must be provided with

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2.4.3 Respiratory Protection IMPORTANT!

Metso Minerals highly recommends that adequate dust-protective devices such as a respirator be worn by anyone exposed to airborne dust, particularly silica dust, to prevent its inhalation. Respiratory protection is required when the air contains contamination such as harmful dusts, fogs, fumes, mists, gases, smokes, sprays, or vapors. The primary objective is to protect the health of workers.

2.4.4 Foot Protection

Respiratory protection must be provided by the Owner when such equipment is necessary to protect the health of personnel. The Owner shall provide the respiratory protection and training programs, which are applicable and suitable for the purpose intended and comply with the latest requirements and recommendations of health authorities and regulatory agencies. IMPORTANT!

The enormous degree of convenience as well as the high safety factor involved when using plastic backing agents has made the use of molten zinc for Crushing Plant liner backing obsolete. See 2.3.1

The Owner shall ensure that affected personnel use protective footwear when working in areas where there is a danger of foot injuries due to falling or rolling objects piercing the sole, and where feet are exposed to electrical or chemical hazards. 2.4.5 Head Protection

IMPORTANT!

The area should be well ventilated. Epoxy fumes can cause nausea or eye or skin irritation. IMPORTANT!

Breathing dust may be hazardous to the health of anyone working at, on, or around the Crushing Plant.

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The Owner should ensure that affected personnel wear a protective helmet approved by OSHA, MSHA (or by other applicable authority) when working in areas where there is a potential for head injuries from falling objects or walking throughout areas with low head clearance. The Owner should ensure that a protective helmet designed to reduce electrical shock hazard is worn by personnel when near exposed electrical conductors which could contact the head.

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2.4.6 Hand Protection

The Owner should ensure that personnel use properly sized appropriate hand protection when hands are exposed to hazards such as those from skin absorption of harmful substances, cuts or lacerations, abrasions, punctures, chemical burns, thermal and electrical burns, and harmful temperature extremes. 2.4.7 Safety Harnesses

2.4.9 Tools

The Owner should ensure that personnel use appropriate tools for the job. Use tools that are specially designed to break away or are easily released to help avoid certain accident situations such as unexpected movement at a nip point or a rotating shaft. Under no circumstances must tools be allowed to come into contact with moving parts while the Crushing Plant is energized. When working in humid or damp environments, use hydraulic tools or electrical tools that are suitably grounded, double insulated, or have ground fault interruption circuits.

The Owner should ensure that any person working on elevated areas not protected by railings, or on hazardous places must wear suitable safety equipment, including safety harnesses, if there is a risk of falling. Confined spaces may also require safety harnesses. 2.4.8 Work Clothing

The Owner should ensure that personnel wear appropriate clothing to help protect against hazardous material and hot surfaces. Loose clothing can get caught in a nip, shaft, or other moving machine components.

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2.4.10 Safety Locks And Tags

Follow all lock-out tag procedures. Refer to appropriate standards and instructions provided by Metso Minerals. DANGER:

For maintenance work, disconnect all devices from electric power sources. Bring all hydraulic gravity or spring loaded devices to a zero-energy state. Follow lockout procedures.

The lockout program, locks, tags and the blocking/restraining devices provided are designed for Operator’s protection. Operator’s responsibility is to follow the program and use the proper equipment. Remember: – Follow procedures. – Stay alert. – Do not take anything for granted. – Verify lockout. – Tag must identify the work being done and the person(s) who locked and tagged the control. – Locks and tags are changed with each shift that comes on. Work to eliminate injury and death. Follow proper procedures at all times!

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MACHINE SAFETY

SECTION

3.1 PROTECTIVE DEVICES AND ACCESSORIES FOR MACHINE SAFETY

3

The location of local E-stop buttons may vary on different machines; therefore the locations of these buttons must be verified from the operating and maintenance manuals specific to the equipment and/or from proper training.

3.1.1 Overview

The machine system has many built-in safety features. Owners and Operators should make themselves familiar with the function and purpose of each feature and make sure all of the features are enabled. Owners and Operators should never attempt to defeat, bypass or disable any safety features. If any of the features are defeated or become disabled, the machine should not be operated until corrective action is taken and all safety features are restored.

In emergency stop situations, the objective is to stop the machine as soon as possible to minimize potential injuries while maintaining the structural integrity of the machine. CAUTION:

Emergency stop not only stops the machine but often it may initiate other protective sequences.

3.1.2 Emergency-Stop (E-Stop)

NOTE: It may be necessary to engage

reset switches before movement can resume. 3.1.3 Safety Interlocks

Use the emergency stop when injury may occur or human life is in danger from continued operation of the machine. This provides the quickest, most sure way to stop the machine. Due to the large inertial forces of the Crushing Plant and Crushing Plant parts and components, the machine can not be stopped abruptly. Large red emergency stop buttons are typically located in control panels near the vicinity of danger points. Emergency stops can be, and often are, in the form of pull cords that run paraller to conveyors and surround hazards. WARNING:

On large complex systems, the E-stop may control only those components that are in the immediate area.

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A safety interlock is a device that will interrupt the supply of electricity, hydraulic oil or compressed air to an actuator or motor. A machine already in operation may need to stop quickly due to Operator error, safety violations, or an unexpected machine event. For example, a safety gate may be interlocked to stop a machine if the gate is opened while the machine is running. Interlocks can also be used to prevent sudden unexpected movement of a machine function or component. During operation, the logic system (i.e. programmable logic controller, microcontroller, relay system or similar device) controls the functions of the machine. Interlocks built into the system employ limit switches and other sensors to help assure proper machine operation.

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The pilot-controlled throttle valve helps prevent uncontrolled actuator movements.

THEREFORE IT IS IMPORTANT THAT INTERLOCKING ARRANGEMENTS ARE NOT REMOVED, MODIFIED OR BYPASSED, AND THAT THEY ARE CORRECTLY ADJUSTED. LIMIT SWITCHES, AND OTHER SENSORS MUST BE KEPT IN GOOD WORKING ORDER.

Pressure transducers monitor the system pressure for information or control purposes. Safety Gates

Electric Motors

Some safety gates are designed so that opening or closing of the gates will prevent or stop a specific machine function in that area. Hydraulic, hydraulic or electric limit interlock switches may cut off the drive or actuator power or initiate an emergency stop mode.

Electric drives and motors may be controlled to stop or reduce speeds, as determined by the safety interlocks at a particular location. Hydraulic System

For specific operation, see later sections of this manual. WARNING:

Components that help protect the hydraulic system include certain valves, such as hose burst valves, pressure relief valves, counterbalance valves and pilot-controlled throttle valves as well as pressure transducers and drain valves for pressure accumulators. Metso Minerals uses these components where applicable in the hydraulic systems to minimize the potential for hazardous situations to occur. A hose break valve functions to lock up if fluid flow is discharged too rapidly from an actuating cylinder, as happens if a hose breaks and the loads react to gravity. The pressure relief valve prevents the system pressure from rising beyond system capabilities. It helps protect the entire fluid system and any operators in the vicinity from bursting hoses and components.

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Safety gates must not be opened during normal machine operation. Exceptions to this rule are defined in the operating instructions.

Safety gates may also be opened for maintenance purposes when the machine has been stopped. Follow all lockout procedures. Cable Switches

Cables or ropes connected to the electrical switches can be used as interlocks also. They may stop machine function in areas where control panels cannot be closely located but where Operators may be working . Know the locations of e-stop pull cords for conveyors.

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3.1.4 Additional Warning Devices

Horns and Lights

If visual contact between work places is obstructed or if communication is difficult, sound and/or light signaling devices may be used before starting the machine or a machine function. The warning device for start-up should operate so that personnel are given sufficient time to move to a safe distance from the machine. It is the responsibility of the Owner to ensure that the Crushing Plant is always equipped with required horns and lights. Safety Signs and Labels

3.1.5 Walkways, Service Platforms, Ladders And Railings

The design of walkways, ladders and railings follow standards and regulations for the application. The walkways provide access to the machine. Safe operating procedures must be followed when on walkways. Never stand, walk or climb in or on any area of the Crushing Plant not designated for such activity. If an area of the Crushing Plant must be accessed and cannot be reached by designated walkways, ladders, or platforms, then the Owner and Operator must make all necessary arrangements for safe access to the area, including but not limited to safe lifting devices and fall protection. CAUTION:

Extreme caution must always be used on machine walkways.

Safety signs have colors to determine the degree of hazard in particular areas. These signs must not be removed. Temporary placement of safety signs and danger tags should also be used on the control panels to warn of maintenance work and lockout situations. Obey all warning and safety signs on the machine and in the manual. Safety Warning Colors Color of safety warnings are typically safety yellow.

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METSO MINERALS SAFETY INSTRUCTIONS 3-3

SECTION 3 - MACHINE SAFETY

3.2 TRANSPORT

3.4 AT THE WORK-SITE

Observe the following precautions before transporting the Crusher Plant:

3.4.1 Precautions

1. Chock chassis tires securely whenever connecting or disconnecting chassis from tractor or dolly. 2. Check tire pressure. Use a protective cage or a clip-on type air chuck and remote in-line valve and gauge when inflating tires. Never exceed maximum inflation pressures of the tire or rim. 3. Check tightness of wheel lug nuts before transport and check frequently during transport.

Observe the following minimum precautions at the work-site: 1. Know the locations of underground and overhead powerlines and other potential hazards. 2. Select the work-site with care. The ground must be firm, level and able to support the weight of the entire plant. Make sure there is enough room for loading ramps, loaders, conveyors, etc. and for safe maneuvering of trucks and loaders.

4. Check that brake system operates correctly.

3. Check that cribbing is secure and that plant has not shifted or settled.

5. Observe maximum axle and tire loading capacities.

4. Make sure that electrical cables are protected from wear and traffic.

6. Protect components being transported using appropriate shipping braces and blocking material.

5. Follow pre-operation checks and start-up procedure covered in the individual manual supplied with your specific unit equipment

7. Travel may be limited to daylight hours only, depending on your specific plant and applicable state regulations. 8. Follow recommended limits on towing speed. 9. Make sure all lights are on and that they are operating correctly. 10. Use traffic warning flags, signs and lights as required. 11. Before moving the Crushing Plant, check all roadways and bridges on the route for weight limits. 12. Check clearance of bridges, overhead lines and other overhead obstructions. 13. Follow all applicable laws and regulations. 3.3 TOWING

Observe the following precautions before towing the Crusher Plant or its components: –

3-4

Check if towing is allowed for each individual equipment.

METSO MINERALS SAFETY INSTRUCTIONS

3.4.2 During operation

Keep watch Do not rely too much on automated systems. Observe Crushing Plant equipment while the system is running. Pay attention to unauthorized persons approaching the site as well as any unusual behavior of the equipment (uncommon noise, vibration, smell, reduced output, etc.). Clearing Crushers Plant equipment can become plugged and stall because of power failures, surges of material or other unplanned events. Clearing Crusher is potentially very hazardous. Shut down the system completely, lock and tag out all applicable controls and follow all instructions in the instruction manual of your specific crusher.

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SAFETY DURING MAINTENANCE AND REPAIR 4.1 GENERAL INFORMATION AND SAFETY LOCKOUTS

Detailed instructions for the operation of the machine can be found in following sections of the manual. Because each machine section may incorporate unique functions, some of which may be automated, maintenance personnel should be knowledgeable of the operation of the machine sections in order to perform the maintenance and repair work as safely as possible.

SECTION

4

– Never service any machine or component without first referencing its maintenance manual. – Before handling chemicals, refer to the MSDS (Material Safety Data Sheets) and Crushing Plant procedures for handling of these materials.

DO NOT COMPROMISE SAFETY DUE TO TIME PRESSURES. FOLLOW ALL CRUSHING PLANT SAFETY AND FIRE PREVENTION PROCEDURES. Before starting any repair, maintenance or troubleshooting work on the machine, ensure the following: – If you have not been trained to perform the required repairs, maintenance or troubleshooting, or you are unsure how to safely perform the activity - STOP! Never attempt to repair, maintain or troubleshoot any aspect of the Crushing Plant unless you are thoroughly trained for the activity and understand how to perform the activity in a safe manner. – Be sure to coordinate all repair and maintenance work with other Crushing Plant operations. – Use lockout and warning signs to inform others that maintenance and repair work are in progress. These signs should only be removed (after all work has been completed) by the person who has placed them there. – Transmit all knowledge of the maintenance work to the succeeding shift. – Know the whereabouts of all personnel in, on, at and around the machine.

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METSO MINERALS SAFETY INSTRUCTIONS 4-1

SECTION 4 - SAFETY DURING MAINTENANCE AND REPAIR

4.2 MECHANICAL SAFETY DURING MAINTENANCE AND REPAIR

4.2.1 General

DANGER: FOLLOW ALL ESTABLISHED LOCKOUT PROCEDURES. REFER TO THE APPROPRIATE STANDARDS.

For repair, maintenance or troubleshooting work, disconnect all devices from electric, pneumatic and hydraulic power sources and follow lockout procedures.

IMPORTANT!

Be sure all mechanical components are brought to a zero energy state including all spring driven devices, cylinders, accumulators, drive shafts, pulleys, rollers, gears, etc., prior to entering the machine and performing the work. Never attempt to perform repair, maintenance, or troubleshooting work on or in proximity to energized mechanical components.

IMPORTANT!

Block up and support parts as necessary to prevent any unexpected motion when performing maintenance.

The lockout instructions, locks, tags and the blocking/restraining devices provided are designed for your protection. Your responsibility is to follow the instructions and use the proper equipment. Remember: •

Follow procedures

•

Stay alert

•

Do not take anything for granted

•

Verify lockout

•

Tag must identify the work being done and the person(s) who locked and tagged the control.

•

Locks and tags are changed with each shift that comes on.

Work to eliminate injury and death. Follow proper procedures at all times!

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SECTION 4 - SAFETY DURING MAINTENANCE AND REPAIR

4.2.2 Fire Safety During Maintenance And Repair

– Protect yourself and others from sparks with proper personal protective equipment and clothing.

4.2.3 Preventive Maintenance

Observe all regulations on fire safety. Sources for fires include, but are not limited to the following: – sparks from grinding – flames and molten metal from welding or torching – electrical arcing – spontaneous combustion – smoking. Before starting any work take the following steps to prevent a fire hazard:

Preventive maintenance will both increase safety and be economically beneficial. It is more safe and economical to replace a worn part during a scheduled shut-down than to repair a broken device in the middle of a production cycle. A machine or device that is not in proper condition, and that has been left without regular maintenance and inspections, is a safety risk for its user. For instance, without lubrication a bearing may fail, bringing a production line down. Furthermore, the hot bearing may present a fire hazard or cause skin burns. Some preventive maintenance suggestions for a machine include:

– Properly dispose of rags with combustible material to avoid spontaneous combustion.

– observing the maintenance and lubrication instructions of the machine and equipment suppliers

– Move flammable materials 10 m (33 ft) or more away from any fire hazard.

– keeping the machine and surrounding area clean and orderly

– Clean up all oil spills and leaks.

– monitoring the vibration levels of the machine and to help predict bearing failures

– Remove any source of flammable gases, liquids or solids.

– monitoring the power consumption of motors to help detect early failures

– Use proper electrical grounding techniques for welding.

– repairing all leaks as soon as possible to prevent more serious conditions that eventually may occur

– Clean up all debris.

– Provide adequate fire extinguishing equipment; inspect such fire equipment regularly. – Arrange for qualified personnel to guard against fire while welding, cutting, or heating operations are being performed, as well as a sufficient period of time after the work is completed.

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– monitoring the condition of pipes and tubes enclosed in ducts; repairing possible leaks

METSO MINERALS SAFETY INSTRUCTIONS 4-3

SECTION 4 - SAFETY DURING MAINTENANCE AND REPAIR

4.2.4 Confined Spaces

A confined space means a space that: 1. is large enough and so configured that a person can enter and perform assigned work; and

4.3 ELECTRICAL SAFETY DURING MAINTENANCE AND REPAIR

4.3.1 General

DANGER:

2. has limited or restricted means for entry or exit (for example, the crushing cavity, tanks, vessels, silos, storage bins, hoppers, vaults, and pits are spaces that may have limited means of entry.); and

Follow all established lockout procedures. For maintenance work, disconnect all devices from electric, pneumatic and hydraulic power sources and follow lockout procedures.

3. is not designed for continuous employee occupancy.

The lockout instructions, locks, tags and the blocking/restraining devices provided are designed for your protection. Your responsibility is to follow the program and use the proper equipment.

Certain confined spaces may require an entry permit program to allow entry. Be sure that all applicable procedures are followed. If you have questions contact your Crushing Plant supervisor for more information.

Remember: DANGER:

•

Follow procedures

Confined spaces may contain high concentrations of gases which may cause injury or death. Follow all established safety procedures.

•

Stay alert

•

Do not take anything for granted

•

Verify lockout

•

Tag must identify the work being done and the person(s) who locked and tagged the control.

•

Locks and tags are changed with each shift that comes on.

Work to eliminate injury and death. Follow proper procedures at all times! Be sure all electrical components are brought to a zero energy state including capacitors and similar electrical devices. Before maintenance work:

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SECTION 4 - SAFETY DURING MAINTENANCE AND REPAIR

– Be sure all control power supplies are turned off, disconnected, and lock out procedures have been followed.

4.3.2 Electrical Fault Situations

– Confirm that ALL power sources are disconnected. Some electrical devices may be supplied by more than one power source.

Diagnostics are provided through pilot lights, alarms, and help messages.

Electrical faults may be caused by component failures such as loose or damaged wiring.

IMPORTANT!

– Be aware that multiple voltage levels may exist in some junction boxes. – Ensure that during lockout procedures, locks and signs are appropriately attached, and subsequently removed only by the person who installed them after all work is completed. Follow Crushing Plant lockout instructions for placement and removal. – For testing and troubleshooting, clear all personnel from the machine just as though the machine were being returned to production mode. Reactivate the necessary power supplies and perform the tests. Then again disconnect all power supplies and follow lockout instructions before further maintenance work is performed. – Be sure electrical supply voltage is disconnected before drilling into any structural frame members. Electrical cables may be inside.

Electrical connections can and do loosen due to vibration in transit and thermal expansion of the wires and lugs in operation. This is especially trua after initial delivery, break in and after major relocation. Loose connections increase current draw, which can result in false trips, intermittent circuits, and burned-out components. As part of the start-up, check and retighten as necessary all electrical connections in the elctrical enclosure. Repeat after the first forty to fifty hours of operation. This work must be performed by properly trained personnel.

IMPORTANT!

Improper phasing will damage backstops in conveyor drive reducers and may damage hydraulic system components.

– Verify that electric motors are disconnected before starting any maintenance work, thereby preventing the supply of electricity to the motor. Generally the disconnects are located in the drive control room. Each person performing maintenance work should install their lock and sign the lockout tag.

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METSO MINERALS SAFETY INSTRUCTIONS 4-5

SECTION 4 - SAFETY DURING MAINTENANCE AND REPAIR

4.3.3 Program Changes

4.4 HYDRAULIC SAFETY DURING MAINTENANCE AND REPAIR

WARNING:

Changes to Metso Minerals' supplied control program should be made only by Metso Minerals personnel. Faulty program code may cause the machine to behave unexpectedly. Any changes to interlock circuitry must be made with extreme caution and be reviewed and approved in writing by Metso Minerals before implementation.

DANGER:

Follow all established lockout procedures. For maintenance work, disconnect all devices from electric, pneumatic and hydraulic power sources and follow lockout procedures.

An electric outlet may be supplied in the logic center and control cabinet for programming purposes only. Do not connect any electrical tools to this outlet. The tool may cause electrical disturbances in the machine control system. This could alter the machine control program and cause unpredictable machine operation.

The lockout instructions, locks, tags and the blocking/restraining devices provided are designed for your protection. Your responsibility is to follow the program and use the proper equipment. Remember:

NOTE: Do not use the logic center or control cabinet’s outlet for anything other than a programming device!

•

Follow procedures

•

Stay alert

•

Do not take anything for granted

•

Verify lockout

•

Tag must identify the work being done and the person(s) who locked and tagged the control.

•

Locks and tags are changed with each shift that comes on.

Work to eliminate injury and death. Follow proper procedures at all times!

Before proceeding with any repair, maintenance or diagnostic procedures on the hydraulic system, bring all components to a zero energy state, including cylinders,

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SECTION 4 - SAFETY DURING MAINTENANCE AND REPAIR

accumulators, spring loaded hydraulic devices, circuitry between valves and actuators, etc.

WARNING:

– Mineral and other oils and additives can cause skin irritation. Inhaled oil mist can also cause internal irritation, headache or nausea. Avoid repeated exposure to these materials. Use appropriate personal protective equipment.

Risk of personal injury due to high pressure fluid jets. Do not check for pressurized leaks with bare hands. Use cardboard or other appropriate techniques.

– Purge entrapped air from the hydraulic system. Entrapped air in the hydraulic system can cause erratic and unexpected movements. – Oil mist in the work area or oil leaking onto floors and walkways will cause a serious risk of slipping. Clean up all spills and repair leaks immediately.

Hydraulic hoses are subject to wear and tear. Pressurized hoses tend to straighten up, bend or twist due to reaction forces. Replace all weakened or deteriorated hoses promptly. Keep hoses properly clamped and secured to help prevent being whipped by broken hoses.

– Hydraulic oil temperature may be extremely high;

– When changing a cylinder, or other hydraulic device, plug all open ports and hose ends. Catch spilled oil in a suitable storage device and avoid introducing dirt into the system. Dispose of all waste fluids as presented by law.

WARNING:

Elevated temperatures levels can be hazardous and may cause severe burns. Wait until machine cools down before doing maintenance or repair.

– Tighten disconnected pipe and hose couplings immediately after reinstallation. Before finishing the work, check all parts and connections that have been serviced or repaired.

– A mixture of air and oil mist may explode at higher temperatures. Hydraulic oil spilled on hot machine surfaces may start a fire. – Pressurized hydraulic hoses should not be handled with bare hands since high-pressure leaks may easily penetrate the skin. Hydraulic fluid pressure in the hoses may exceed 3000 PSI/210 bar/21MPa.

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– Avoid letting dirt and other impurities into the system while doing maintenance work. Use lint free cloths for cleaning the hydraulic components system.

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– Before starting up the pumps, make sure that maintenance work is completely finished in all work areas. When starting up the pumps, stay at a distance from the areas which were repaired. – Before opening the main valves, make sure that there is no one working between any parts of the machine, since pressurization of the system may cause machine motion.

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SECTION 4 - SAFETY DURING MAINTENANCE AND REPAIR

– Once the system is in the pressurized state, test repaired system for proper operation before putting system back into production.

4.5 GENERAL MAINTENANCE WORK

The following are some of the do's and don'ts to be followed as part of normal Crushing Plant procedures

Check the system for possible leaks after repair. Leaking fittings must not be tightened when under pressure. To seal threaded fittings, use appropriate sealing rings or a sealing compound suitable for hydraulics.

– Do not perform any maintenance on moving machinery. This includes such items as adding lubricating oil or greasing parts while the crusher is in operation. – Never clear a jam on or in the feeder, crushing cavity or conveyors when system is energized. – Do not put hands or feet on the release cylinders, which protect the crusher from tramp iron overloads while the crusher is in operation. – Do check the manufacturer's recommendations for periodic maintenance procedures. These maintenance procedures are designed to not only avoid damage to the equipment but also to avoid harm to the Operator. – Do avoid spillage around the crusher. Operator should make it a habit to keep the area immediately adjacent to the crusher free from spillage, which could cause people to trip and fall. – Never look into the crushing cavity while crusher is in operation. – When using a crane or other lifting device to raise or lower a load keep all personnel clear of the area. – Never detach a lifting device from its load until the load is securely affixed at its designation, or steps have been implemented to prevent the load from unintended shifting or falling. – Never walk, stand, crawl or lay under any load hanging from a crane or other lifting device.

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LOKOTRACK LT106 INSTRUCTION MANUAL 140561-EN

LOKOTRACK LT106

CHAPTER

0

This instruction manual is valid for diesel engine driven Lokotrack LT106 manufactured by Metso Minerals. Lokotrack LT106 is a portable jaw crusher unit, which is intented to be used in recycling crushing applications in crushing plants.

Because of the continuous development of the product, the manufacturer reserves a right to alter the technical specifications written in this manual, without any advance information. This is the first edition published in July 2007 in Tampere, Finland.

Manufacturer: Metso Minerals (Tampere) Oy P.O. Box 306 33101 Tampere Finland Tel +358-204-84 142 Fax +358-204-84 143

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LOKOTRACK LT106 INSTRUCTION MANUAL

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CHAPTER 0 - LOKOTRACK LT106

This Page Left Intentionally Blank.

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LOKOTRACK LT106 INSTRUCTION MANUAL

0-108-EN

07/07

TABLE OF CONTENTS 1 PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

3 LT106 MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 MAIN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 DIESEL ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 CRUSHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 FEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 MAIN CONVEYOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 SIDE CONVEYOR (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 MAGNETIC SEPARATOR (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 HYDRAULIC CABIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 HYDRAULIC SETTING CONTROL (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11 FEED HOPPER FOLDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12 ENGINE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13 HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1 3-1 3-2 3-2 3-2 3-2 3-2 3-2 3-2 3-3 3-4 3-4 3-5 3-7

4 CONTROL PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 OPERATING PANEL SWITCHES/BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 DRIVE CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 DRIVING CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 REMOTE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 HYDRAULIC MODULE CENTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 IC500 CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1 4-1 4-2 4-2 4-3 4-4 4-5

5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.1 DRIVING-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.2 BEFORE STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.2.1 Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.2.2 Daily checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5.2.3 Preparing the equipment for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 5.3 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 5.4 CRUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 5.4.1 Before crushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 5.4.2 Restricted area during crushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 5.4.3 Preparing the crushing site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 5.4.4 Driving to the crushing site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 5.4.5 Measures before crushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 5.4.6 By-pass chute. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

5.4.7 Crusher speed selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 5.4.8 Feed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 5.4.9 Crusher setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 5.4.10 Clearing of the jammed main conveyor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 5.4.11 Removal of the steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 5.4.12 Crushing site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 5.4.13 Feeding measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 5.4.14 Recycling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 5.5 STARTING THE CRUSHING PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 5.6 DURING RUNNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 5.7 MOVING ON THE CRUSHING SITE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 5.8 STOPPING THE CRUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 5.9 SHUTTING DOWN THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 5.10 CONNECTING LOKOTRACK UNITS (INTERLOCK). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 5.11 USING THE PROCESS CONTROL SYSTEM (IC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 5.12 LEVEL DETECTOR AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 5.13 ENGINE PREHEATER (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 5.13.1 Setting the day of the week and the time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 5.13.2 Timer use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 5.13.3 Forced start (manual run) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

6 MOVING AND TRANSPORTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.2 MOVING ON THE SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.2.1 Some hints for turning the LT:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6.3 TRANSPORT FROM ONE SITE TO ANOTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6.3.1 Transport equipment needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6.3.2 Preparing for a transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 6.4 DRIVING ONTO/OFF A TRAILER TRUCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

7 CRUSHING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.1 CRUSHING LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.2 FEEDING MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 7.3 DISCHARGE ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 7.4 CRUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 7.5 BY-PASS CHUTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 7.6 FEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 7.7 MINIMUM SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 7.7.1 Feed material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 7.7.2 Setting adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 7.8 CLEARING OF THE BLOCKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 7.9 REMOVAL OF THE STEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 7.10 RECYCLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 7.11 OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

7.12 RADIO CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

8 LUBRICANT RECOMMENDATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.2 CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.3 FEEDER / SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.4 TRACK GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.5 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.6 HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 8.7 GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 8.8 FILLING VOLUMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

9 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9.1 PERIODICAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9.2 RUNNING-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 9.2.1 Hydraulic adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 9.3 FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 9.4 FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 9.5 CRUSHER SPACER REMOVAL & ASSEMBLY / TOGGLE PLATE CHANGE . . . . . . . . . . . 9-5 9.6 TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 9.7 ADDING FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 9.7.1 Adding hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 9.7.2 Adding Engine Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 9.7.3 Removing Engine / Hydraulic Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 9.8 ENGINE FILTER CHANGE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 9.8.1 Replacing the Engine Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 9.8.2 Replacing the Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 9.8.3 Engine Air Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 9.8.4 Fuel tank Breather change.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 9.9 REPLACING THE HYDRAULIC OIL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 9.9.1 Crusher Drive Pump Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 9.9.2 Device Pump Circuit Pressure Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 9.9.3 Device Pump Circuit Return Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

10 SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10.2 BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10.2.1 Fluid level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10.2.2 Battery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 10.2.3 Cleaning batteries, terminals and cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 10.3 OTHER ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 10.3.1 Charging circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 10.3.2 Starter circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

10.3.3 Fuse List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 10.4 WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 10.5 PRESSURE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 10.6 CRUSHER SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

APPENDICE Symbol Identification Additional information Noise levels Recycling

PREFACE

SECTION

This instruction manual is intended to assist owners and users of Metso Minerals products in the proper use of the equipment.

1

This instruction manual must be read and used by each person who works with the equipment, typically:

It includes important references to safe, proper and economical operation of the equipment. Following these instructions will help to avoid possible danger, reduce repair costs and breakdowns and to increase the reliability and life of the equipment.

–

operations, including installation, startup, operation, application engineering, materials handling, site labour, environmental engineering and safety departments.

This manual must be complemented by those instructions necessary because of existing national mandatory rules relating to accident prevention and environmental protection.

–

maintenance, including inspection and repair.

–

transport, materials handling and rigging.

A copy of this manual must be kept at the equipment's location and made available to the operators as required. In addition to this manual and accident prevention regulations mandatory in the country of use and at the equipment's place of operation, generally recognized rules for safe and professional operation must be observed.

Note that this instruction manual contains information and instructions on alternative and optional equipment. Normally the machines have only some of them. Before maintaining and servicing, find out which alternative and optional equipment your machine has. See separate instruction manuals for more detailed instructions when servicing the main components. There may be optional equipment which have separate instruction manuals. Those manuals must be read and used by each person who works with the equipment.

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SAFETY

SECTION

2

Please refer to the general Safety Instructions in Part A of this Instruction Manual folder.

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SECTION 2 - SAFETY

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2-2

SAFETY

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LT106 MAIN COMPONENTS

CHAPTER

3

3.1 MAIN ASSEMBLY

4

3

1

7

5

6 2

Reference 1 2 3 4

Description

Reference

Diesel engine Tracks Crusher Feeder

5 6 7

Description

Main conveyor Side conveyor (optional) Magnetic separator (optional)

Figure 3.1 Main assembly

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3.2 DIESEL ENGINE The operating power of the LT106 is generated from the Caterpillar diesel engine. The engine runs the hydraulic pumps.

3.3 TRACKS The LT106 moves with tracks. The tracks ensure safe and fast movements of the machine even in the rough terrain.

3.4 CRUSHER The Lokotrack C106 jaw crusher is the heart of the LT106. The crusher crushes the feed material into smaller pieces.

3.5 FEEDER The feeder ensures even and continuous material flow into the crusher. The feed material smaller than the opening of the feeder grizzly goes through the grizzlies passing the crusher. This increases the capacity and prevents material packing in the crusher.

3.6 MAIN CONVEYOR The main conveyor transfers the crushed material from the crusher to the stock pile or to the next process.

3.7 SIDE CONVEYOR (OPTIONAL) The optional side conveyor transfers the material that has passed the crusher through feeder grizzlies to the stock pile beside the machine.

3.8 MAGNETIC SEPARATOR (OPTIONAL) The optional magnetic separator is installed above the main conveyor. It separates magnetic objects from the crushed material and transfers those to a separate pile beside the machine.

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3.9 HYDRAULIC CABIN

7

10

13

8

12 14 15

9

11

16 17

18

1

2

3

4

5

6

LOCATION: on the left front side of the machine Reference

15 16

Right track - Control valve

8

Pressure gauge - device pump Screen module connector - Electrical connection point Socket for service light

Description C-jaw hydraulic setting adjustment valves High pressure water spraying pump (optional) Main conveyor - Control valve Hydraulic Power Take Off - Control valve and output socket Fast drive - Control valve (A -side) Magnetic separator - Control valve (B-Side) Left track - Control valve

17

9

Fuel filling pump (optional)

18

Feeder Side conveyor - Control valve (A -side) Hand valves - Control valve (B-Side)

1

Description Hand valve - Long main conveyor folding (option)

Reference 10

2

Not in use

11

3

Not in use Hand valve - Side conveyor folding up/down

12

4 5 6 7

13

Hand valve - Side conveyor folding in/out

14

Figure 3.2 Location of hydraulic valves

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3.10 HYDRAULIC SETTING CONTROL (OPTIONAL)

3.11 FEED HOPPER FOLDING

1

1

3

Reference Description 1 Left side wall lifting and lowering 2 3

4

2

Rear wall lifting and lowering Right side wall lifting and lowering

3 2

Reference Description 1 Manual valve 2 3 4

Return rod pressurizing Adjustment wedge movement Return rod pressure sensor Figure 3.3 Hydraulic setting control

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3.12 ENGINE MODULE

Figure 3.4 a) Engine module

1. Measuring points of the crusher

4. Oil fill port

a) Crusher drive pump return line (when crusher running to normal direction) b) Crusher drive pump charge pressure c) Crusher drive pump pressure (when crusher running to normal direction) 2. Engine primary fuel filter and water separator

5. Oil filter 6. Charger 7. Coolant expansion tank 8. Crusher circuit filter 9. Hydraulic pressure filter

3. Dipstick

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Figure 3.5 b) Engine module

1. Air cleaner

6. Hydraulic pressure filter

2. Air precleaner

7. Coolant expansion tank

3. Fuel filter, secondary

8. Batteries

4. Mechanical fuel transfer pump

9. Crusher circuit filter

5. Engine electronics

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3.13 HYDRAULIC TANK 1. Hydraulic return filter 2. Breather 3. Hydraulic oil sight glass

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CONTROL PANELS

CHAPTER

4

4.1 OPERATING PANEL SWITCHES/BUTTONS 1. Emergency stop

6. Process ON

2. Lubrication unit

7. Key switch

3. Radio key

8. Signal horn

4. Water pump

9. Process OFF

5. Display

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10. Work light

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4.2 DRIVE CONTROL BOX 4.2.1 DRIVING CONTROLS 1. Track, left-hand 2. Track, right-hand 3. RPM of diesel engine 4. Emergency stop

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4.3 REMOTE CONTROL 1. Emergency stop

7. Crusher start

2. Feeder stop

8. Crusher, counter-clockwise swing

3. Feeder start

9. Crusher, clockwise swing

4. Feeder speed -

10. Crusher setting - increase

5. Feeder speed +

11. Crusher setting - decrease

6. Crusher stop

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4.4 HYDRAULIC MODULE CENTER 1. Safety switch for conveyors 2. Fuel pump (optional) 3. Socket for screen module 4. Emergency stop 5. Hand valves

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4.5 IC500 CONTROL SYSTEM Please refer to a separate IC500 Instruction Manual for information on usage of this control system. The manual is attached to this Instruction Manual folder.

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OPERATION

CHAPTER

5

Daily procedure before startup

Figure 5.1 Before start up

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5.1 DRIVING-IN PERIOD

5.2 BEFORE STARTUP

Note the special service procedures that must be performed during the first 200 operating hours of the LT. Instructions for those measures are included in the service instructions chapter of the manual.

5.2.1 Refueling IMPORTANT! –

Shut down the engine or set it to idle while refueling.

–

Use only clean diesel fuel or engine fuel oil. Check the quality requirements for fuel from the instruction manual of the Caterpillar engine.

–

In cold operating conditions, note the low temperature properties of the fuel.

–

The fuel must be stored so that the it cannot be contaminated by water or impurities.

–

Replace the fuel filter frequently enough (see the servicing instructions). A clogged or damaged filter may reduce the engine capacity or damage the injection pump or injector nozzles. WARNING! Diesel fuel and engine fuel oil are flammable fuels. Do not smoke, light an open fire or generate sparks when fuel is being handled nearby.

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5.2.1.1 Refueling with an electric refueling pump 1. Switch the ignition on 2. Open the protective plug of the pipe fitting (1), clean the filling hose and the pipe fittings carefully and connect the charging pipe to the shut-off valve 3. Open the shut-off valve (2). The refueling pump does not tolerate running dry!

5

3

4. Turn the switch (3) to the right and turn on the refueling pump from the control switch (5). The pump stops automatically when the tank is full. 5. Turn the switch of the refueling pump (5) and the switch (3) to the “OFF” position. 6. Close the shut-off valve, remove the filling hose and install the shield plug of the pipe fitting.

Figure 5.3 Refueling pump switch on the auxiliary control panel

If the fuel flows poorly when refueling, the pressure filter (4) may be clogged. Replace the filter, if necessary. 5.2.1.2 Refueling through the filler cap When adding fuel through the filler cap (6), be careful not to let any dirt enter the fuel tank through the opened cap. Clean around the cap before opening it.

NOTE: If the selector switch (3) is switched ON for the hydraulic operation, the process is not able to start.

6

1

2

4 Figure 5.4 Fuel filler cap

Figure 5.2 Filling connections of the electric refueling pump

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5.2.2 Daily checks 1. Check the condition of the engine air filter and the sealing of the housing. The outer filter element must be replaced every 40...50 hours or weekly, depending on the operating conditions. The clogging indicator (1) of the air filter warns, if the filter is clogged, and the filter element (2) must be replaced. The safety element of the filter (3) must be replaced in conjunction with every third replacement. When replacing the elements, take extra precautions not to let any dust enter the intake channel.

3

1

Figure 5.5 Intake air filter of the engine

FULL

IMPORTANT!

2

Check that the clamps on the pipe of the intake air filter are properly tightened. If the tightening is loosen or insufficient, the engine takes air through the intake filter, which might damage the engine.

ADD

2. Check that the oil level of the engine is between the ADD and FULL marks on the dipstick. Add oil, if necessary. 3. Check that the coolant level is approximately 50 mm (2 in) below the sealing face of the refiller cap. Open the cap carefully if the engine is warm.

Figure 5.6 Engine oil dipstick

4. Check the fuel level from the process control system (IC) screen. 5. Check that the hydraulic shut-off valves (4) are opened. The engine will not start if a shut-off valve is closed.

4

WARNING! Do not open the cooler cap when the engine is hot.

Continued on the following page... Figure 5.7 Hydraulic shut-off valves

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6. Check the hydraulic oil level from the sight glass. Add hydraulic oil, if necessary.

IMPORTANT! Make sure that there are no leaks in the hydraulic system.

7. Check that the emergency stop button has not been pushed. If any of the buttons are in the down position, the engine cannot be started. 8. Check the possible alarm devices.

Figure 5.8 Sight glass for hydraulic oil

NOTE: When checking the hydraulic oil level, make sure that all hydraulic cylinder functions are in.

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5.2.3 Preparing the equipment for use 1. Lower the ladders of the working platforms to the down position. 2. Lift up the light pole. 3. Lower the side conveyor, and drive it into the operating position.

IMPORTANT! The side conveyor must not be switched on if it is in transport position Figure 5.10 Side conveyor location

Figure 5.9 Do not switch the side conveyor on while it is in a transport position.

4. Lift the side walls up. 5. Make sure that the unit is on even ground. 6. Make sure that the cavity is empty.

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5.3 STARTING THE ENGINE WARNING! Never use startup spray or similar to help the engine start, because it might cause a destructive explosion in the induction manifold.

4

1 2

WARNING!

3

Make sure that there is nobody on top of or near the LT. Alert everyone in the vicinity before starting the machine. NOTE: In cold weather (below +5 °C) (41 °F) use of the engine preheater (optional) is recommended before starting the engine. See the preheater instructions, page 5-25.

Figure 5.11 The startup buttons on the control panel

Read the previous paragraph first Before startup on page 5-2. 1. Make sure that the hydraulic shut-off valves are fully open. If the shut-off valves are not fully open, the position switch of the shut-off valves will cause an emergency stop function. See figure 5.12. 2. Switch the power on from the key switch (1) on the control panel by turning the key on position 1. Wait until the process control system starts up and the display panel (4) reports that it is ready to start (fig. 5.11). 3. Start the engine by turning the key switch (1): keep the key turned clockwise in position 2 for a couple of seconds. Release the key when the engine has started (fig. 5.11). NOTE: The machine gives a sound signal before starting the engine as a part of the startup sequence. 4. Monitor the display panel (4) after starting the engine. Observe the running of the engine and the pumps, and pay attention to any unusual noise, smoke or similar, and determine the cause (fig. 5.11).

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Figure 5.12 Hydraulic shut-off valve

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5.4 CRUSHING

5.4.2 Restricted area during crushing

5.4.1 Before crushing

WARNING!

Before starting the crushing, prepare the working site for crushing and perform the necessary inspections described in the next paragraps.

Before starting the crushing process and during the crushing, make sure that the restricted area is clear of people.

23000

R3

0 00

17000

3800

R

R3500

0 450

4700

Figure 5-13 Restricted area during crushing

5.4.3 Preparing the crushing site

IMPORTANT!

In order to ensure the efficient and safe operation of the LT, the crushing must be performed on as steady and as level a platform as possible. Apply a layer of crushed material on the crushing site and level the surface.

Before starting the machine, make sure that there are no personnel in the vicinity of the machine, whose safety may be endangered! Walk around the machine and make sure that there is no-one on, next to or under it. Before starting the machine, caution everybody in its vicinity that you are about to start the machine.

5.4.4 Driving to the crushing site

IMPORTANT!

Drive the equipment as instructed in section 6.2.

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Do not initiate the process before the feeder side panels have been raised in order not to damage the rubber rams!

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5.4.5 Measures before crushing 1. Check the tension of the crusher belts. The belt deflection must be 20 mm (D) when pressed with a force of 35-50 N (F) in the middle of the belt pulleys.

F

2. Check the condition of the crusher wear parts. 3. Check the oil level of the vibrators. The oil level of the vibrators is checked by opening the check nipple, located in the vibrating equipment. Make sure that a drop of oil comes out when opening the nipple. When checking the oil level make sure that the unit is on an even surface. Refer to a separate vibrating equipment manual.

D

Figure 5.14 Checking the tension of the crusher V-belts

4. Make sure that the bearings are lubricated in accordance with the instructions. 5. If the unit is equipped with a side conveyor, lower the side conveyor by the means of hand valves located in the hydraulic cabin (Refer to figure 4.11). –

Turn the side conveyor down

–

Erect the conveyor to it’s full lenght

–

Secure the side conveyor with swinging locks See figure 6.4.

Figure 5.15 Check the oil level of the vibrators

NOTE: If the side conveyor is not used in process, disable it from the IC control panel. NOTE: Make sure that the machine is always operated in a safe manner, and that it is in good mechanical condition. Make sure that the machine is firmly positioned and that there is no risk of its inclination. Operation of the machine is permitted only when all necessary protective and safety devices, e.g. guards, emergency stop devices, silencers, aspirators etc. are in place and in full operating condition. Continued on the following page...

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6. Lift the walls of the feeder to the up position, if they have been lowered to the transport position. a. Lift the side walls to the up position. b. Lift the end wall to the up position. c. Install the safety wedges to the locking position. Hit the wedges in with a hammer and tight the wedges on their place with locking nuts.

Lowers

NOTE: You cannot rise the side walls unless hydraulic hand valve switch 3 in the hydraulic control panel is switched to position “1”. It is strictly prohibited to use the process when the side walls are lowered. Continued on the following page...

Rises Figure 5.16 Riser wall control valves

B

A A

C

Figure 5.17 Driving the riser walls to the up position

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7. If the unit is equipped with an extended dicharge conveyor, proceed as follows. a. Activate the hand valves from the hydraulic cabin’s electric control box. b. Release the transport lockings. Lift the conveyor slightly to allow the removal of the locking pins. c. Turn the drive end of the conveyor into the crushing position. d. Reinstall the locking pins. e. Reset the trip wire switches. Adjust tightness if necessary. f. Secure the side rubber position at both joints.

Figure 5.18 Transport position

g. Deactivate the hand valve selector switch. When preparing the conveyor for transport, a. Activate the hand valves from the hydraulic cabin’s electric control box. b. Remove the locking pins (crushing position). Lift the conveyor slightly to ease the removal of the locking pins. c. Lower the conveyor drive head into the transport position. d. Mount the transport lockings. e. Deactivate the hand valve selector switch. Figure 5.19 Crushing postion

IMPORTANT! Observe great care when driving the unit onto the low bed due to the reduced ground clearance at the conveyor end.

IMPORTANT! Continued on the following page...

The LT must be on an even ground, before the discharge conveyor can be folded.

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8. Check that there is no uncrushed material left in the crusher. 9. Make sure that the whole length of the tracks is consistently on the ground in order to avoid excess vibration and swinging. 10. Check the spirit levels in the inner walls of equipment cabin to ensure that the LT is in the horizontal position.

NOTE: If the unit is equipped with a screen module, lower the screen module support legs down. Refer to screen module instruction manual.

Figure 5.20 Make sure that the crushing site is steady enough.

Figure 5.21 The spirit levels in equipment cabin

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5.4.6 By-pass chute Location of the by-pass chute hatch. The material flow that passes below the feeder grizzlies can be directed towards the main conveyor (fig. 5.22) or towards the optional side conveyor (fig. 5.23). With the optional screen deck, materials larger than the mesh openings can be directed towards the main conveyor (fig. 5.24). Turn the lever to change the direction of the material flow. When using the centre position, lock the lever in place using a bolt. Figure 5.24 The flow of materials has been screened and directed either to the side conveyor (pass-through) or to the main conveyor.

Figure 5.22 The chute has been directed towards the main conveyor.

Figure 5.23 The chute has been directed towards the side conveyor.

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5.4.7 Crusher speed selection NOTE: The feeder starts automatically when the process is started and stops when the process is stopped. If the hydraulic temperature of the unit is extremely cold (-5oC/23oF), the system will ask to carry out a cold start of the process. The feeder will not start until the temperature of the oil has reached a certain temperature.

The IC system of the Lokotrack controls the crusher speed. The crusher can run either on target speed or with a stabile fixed speed.

5.4.7.1 Target speed When the target speed is set on the IC system, the crusher tries to maintain the desired speed value by adjusting the control current to the crusher pump. Refer to the IC system manual for more details.

When the process is running and the feeder is in automatic mode, the IC controller adjusts the feeder speed according to the crusher and other device operations in the LT. The IC controller tries to keep the best and equal material flow to the crusher to prevent overfilling.

5.4.7.2 Stabile fixed speed When the target speed function is disabled the fixed control current can be used to drive the crusher. With this way of control, the IC system keeps the control current stabile all the time. Therefore it does not effect to the increasing and decreasing loads, which alter the speed of the crusher.

5.4.8 Feed control The feeder can be stopped and restarted again during the crushing process. The “feeder start” and “stop” buttons are located in the remote control box on the service platform. If the machine is equipped with a radio control feature (optional), the feeder can be started and stopped using the radio control feature. To stop and restart the feeder do the following: 1. Stop the feeder during the crushing process by pressing the "feeder stop" button. 2. Restart the feeder after it has stopped completely by pressing the "feeder start" button.

In order to stabilise the feed rate, the feeder always starts at minimum speed regardless of the speed setting. After a while the speed changes to the set value. In order to control the capacity, the feeder speed can be adjusted using the feeder speed +/- switch, but only in feeder manual mode. The switch is located in the control box on the service platform. The speed can also be adjusted by using the optional radio controller. NOTE: When the process is running, the automatic control controls the stopping of the feeder. The feeder will stop if the speed of the crusher decreases or the level indicator (optional) of the crusher indicates an alarm. NOTE: If the feeder speed is too high, stones may fall over the flanks of the hopper. NOTE: Radio control will by-pass the feeder controls located in the remote control box on the service platform. The best capacity can be reached by having the feeder remain running for as long as possible. An overfilled feeder will reduce the capacity and cause unnecessary wear.

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5.4.8.1 Feeder Automatic Control The feeder control mode can be either manual or automatic. The selection is done in the feeder parameter F5. Refer to the IC Instruction Manual for the parameter change. If manual speed is selected, feeder speed is controlled by a remote control housing or radio control. If the crusher operation pressure or speed exceeds the preset alarm values, feeder speed will automatically be reduced in prior to stop. It is recommended to use manual speed when the unit is followed with a secondary stage crushing or a screen. Feed rate does not fluctuate as much as with automatic feeder speed. It is recommended to use automatic feeder speed when material throughput fluctuation does not interfere the following process, eg. recycling. With automatic feeder speed the throughput of the crusher can be maximized.

5.4.10 Clearing of the jammed main conveyor NOTE: Never try to clear the blockage with excavator. If the conveyor stops, follow these instructions: –

Stop the process immediately.

–

Clear the jammed main conveyor as well as possible. When most of the material is removed, the main conveyor can be started by using a manual lever in the hydraulic valve manifold.

NOTE: Do NOT use this method if the rock is too big to pass under the magnetic separator! Use the hook to remove iron bars and wires. Be very careful not to hurt yourself. Never use hook when the machine is running.

5.4.8.2 Feed Material Refer to the C-Jaw instruction manual for the feed material.

5.4.9 Crusher setting The crusher setting is the most important crusher parameter since it determines the crusher's capacity as well as the top size of the crusher product. It is therefore indispensable for everyone to understand how the crusher setting is measured.

5.4.11 Removal of the steel Always stop the machine (feeder, crusher, conveyors and engine) before removing metal from it. Make sure that the machine can not be started when removing metal from it.

Refer to the C-Jaw instruction manual for setting measurement

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5.4.12 Crushing site The unit should be located near the material pile to make loading easy and quick. Shape the feed material pile with a wheel loader or excavator so that it is distributed over a small area and piled high enough for easy loading (fig. 5.25).

The place where the crusher is to be located must be even. The machine must not be allowed to sway. The surface below the crusher must be levelled and evened out. Spread some fine-grained material on the ground, distributing it evenly (fig. 5.27). Next, harden the underlying ground by driving the unit back and forth over the site (fig. 5.28).

Figure 5.25 First shape the material pile

The location of the discharge pile must be chosen so that it doesn't cause any danger to workers or passers-by. Make sure that there is enough space for the discharge pile, the discharge machinery (wheel loader or excavator) and the lorry (fig. 5.26).

Figure 5.27 Spread some fine-grained material on the ground and even it out.

Figure 5.28 Strengthen the underlying ground by driving the unit back and forth over it. Figure 5.26 General measures taken on the site.

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During the crushing process, make sure that the unit is in horizontal position. The maximum inclination allowance is 1 degree in lateral direction and 2 degrees in longitudinal direction (fig. 5.29 and fig. 5.30). For purposes of maintenance, it is recommended that you dig a hole under the unit (fig. 5.31).

Figure 5.29 The maximum lateral inclination permitted during the crushing process is 1 degree.

Figure 5.30 The maximum longitudinal inclination permitted during the crushing process is 2 degrees.

Figure 5.31 Dig a hole under the unit for maintenance purposes.

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5.4.13 Feeding measures

If the feed material contains metals, someone should stand next to the feeder and remove the metal pieces before they are able to enter the crusher.

5.4.13.1 Loading Equipment The unit can be loaded with the help of either an excavator or a wheel loader.

• •

LOADING USING AN EXCAVATOR

The unit can be loaded from the side or the rear. Find a suitable loading site and move the excavator bucket to its loading position. Then drive the unit into a suitable position below the excavator bucket. The operator of the excavator must have full visibility to the upper part of the feeder (fig. 5.32).

LOADING USING A WHEEL LOADER

The unit can only be loaded from the rear. The maximum bucket width is 2400 mm (95") for standard-size hoppers. In the case of 6 m3 hoppers, the maximum bucket width is 3200 mm (126"). If required, use the feed material to make a loading ramp to ease access to the feeder. Drive the unit as close to the pile as possible to make loading quick and easy. NOTE: The feeder has two basic applications: a. stabilising the feed rate b. separating the fine material before it enters the jaw crusher. If the feeder is too full, it will not separate the fine material, which in turn will result in decreased operating capacity. NOTE: Do not drive the excavator bucket into the material or try to force the material into the jaw cavity.

Figure 5.32 The operator of the excavator must have full visibility to the upper part of the feeder.

NOTE: Keep feed gate closed during operation.

Load the material into the rear end of the feeder, on top of the solid base (fig. 5.33). WARNING! When the impactor crusher is fed from rear, the crusher rotor might shoot the feed material directly backwards if e.g. the protective chains / rubbers are worn.

Figure 5.33 Load the material into the rear of the feeder, on top of the solid base.

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5.4.14 Recycling In recycling applications the metal objects should be removed from the feed before entering the crusher. Maximum alloved diameter of the steel Ø16 mm. Maximum allowed length of the steel in the feed 1,0 m. The most efficient way is to prepare the feed material and remove all the metal from it before loading it to the LT106. The optional magnetic separator can be used for the removal of small metal objects.

Figure 5.34 Removal of metal objects during the crushing of recyclable materials.

WARNING! The crusher rotor can shoot material backwards if the protective curtains have worn. Keep the protective curtains in appropriate condition.

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5.5 STARTING THE CRUSHING PROCESS 1. After a cold start, let the engine idle for a few minutes or until it has warmed up. 2. Make sure that there is nobody on top of or near the LT. Warn everyone in the vicinity.

4

3. Start the process with the button (2) on the control panel. Monitor the messages appearing on the display screen of the process control system (4).

1 2

3

4. When the equipment has started up, proceed with the crushing. The crushing parameters are adjusted via the process control system. Further instructions are provided in the separate instruction manual for IC-system.

Figure 5.35 Starting from the control center

5.6 DURING RUNNING WARNING! Shut down the crusher before climbing on top of the machine. Blockages, etc. must be cleared with the engine shut down. When the LT is running, observe the normal function of the machine parts. If abnormalities occur (loud noises, strong odors, components that heat up intensively, etc.), the equipment must be shut down and the cause determined immediately. Any error messages concerning the operation of the machine will appear on the process control system screen. If the machine gives an alarm or shuts down, check the messages on the display screen first.

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5.7 MOVING ON THE CRUSHING SITE

5.9 SHUTTING DOWN THE ENGINE

1. Stop feeding the material and let the fed material pass through the crusher and the conveyors.

IMPORTANT!

2. Stop the process by pressing the button (3) on the control panel. 3. Wait for the crusher and the conveyors to stop (If the unit is equipped with a screen module, lift the module support legs up before moving. Refer to screen module instruction manual). 4. Drive the equipment as instructed in section 6.2.

5.8 STOPPING THE CRUSHING Stop the crushing process by pressing the button (3) on the control panel. WARNING! The crusher may rotate for several minutes after the crushing process has been stopped.

Do not shut down the engine before the crusher has stopped completely. Let the engine idle without load for a few minutes before shut-down to allow the temperature to settle. It helps avoid ‘after-boiling’ of the coolant and cool the supercharger, which extends the operating life of the engine and reduces operating failures. Shut down the engine by turning the key switch (1) to the “0” position. WARNING! After the engine has been shut down, some pressure remains in the hydraulic system and in the cooling system of the engine. Let the machine cool down sufficiently before opening the pressurized components, and always make sure that the system is pressure-free before performing any servicing or checks.

1 3

Figure 5.36 Shut-down from the control center.

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5.10 CONNECTING LOKOTRACK UNITS (INTERLOCK) Consecutively operating LT crushing units can be interlocked with connection cables. In that case the interlocked Lokotracks are transmitting information between units. E.g. an overload, a material level alarm or a mulfunction stops the feeder of the previous LT. The connection box for the primary unit is located under the feeder, and the connection box for the secondary unit under the main control box. See figure 5.37.

1

1

1

Figure 5.37 The Interlock connections of the LT

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5.11 USING THE PROCESS CONTROL SYSTEM (IC)

1

The LT is equipped with an IC process control system which controls and monitors the functions of the unit. The display screen of the system has been installed in the control center located in the equipment cabin, on the right side of the LT.

5

Use your fingertips to operate the panel. NOTE: Do not use a screwdriver or other pointed objects to press the buttons or the display. It might damage the surface of the display or the buttons. Do not use protective gloves when pressing the buttons, for you might accidentally press several buttons at the same time.

4 3

2 Figure 5.38 Control panel of the process control system (UCD), main menu

(1) The LCD screen displays information and settings relevant to the current mode of the machine. (2) The function keys 1-5 are used to control the system, to select information for display and to change settings. These keys have different functions in different operating modes. (3) The key icons indicate the key functions available at the moment. (4) The status bar of the system displays general information, such as the fuel level and time. (5) The main display shows information on the function that has been selected. Further information about using the system is provided in the IC instruction manual.

The INFORMATION key gives you more information about the current mode of the LT The HELP key gives you more instructions for using the functions displayed on the screen

The OPTIONS key allows you to customize the settings of the functions The SETTINGS key allows you to set crushing parameters and to control the manual drive functions The DIAGNOSTICS key allows you to view diagnostics, troubleshooting and log information Figure 5.39 The most important key icons of the process control system

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5.12 LEVEL DETECTOR AMPLIFIER The amplifier is located inside the control panel. Factory default settings: Telco on: 2 sec Telco off: 1 sec Sensitivity: 45%

Switch positions: Long/short operation: Short (right position) Dark/light function: Dark (left position) Indicator/diagnostic lights: Green led - Power on Yellow led - Relay output activated Red led (LT or LR) - Sensor fault indicator NOTE: If LT or LR is lit, the level sensor wire harness must be replaced.

1 2 3 4

6

5 7 Reference 1 2 3 4

Description Telco on: 0 - 10 sec Telco off: 0 - 10 sec Sensitivity: 0 - 100% Long/short operation

Reference 5 6 7

Description Dark/light function Sensor diagnostic light Sensor diagnostic light

Figure 5-40 Level detector amplifier

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5.13 ENGINE PREHEATER (OPTIONAL) The LT can be equipped with a fuel-operated engine preheater. The preheater facilitates the startup of the engine and reduces wear. When the outside temperature is below +5 °C (+41 °F), the preheater should be used for at least 20 minutes, and if the temperature is below –10 °C (14 °F), the period should be at least 40 minutes.

1

The preheater control panel is located in the equipment cabin on the right side of the machine, next to the main control panel.

2

5.13.1 Setting the day of the week and the time Press the time setting key (3) for 3 seconds (the time will start to flash) and set the correct time using the arrow keys. Wait a moment for the day of the week to start flashing on the screen. Set the time of the week using the arrow keys.

Memory location number Alarm indicator Day of the week Time display

5.13.2 Timer use The timer allows you to program the daily start of the heating in seven-day periods. You can program three different starting times for every day of the week, one of which is displayed at a time. The selector switch (2) must be turned to the left position when using the timer.

Heater on

Activating the timer use Turn the selector switch (2) to the left position. Press the program selecting key (4) until the memory location of the desired starting time appears on the screen.

3

Disabling the timer Press the clock key (3) briefly (the time disappears from the screen). Setting the heating period Keep the left arrow key (6) pressed for 3 seconds (the numeric value will flash). Set the heating period with the arrow keys, between 10 - 120 minutes. During the heating, it is only possible to change the duration of the current period with the arrow keys (the time is not saved in the memory), with the final time being between 1 - 120 minutes. The heating period cannot be set when the preheater is in ignition mode (immediately after the heater has started).

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4

5

6

Setting the time Program selection Forced start / stop Arrow keys Figure 5.41 Preheater control panel

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CHAPTER 5 - OPERATION

Setting the starting time Press the program selecting key (4) once; the memory location number will appear on screen. Set the starting time for heating using the arrow keys (6). Wait a moment for the day of the week to appear on the screen. Set the correct time of the week using the arrow keys. You can change the starting times saved in other memory locations by pressing the program selecting key again.

1

Deleting a starting time

2

Press the program selecting key (4) until the memory location of the desired starting time appears on the screen. Wait a moment. Press the program selecting key until only the time is displayed on the screen.

Memory location number Alarm indicator

5.13.3 Forced start (manual run)

Day of the week

When using forced start, the preheater starts immediately. Turn the selecting switch (2) to the right and keep the key for forced start (5) pressed for a while until the heater starts. Shut down the heater by pressing the key again.

Time display Heater on

NOTE: Preheater use consumes battery power. If the preheater is used for long periods consecutively, battery charge level may weaken to such an extent that the charge is not sufficient for starting the engine.

3

If the preheater will not start, check the battery charge level and the fuel level in the tank.

4

5

6

Setting the time Program selection

Further instructions on using the preheater are provided in the instruction manual of the heater.

Forced start / stop Arrow keys

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MOVING AND TRANSPORTING

CHAPTER

6

6.1 GENERAL Because of the size and weight of the equipment, special attention must be paid when moving the LT. Always make sure that nobody is on top of or near the LT. Use always approved lifting equipment with adequate capacity when preparing for a transport.

IMPORTANT! The hydraulic oil temperature must be observed during longer moves. The temperature may be a maximum of 90 °C. Oil that is too hot might damage the sealings.

WARNING!

NOTE!

Make sure that the lighting is appropriate at the site or near the LT.

Longer moves (more than 100 m) must be driven with the feeder end of the machine first, when the driving gear comes after the track. In that case, the lower end of the track remains tight, because the ground supports the track and it does not bend down. This helps to prevent the chain from jumping over the driving wheel teeth.

MAXIMUM INCLINATIONS Sideways 5° Lengthwise 15 °

NOTE! WARNING! Make sure that there is nobody on top of or near the LT.

When driving on a sloping surface or onto a trailer truck, the automation may stop the LT if the hydraulic fluid or the coolant level is too low. If the machine stops unexpectedly, check the fluid levels.

IMPORTANT! NOTE!

Make sure that –

the driving route is smooth enough

–

differences in altitude or inclinations do not prevent driving

The track drive does not function if the selector switch of the hydraulic functions has been switched ON.

WARNING! In case the surface is slippery or icy, make sure that the sanding is sufficient enough to prevent the unpredictable movement of the LT.

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6.2 MOVING ON THE SITE WARNING! When moving the machine, pay attention to the light pole and exhaust pipe length. They may exceed the height of the other parts of the machine. Avoid power lines, bridges, branches and other work site obstacles.

1

Internal moves on the work site can usually be performed by track drive. 1. Make sure that the load bearing capacity of the ground is at least 20,000 kg/m2 (4100 lbs/ft2). 2. Start the engine as instructed in section 5. 3. Connect the drive control box to one of the alternative cable connectors (1) (fig. 6.1). If the machine is equipped with an optional radio remote control box, switch on the radio control preselection from the main control board (2) (fig. 6.2), when driving with the radio control.

Figure 6.1 Connecting the drive control box

2

4. Adjust the engine speed with the switch in the drive control box to the desired speed between idle and max rpm. Figure 6.2 Radio control preselection on the main control board

5. Drive the machine to the desired area using the manual levers on the drive control box, or by the radio control (if equipped).

WARNING! The drive control box must be disconnected from the unit immediately after driving. The drive control box is allowed to be lifted and held only from its handles. Do not pull the box from the cable or drag or move it otherwise. Figure 6.3 Driving the equipment with the help of the manual levers on the drive control box

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6. The driving speed can be changed by adjusting the engine speed with a switch located in the drive control box. Note: the machine does not move if the engine speed is too low. Driving speed range Slow driving Normal driving Fast driving

Engine speed idle...1200 1200...1900 1900...

7. In the case the ground is soft , drive the tracks backwards and forwards few times in order to make the ground more compact before placing the LT on a new crushing site. 8. If you do not proceed with crushing after moving the machine, shut down the engine as instructed in section 5. NOTE! When the radio control use is switched on, you cannot use the cable drive control box.

6.2.1 Some hints for turning the LT: –

the LT turns easier when driven forward with the minimum power required.

–

the LT turns easier on hard than soft ground.

–

If the LT cannot be turned when driving uphill, drive a short way downhill and turn the unit at the same time.

–

By driving the center of one of the track onto a small rise, rock, or similar, it becomes easier to turn towards the lifted side.

–

Always select an appropriate surface for turning the LT. Only attempt to turn the LT in a location where the turning is easiest.

–

When turning on soft ground, change the direction gradually.

–

Avoid turning the unit completely at one time, so that material does not accumulate on the sides of the tracks.

IMPORTANT! If driving on uneven ground or with the LT connected to Lokolinks, you have to exercise special caution when driving the unit. Always note the ground clearance of the machine and the irregularities of the ground. IMPORTANT! Avoid turning the machine in situations when the traction force is on the upper section of the chain track. The chain track may loosen as the tension spring inside the track frame cannot hold the pressure any longer, which might cause the track chain to jump over the sprocket.

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6.3 TRANSPORT FROM ONE SITE TO ANOTHER When the LT is transported on public roads, note that it is a special transport which may need transportation permits. Check the local regulations, for they vary in each country. The feeder side walls, side conveyors, light mast, stairs etc. must be placed in transport position. Refer section 6.3.2. The screen unit (if equipped) must be placed in transport position . See section for screen module.

6.3.1 Transport equipment needed –

a trailer truck for transporting the LT

–

a trailer truck for transporting the side conveyor

IMPORTANT! PRIOR TO TRANSPORT MAKE SURE THAT •

THE COMPONENTS THAT EXCEED THE FREE TRANSPORT HEIGHT AND WIDTH HAVE BEEN REMOVED

•

THE LOAD IS APPROPRIATELY FASTENED

•

ALL THE LATCHES OF THE HATCHES AND THE ENGINE COVER ARE LOCKED

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6.3.2 Preparing for a transport WARNING! Make sure that the process has stopped, and there has not been left material into the LT.

•

Drive the side conveyor into transport position. See figure 6.4.

•

Open the safety wedges of the feed hopper walls and lower the walls to the down position. Lower first the rear wall and then the side walls. See figure 6.5. Figure 6.4 Turn the side conveyor up

Figure 6.5 Lower the feed hopper walls

WARNING! WARNING! Stay out of the turning feed hopper wall. Check visually from the ground, that the hinge pins of the feed hopper walls are properly positioned and there are no damage in the lugs of the cylinders. Make sure the condition of the feed hopper extensions. Check also that the extensions are properly fastened.

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Do not extend the feed hopper extension, or mount any additional extensions. WARNING! Make sure that there has not been left material or loose parts into the feed hopper.

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•

•

Lower the upper part of the main conveyor to the down position, if there is a risk of exceeding the transportation height. See section 7.

•

Disassemble the dust removal unit, if the transport height is exceeded. WARNING! The machines equipped with discharge hopper, dust encapsulation or other device exceeding transport height must be disassembled safely.

Fasten the conveyor locking (if equipped). WARNING! Make sure that there has not been left material on to the conveyor. Do not go under the conveyor.

WARNING! Always use approved lifting equipment with adequate capacity.

WARNING!

Stay away under the lifted load.

If the machine is equipped with a hoist of the impact crusher, make always sure that the hoist is locked into the transport position.

•

Lower the light pole. WARNING! Make sure that the LT is not located underneath the electric power lines when preparing for a transport.

•

Drive the hydraulic hammer(if equipped) into the transport position. Lock the hammer with a locking bar. WARNING! Make sure that there is no one in the danger area, when the hammer is prepared for a transport. Beware, that the hydraulic hammer or the boom don’t hit the hydraulic hoses, or the hydraulic hoses of the hammer or the boom don’t hit the other parts of the machine.

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6.4 DRIVING ONTO/OFF A TRAILER TRUCK The LT must be driven onto and off the truck trailer with extreme precaution. Slow down the driving speed from the driving panel by decreasing the engine speed.

The ramp must have as low a gradiant as possible (rise max.1:4), when the LT is driven onto the truck trailer. Refer to the picture below, but remember that the picture is for reference only, and not necessary from your machine.

WARNING!

WARNING!

Drive the unit onto/off the truck trailer with great care.

Make sure that the ramp is properly positioned and in perfect technical order.

Make sure that there is nobody in the danger area. When driving the unit onto/off the truck trailer, always make sure that no component of the Lokotrack hits the truck tractor. Also make sure, that the load is not on top of the truck tractor’s cabin and does not cause any danger to the trailer truck’s driver especially if the conveyor end is in front.

Shut down the engine as instructed in section 5.9.

Figure 6.6 Driving the unit onto a truck trailer

NOTE! The actual weight of the unit can be calculated by adding the weight of the optional equipment to the weight of the basic unit. Check the actual weight of the unit from the transport drawing.

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NOTE! The weights are indicative. Actual weights may vary due to manufacturing tolerances.

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Make sure that the load is properly fastened. Refer to the figure below. Discharge end

Loading end

Figure 6.7 Fastening the LT

Make sure that the truck trailer is wide enough for the Lokotrack, and most of the track’s width is on the truck trailer on both sides. Refer to the figure below.

Figure 6.8 LT on the trailer truck

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CRUSHING

CHAPTER

7

7.1 CRUSHING LOCATION The LT106 should be located near the material pile to make loading easy and fast. Shape the feed material pile with the wheel loader or excavator so that it is in small area and high enough for easy loading (Figure 7.1). The location of the discharge pile must be chosen so that it doesn't cause any danger to workers or passers-by. Ensure that there is enough space for the discharge pile, discharge machinery (a wheel loader or excavator) and a lorry (Figure 7.2).

Figure 7.3 Spread some fine material on the ground, then rub it smooth.

Figure 7.1 First shape the material pile

Figure 7.2 General measures taken on the site.

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The location where the crusher is to be placed must be even. The machine must not be allowed to sway. The surface below the crusher must be levelled and evened out. Spread some fine-grained material on the ground, distributing it evenly (Figure 7.3). Next, harden the underlying ground by driving the LT106 back and forth over the site (Figure 7.4).

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Figure 7.4 Strenghten the underlying ground by driving the LT106 back and forth over it.

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While crushing, make sure the LT106 is in horizontal position. The maximum inclination allowance is 1 degree in lateral direction and 2 degrees longitudinal direction (Figure 7.5 and Figure 7.6).

For purposes of maintenance it is recommended that you dig a hole under the LT106 unit (Figure 7.7).

Figure 7.7 Dig a hole under the LT106 for purposes of maintenance.

Figure 7.5 The maximum lateral inclination permitted during the crushing process is 1 degree.

Figure 7.6 The maximum longitudinal inclination permitted during the crushing process is 2 degrees.

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7.2 FEEDING MEASURES LOADING EQUIPMENT The LT106 can be loaded with the help of either an excavator or a wheel loader. LOADING USING AN EXCAVATOR The LT106 can be loaded from the side or the rear. Find a suitable loading site and move the excavator bucket to its loading position. Then drive the LT106 into a suitable position below the excavator bucket. The operator of the excavator must have full visibility to the upper part of the feeder (Figure 7.8). Load the material into the rear end of the feeder, on top of the solid base (Figure 7.9).

Figure 7.8 The operator of the excavator must have full visibility to the upper part of the feeder.

If the feed material contains metals, someone should stand next to the feeder and remove the metal pieces before they are able to enter the crusher. LOADING USING A WHEEL LOADER The LT106 can only be loaded from the rear. Maximum bucket width is 3200 mm (126"). If required, use the feed material to make a loading ramp to ease access to the feeder. Drive the LT106 as close to the pile as possible to make loading quick and easy. NOTE: The feeder has two basic applications: stabilising the feed rate and separating the fine material before it enters the jaw crusher. If the feeder is too full, it will not separate the fine material, which in turn will result in decreased operating capacity.

Figure 7.9 Load the material into the rear end of the feeder on top of the solid base.

CAUTION! Do not hit the excavator bucket into the material or try to force the material into the jaw cavity.

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7.3 DISCHARGE ARRANGEMENT ALTERNATIVES –

Wheel loader

–

Stack conveyor

–

Additional process

–

Lokotrack (secondary)

Check the height and volume of the discharge pile. Do not let the pile grow so high that it reaches the the conveyor. The distance between the pile and the conveyor must always be at least 200 mm (9") (Figure 7.10). When discharging with the help of the wheel loader, be careful not to damage the conveyor. Discharge from the side, do not push the material under the LT106 unit.

Figure 7.10 The distance (h) between the pile and the conveyor must always be at least 200 mm (9").

The material emitted from the vibrating chute can be directed to either the main conveyor or the side conveyor with the help of the control plate.

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7.4 CRUSHING Release the transport locks from the side conveyor (optional). Turn the side conveyor down with the help of the controls located in the hydraulic valve section (Figure 7.11 and Figure 7.12).

Figure 7.11 Turn the side conveyor down with the help of the control levers.

Figure 7.12 Conveyor control switches: 1) Side conveyor up/down, 2) Side conveyor in/out, 3) Main conveyor folding. NOTE: The control switch for manual valves, refer to Chapter 3.9

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NOTE: A lifting instrument, such as a rope or chain, that is used to lift a single side wall, will not be strong enough to lift the entire LT106 unit.

Turn up the side walls of the feed hopper and lock them in place with the help of the wedges (Figure 7.13).

When the side wall is lifted vertically against the joint hinge, the mass of the entire LT106 may apply to the lifting instrument.

Figure 7.13 Turn up the side walls of the feed hopper. NOTE: Do not stand in side of the frame when mounting the wedge on it's place

If the additional side walls of the unit are not lifted with hydraulic cylinders, be extremely careful when lifting or lowering them. In this case, the side walls must be lifted and lowered using a crane. WARNING! Make sure that there is no-one below the side walls, or too near them, as it may cause an accident risk.

When lifting the side walls, first lift the side wall to its uppermost position with the crane (phase 1) and position the wedges. When positioning the wedges, the crane must not make any corrective measures. If the wedge cannot be fitted in its place, the mechanic must move away from the side wall and give new instructions to the crane attendant. After this, place the wedge first at the crusher end (phase 2) and then at the feeding end (phase 3). Once the wedges are fitted in their positions, make sure that they are tightly in their positions by hammering them. Finally, secure them with screws or chains. Lifting or lowering the side walls must in no circumstances be done with the help of an excavator. The order of lifting the walls: first, lift both side walls, then the back side wall. After lifting the back side wall, position and lock its wedge as well. To lower the walls, perform the steps above in reverse order. Before removing the wedges, first set and tighten the lifting ropes of the crane. Do not perform any corrective measures during the operation. NOTE: If the side walls are lifted with the help of a hydraulic cylinder, they are lifted in the same order as explained above. Lift and lock one side wall at a time, as explained above. When positioning the wedges, do not lift or lower anything.

Figure 7.14 Turn the rear wall of the feed hopper upwards.

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Turn the light pole up (Figure 7.15). Make sure that the crusher is always operated in a safe manner and that it is in good mechanical condition. Make sure that the crusher is securely stationed so that there is no risk of its inclination.

starting the machine, caution everybody in its vicinity that you are about to start the crusher.

Operation of the crusher is only permitted, when all necessary protective and safety devices, e.g. guards, emergency stop devices, silencers, aspirators etc. are in place and in full operating condition. Before starting the crushing process, make sure that no-one is on, next to or under the crusher. Before

Figure 7.15 Turn the light pole up

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Starting the crushing process

Refer to the Crusher Instruction Manual for further information on the crushing process.

Before starting the crushing process, always make sure that the crusher cavity is empty. If there is material on the cavity, clear the cavity as instructed in Chapter 7.8 .

WARNING!

When the crushing process has started, the RPM speed of the diesel engine cannot be adjusted by the operator before the crushing process has been stopped again. Initiate the crushing process by pressing “Process ON” -button (ref 4.1 and 4.2) NOTE: When starting the crushing process, the automatic control function takes care of starting the devices, delays, monitoring any possible problems and adjusting the RPM level of the diesel engine. The initiation of the crushing process takes about one minute after the process button has been pressed. –

Connect the water supply (if needed).

–

Turn on the lights if required.

In case of emergency press the "Emergency stop"-button to stop the LT106. Do not attempt to crush stones that are too large to fit inside the cavity. Having to reposition rocks wastes time, reduces capacity, and imposes unnecessary loads on the crusher. You can stop the feeder and crusher in order to safely remove uncrushable objects from the feeder. Both the crusher and the feeder can be restarted from the remote control box located in the service platform. CAUTION! Clay, wood and any non-stone-based materials must be prevented from entering the crusher. This may overload and damage the crusher. Also make sure that no explosives are allowed to enter the crusher.

Stop the crushing process by pressing the "Process OFF” -button. NOTE: When stopping the crushing process, the automatic control function takes care of turning off the equipment, delays, monitoring any possible problems and adjusting the RPM level of the diesel engine. The termination of the crushing process takes approximately 1 minute. 1. Process options eg. side conveyor, magnet separator or hydraulic PTO must be selected before the process start. Process options are editable during the process. 2. You can stop the feeder and crusher in order to safely remove uncrushable objects from the feeder. Crusher and feeder can be restarted from the service platform. Load some material into the feed hopper while the vibrating chute is running. For further instructions, refer to Chapter 7.6 . When loading with the help of a wheel loader, the feed hopper must be almost empty before any more material can be loaded into it. When loading with the help of an excavator, more than one bucketful can be loaded in to the hopper at a time.

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Figure 7.16 "Emergency stop" - buttons (for more information, refer to 5.5)

NOTE: The side conveyor must not be switched on if it is in transport position

Figure 7.17 Do not switch the side conveyor on while it is in a transport position.

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7.5 BY-PASS CHUTE Location of the by-pass chute hatch. The material flow that passes below the feeder grizzlies can be directed towards the main conveyor (Figure 7.18) or towards the optional side conveyor (Figure 7.19) .With the optional screen deck, materials larger than the mesh can be directed towards the main conveyor. (Figure 7.20). Turn the lever to change the direction of the material flow. When using the centre position, lock the lever in place using a bolt.

Figure 7.20 The flow of materials has been screened and directed either to the side conveyor (pass-through) or to the main conveyor.

Figure 7.18 The chute has been directed towards the main conveyor.

Figure 7.19 The chute has been directed towards the side conveyor.

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7.6 FEED CONTROL The feeder can be stopped and restarted again during the crushing process. The “feeder start” and “stop” buttons are located in the remote control box on the service platform. If the machine is equipped with a radio control feature (optional), the feeder can be started and stopped using the radio control feature.

The best capacity can be reached by having the feeder remain running for as long as possible.

To stop and restart the feeder do the following: 1. Stop the feeder during the crushing process by pressing the "feeder stop" button. 2. Restart the feeder after it has stopped completely by pressing the "feeder start" button. NOTE: The feeder starts automatically when the process is started and stops when the process is stopped. If the hydraulic temperature of the unit is extremely cold (10oC/14oF), the system will ask to carry out a cold start of the process. The feeder will not start until the temperature of the oil has reached a certain temperature. In order to stabilise the feed rate, the feeder always starts at minimum speed regardless of the speed setting. After a while the speed changes to the set value. In order to control the capacity, the feeder speed can be adjusted using the crusher speed +/-switch. The switch is located in the control box on the service platform. NOTE: When the process is running, the automatic control takes care of stopping of restarting the feeder. The feeder will stop if the speed of the crusher decreases or the level indicator (optional) of the crusher indicates an alarm. DANGER! If the feeder speed is too high, stones may fall over the flanks of the hopper.

NOTE: Radio control will by-pass the feeder controls located in the control box on the service platform.

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7.7 MINIMUM SETTING The hardness of the feed material will effect the minimum setting. Refer to the C-Jaw instruction manual for the setting ranges.

7.7.1 FEED MATERIAL Feed sizes depending on the material in question: Concrete 0...550 mm (22"). Concrete with rebars 0...550 mm(22"), the maximum length of the rebars 500 mm(20") and max. diameter is 20 mm(3/4"). Construction rubble (mixed, including fines) 0...550 mm(22"). Bricks 0...550 mm(22"). Figure 7.22 Measurement of the material dimensions.

Rock 0...550 mm(22"). Asphalt 0...550 mm(22") (only if the temperature is below +10º C(50º F) and the bitumen content is low). Slag 0...550 mm(22"). The size of the material is measured as illustrated in figure 7.7.1.

7.7.2 SETTING ADJUSTMENT Manual setting adjustment: refer to the C-Jaw Instruction Manual for instructions on setting adjustment. Hydraulic setting adjustment: Settings can be adjusted only when the crusher is in the maintenance/adjustment mode.

Figure 7.21 Setting adjustment

–

10: opens the setting

–

11: closes the setting.

–

6: crusher stop-button: crusher in maintenance/adjustment mode.

The process does not have to be stopped completely when changing settings. Process is restarted with the crusher start button (7) and the feeder start button (3), see Chapter 4.3 .

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7.8 CLEARING OF THE BLOCKAGE CAUTION! Never try to clear the blockage with an excavator. If the process is initiated with material in the cavity, the crusher tries to start with slow ramp and if the rock is strong enough to prevent crusher from starting, the alarm # 3 (“Crusher pressure rising too fast on start”) will be shown in the display. The process will be fully activated but the feeder and the crusher will not function. You can swing the crusher clockwise and counter clockwise with the buttons 8 and 9 (Figure 7.23) of the remote control box, located on the service platform. When the cavity is clear, switch on the crusher using the “Crusher start” -button (# 7, Figure 7.23). Start the feeder. Figure 7.23 Remote control

7.9 REMOVAL OF THE STEEL WARNING! Always stop the machine (feeder, crusher, conveyors and engine) before removing metal from it. Make sure that it can not be started during removing metal from it.

WARNING! Use a hook to remove iron bars and wires. Be very careful not to hurt yourself. Never use a hook when the machine is running.

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7.10 RECYCLING In carrying out recycling processes with the crusher, all metal objects should be removed from the feed before they enter the crusher.

The optional magnetic separator can be used for the removal of small metal objects. The maximum diameter allowance for steel objects entering the crusher is 20 mm. The maximum length allowance is 0,5m.

The most efficient method is to prepare the feed material for the process and remove all the metal pieces from it before loading it to the LT106. Someone should stand next to the feeder and remove the metal pieces. Be very careful when touching the feed material. The feeder must be stopped when removing larger objects. Never climb on top of the feeder.

Figure 7.24 Removal of metal objects during the crushing of recyclable materials.

7.11 OPTIONAL EQUIPMENT LEVEL INDICATOR

INTERMEDIATE CABLE FOR SECONDARY UNIT

The purpose of the level indicator is to control the feed material level that enters the crusher. The indicator stops the feed process and emits a light signal when the material level is too high. The indicator resets itself automatically.

The LT106 unit is equipped with a 6-pin socket allowing information flow between the primary and the secondary unit. The socket has three different functions:

Keep the level indicator clean to ensure that it functions proper function.

Pins 1&2: When connected, LT106 gets information on the connection of the secondary unit..

Refer to the IC500 Instruction Manual for further information on switching the level indicator to ON or OFF position. HYDRAULIC OUTPUT

Pins 3&4: Feeder ON/OFF information (secondary feed/emergency functions can be connected to this). Normally open contact required. Pins 5&6: For the level sensor of the secondary unit. Normally closed contact required.

The hydraulic output can be set ON/OFF permanently or ON with the process. Refer to the IC500 Instruction Manual for further information on how to select the hydraulic output.

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7.12 RADIO CONTROL BOX

(OPTIONAL)

11

2

1

3

a)

4

6

7

9 10

5

8

b) * The directions right and left are defined from the direction of travel of the material from the feeder side perspective.

Reference Description 1 Drive control, left track * (function a) 2 Drive control, right track * Main switch for the radio control box 3 (on/off) (not shown in the picture) 4 5

6

Sound signal button

Reference Description 7 Adjusting the feeder speed +/8 Changing the radio frequency ** 9 10

Control box mode selection a) track drive (orange symbols) b) conveyor control (white symbols) - Adjusting the engine speed +/(function a) - Feeder on/off (function b)

11

Radio control on (green signal light) Weak battery power (red signal light) Remote stop (crushing, hydraulic operations and the engine are stopped)

Figure 7-25 Drive control box

**When changing the frequency, hold the horn button (4) down and press the radio frequency button (8) to find a correct channel.

07/07

(Push the button as many times as many channels you need to change to)

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CHAPTER 7 - CRUSHING

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LUBRICANT RECOMMENDATION 8.1 GENERAL

CHAPTER

•

This section contains information and instructions on several alternative and optional equipment. Normally Lokotracks have only some of them. Before maintaining and servicing, find out which alternative and optional equipment your Lokotrack has.

ELF –

•

•

•

•

See further instruction in your feeder/screen manual.

–

Oil designation to DIN 51517, part 3: CLP 220.

•

–

ISO viscosity to DIN 51519: ISO - VG 220.

•

–

Kinematic viscosity at 40°C(104ÉF): Min. 198 mm2/s (cSt). Max. 242 mm2/s (cSt).

–

FZG test A /8,3/90 to DIN 51354, p. 2: Min. breakdown load stage 12.

Mobilgear 630, SHC 220

PANOLIN –

8.4 TRACK GEAR

Q8 Goya 220, El Greco 220

MOBIL –

•

Lamora 220

KUWAIT –

8.3 FEEDER / SCREEN

Renolin AWD 220

KLÜBER –

See further instruction in your crusher manual.

Giran L 220

FUCHS –

8.2 CRUSHER

Reductelf SP 220, Elf Epona Z 220

FINA –

•

8

EP Gear Synth 220

TEXACO –

Syngear 220

TOTAL –

Varter EP 220

8.5 ENGINE Allowed oil grades are: 10W30 and 15W40 (refer to the C-9 Operation and Maintenance Manual).

Recommended brands are e.g.:

OIL GRADE PLUG

•

Engine is equipped with oil grade plug. (refer to the C-9 Operation and Maintenance Manual).

•

AGIP –

Blasia 220ARAL

–

Degol BG 220

Oil Grade

1

10W30

2

15W40

Alphasyn T 220, Aplha ZN 220

DEA –

07/07

Enersyn HTX 220

Plug

CASTROL –

•

Gear RSX 220

BP –

•

OIL GRADE DETECTION

AVIA –

•

Factory filled oil type: 10W30 (plug position 1).

Trion EP 220, Intor HCLP 220

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CHAPTER 8 - LUBRICANT RECOMMENDATION

8.6 HYDRAULICS

In summer time e.g. in hot climate conditions, when the ambient temperature exceeds +35ºC(95ºF), the use of a special hydraulic oil of ISO VG 68 class is recommended. The max. allowable operating temperature with this oil type is about +90ºC(194ºF) and min. allowable starting temperature is about -10ºC (14ºF).

Basic requirements for the hydraulic oil quality: –

viscosity index should be min. 150

–

min. viscosity 16 cSt at operating temperature

–

max. viscosity 1000 cSt at starting temperature

Attached some examples of oil brands meeting these requirements:

Unless otherwise mentioned, the factory fill oil is a special hydraulic oil of ISO VG 46 class. The max. allowable operating temperature with this oil type is about +80ºC (176ºF) and min. allowable starting temperature is about -20ºC(-4ºF), which makes it suitable for use all year round in most operating conditions.

–

BP Energol SHF 68

–

Mobil DTE 16

–

Teboil Tebo Hydraulic Oil 68

Oil amount is 520 litres (140 gal).

Attached some examples of oil brands meeting these requirements: –

BP Energol SHF 46

–

Esso Univis N 46

–

Shell Tellus Oil T 46

–

Teboil Tebo Hydraulic Oil 46

–

Mobil DTE 15

8.7 GREASE The grease must be NLGI EP 2 Type. Grease containing Molybdenum additives in NOT recommented.

In winter time e.g. in cold climate conditions, when the operating temperature of the oil stays below +60ºC (140ºF), the use of a special hydraulic oil of ISO VG 32 class is recommended. The max. allowable operating temperature with this oil type is about +65ºC (149ºF) and min. allowable starting temperature is about -30ºC (22ºF). Attached some examples of oil brands meeting these requirements:

8-2

–

BP Energol SHF 32

–

Esso Univis N 32

–

Mobil DTE 13

–

Shell Tellus Oil T 32

–

Teboil Tebo Hydraulic Oil 32 S

LOKOTRACK LT106 INSTRUCTION MANUAL

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07/07

CHAPTER 8 - LUBRICANT RECOMMENDATION

8.8 FILLING VOLUMES

LT106 AMOUNT

TYPE

Hydraulics

520 l / 140 gal

ISO VG 46

Final drive

4,5 l / 1,2 gal

ISO VG 220

Fuel tank

600 l / 160 gal

Feeder vibr. unit

4 l / 1 gal

ISO VG 150

CATERPILLAR C9

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Engine oil

28 l / 7,5 gal

Water

36 l / 9,5 gal

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07/07

MAINTENANCE

CHAPTER

DIESEL ENGINE Change engine oil Change the engine oil filter Drain water from fuel Change the primary fuel filter Change the fine fuel filter Check the service indicator of the air filter. Change the cartridge if necessary. Change the safety cartridge every third time See the engine operating manual for other maintenance. JAW CRUSHER Check V-belt tension. Check the tightness of the jaw bolts daily during the first 40 operating hours after jaw installation. Then weekly. Check the tightness of cheek plate bolts. Check the side guide plates and the protection rubber of the toggle plate. Lubricate crusher drive jack shaft 10g/40h/bearing Check wear on the jaw plates.

When needed

Every 12 months 2000-2200 h

Every 6 months 1000-1200 h

Daily 8-16 h

Carry out periodical maintenance according to given operating hours rather than given period.

Monthly 200-250 h

NOTE: Grease lubrification specification NLGI EP 2.

Weekly 40-50 h

9.1 PERIODICAL MAINTENANCE

9

X X X X X X X

X X

X

X X X X

75oC/

Check the sound, temperature (max. 167oF) and grease flow in the eccentric bearings. Lubricate eccentric shaft bearings. Check wear on the cheek plates. Check toggle plate for aligment, straightness and cracks. Check toggle seats, clean as necessary. Check the tightness of the mounting bolts of the labyrinth covers and the frame bearings. Check the tightness of the frame tie rods. Check the mounting of the flywheel. Check the tightness of the frame mounting bolts on the side plates. Check the bearings on the eccentric shaft.

07/07

X X X X X X X X X X

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9-1

Check for any wear on the contact surfaces of the pitman and front frame. Check rubber damper condition of the jaw crusher Mounting of the crusher no horizontal movement. Check the locking mechanism. Check for any wear on the contact surfaces between the side plates and cheek plates. MECHANICAL SETTING ADJUSTMENT Lubricate the cap nuts of the setting adjustment device. Check the rubber covers. AUTOMATIC LUBRICATING DEVICE Check operation and grease amount (add grease if necessary) VIBRATOR UNIT Oil change (1000h) Check oil level Replace breather FEEDER Clean vibration unit from outside. Check tightness of vibration unit joints. Check the wires/hoses. Check tightness of screen deck mountig bolts CONVEYORS Lubricate the bearings of head and tail pulleys. 5g/40h/per bearing Check the belt tension. HYDRAULICS Check oil level Check the oil temperature (max 90ºC / 194ºF). Check the fixing bolts of all components. Check pipes and hoses.

X X X

X X

X

X* X

X X

X X X X

X X X X X X X

Change the hydraulic oil filters Clean the hydraulic tank Check the breather of the hydraulic tank. Replace every 6 months

LOKOTRACK LT106 INSTRUCTION MANUAL

When needed

X

Change hydraulic oil

9-2

Every 12 months 2000-2200 h

Every 6 months 1000-1200 h

Monthly 200-250 h

Weekly 40-50 h

Daily 8-16 h

CHAPTER 9 - MAINTENANCE

X X X

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X

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FINAL DRIVE Check oil level. Change oil BATTERY Check fluid level. Check the cleanliness of the battery terminals. TRACKS Check tension of track chains. Check tightness of track bolts. MAGNETIC SEPARATOR Lubricate the bearings. 3g/40h/Bear. Check the belt tension. FUEL TANK Breather replacement Fuel fill pump filter replacement (optional) *

When needed

Every 12 months 2000-2200 h

Every 6 months 1000-1200 h

Monthly 200-250 h

Weekly 40-50 h

Daily 8-16 h

CHAPTER 9 - MAINTENANCE

X X X X

X X X X X X

First oil change

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LOKOTRACK LT106 INSTRUCTION MANUAL

9-3

CHAPTER 9 - MAINTENANCE

9.2 RUNNING-IN

9.2.1 HYDRAULIC ADJUSTMENTS

Carry out the maintenance during running-in period as follows.

All components are set to operate at optimal speed. If adjustments is needed it is allowed only for Metso Minerals authorized persons.

200-250 h –

Change the engine oil (Note the warranty policy of the CAT engine!).

–

Replace the engine oil filters.

–

Replace the filters of the hydraulic oil.

–

Replace the breather of the hydraulic oil tank.

–

Change the vibrator’s oil

9.3 FINAL DRIVE Change final drive oil after first 150 operating hours. After that every 1500 operating hours. Oil amount is 4.5l (1.2 gal). Oil quality is ISO VG 220.

Crusher See the Crusher instruction manual for further information.

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CHAPTER 9 - MAINTENANCE

9.4 FUEL LEVEL The fuel level can be checked from the fuel amount indicator in the display (figure 9.1). Fuel tank capasity 600l (160gal).

9.5 CRUSHER SPACER REMOVAL & ASSEMBLY / TOGGLE PLATE CHANGE Please refer to the C106 manual.

NOTE: The system will inform about a low fuel amount by a display alarm, but it will not prevent the machine from running out of fuel.

Figure 9.1 Checking the fuel level

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CHAPTER 9 - MAINTENANCE

9.6 TRACKS Tension –

–

Frame Check that the track chains are properly tensioned (figure 9.2). Adjust as necessary. Measure in the middle of main pulley and idler. To tension tracks pump more grease into regulating cylinder with a grease gun. Correspondingly, the tracks are loosened by letting grease flow out through the opened grease nipple and moving the Lokotrack if needed.

Check the welded structure for cracks or weld failures, and carry out any necessary repairs as soon as possible. Track shoe bolt torque –

With lubricant: 304-358 Nm / 224-264 ft/Lb

–

Without lubricant:365-430 Nm / 269-317 ft/Lb

Check track shoes for damage.

Figure 9.2 Check that the track chains are properly tensioned. The correct deflection (X) is 25 mm (1")

9.7 ADDING FLUIDS 9.7.1 Adding hydraulic fluid Adding hydraulic oil: •

open the oil addition plug in the top of the return filter

•

add oil through the return filter in order to prevent impurities from entering the hydraulic system

•

the correct hydraulic oil level is in the middle of the upper sight glass

NOTE: The unit must be in operating and horizontal position when the hydraulic oil level inspection is carried out.

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CHAPTER 9 - MAINTENANCE

9.7.2 Adding Engine Fluids Add the engine oil through plug 2. Check the amount of oil with dipstick 1 (see chp 8.8 Filling volumes).

Callout Description 1 Engine oil dipstick 2 Engine oil plug (addition)

Callout Description 3 Engine coolant water expansion tank

Figure 9.3 Adding engine fluids

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CHAPTER 9 - MAINTENANCE

9.7.3 Removing Engine / Hydraulic Fluids

9.8 ENGINE FILTER CHANGE INFORMATION

Observe the following instructions: –

remove the plug

9.8.1 Replacing the Engine Fuel Filters

–

open the valve

Engine fuel filters must be replaced every 200 h of engine running hours or at least once a year.

Make sure that the drain pan will be able to hold all the fluid (See 8.8 Filling volumes).

For more information, refer to the Caterpillar C-9 Operation Manual.

9.8.2 Replacing the Engine Oil Filter Engine oil filter must be replaced every 200 h of engine running hours or at least once a year

9.8.3 Engine Air Filter Change The condition of the filter must be observed every 8h of operation. Air filter is a three stage filter : – Precleaner. –

Primary cartridge

–

Safety cartridge

Filter assembly contains an indicator. If the indicator shows red the primary filter must be replaced. Replace the safety cartridge (fig. 9.5) in every third primary filter replacement.

Callout Description 1 Coolant valve (under the cooler) 2 Engine oil 3 Hydraulic oil Figure 9.4 Draining engine fluids

Figure 9.5

9-8

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CHAPTER 9 - MAINTENANCE

Figure 9.6 Undo the filter housing latches to remove the cover.

Figure 9.8 Install new cartridges on their place (always check that the replacement filter size is correct. If the replacement filter is shorter than original it might cause a serious engine damage).

Figure 9.7 Draw the primary cartridge out from it's place. If needed draw the safety cartridge out from it's place. Figure 9.9 Close the air filter housing cover correctly on it's place and make sure that all latches are properly closed.

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CHAPTER 9 - MAINTENANCE

9.8.4 Fuel tank Breather change.

9.9.1 Crusher Drive Pump Filter Change

Breather is located side by the engine cover (fig. 9.6). Breather is a spin on type. Breather must be replaced every 2000 hours or once a year.

Filter location: The filter locates on the pump itself. Filter is a spin-on-type replaceable filter. The crusher drive pump is the hydraulic pump closer the engine.

Figure 9.10 Fuel tank breather

Figure 9.11 Crusher drive pump filter

Replacement information:

9.9 REPLACING THE HYDRAULIC OIL FILTERS First hydraulic oil filter change should take place at 1000 h of engine operation. Before startup of the unit the filter replacement is not necessary as the filters are renewed after the test run. Hydraulic filters: –

Cursher drive pump filter

–

Device pump pressure filter

–

Device pump return oil filter

–

Hydraulic tank breather

Work must be carried out when the engine is stopped and main switch in off position. Close the suction valves under the hydraulic tank. Undo the filter by turning the filter in counter clock wise. Disposel the used hydraulic filter according to the country legislation. Lubricate the O-ring of the new filter. Spin the new filter to the hand tightness and turn 30 ° (1/12 of the round ) to secure filter installation. Filter must be replaced every 2000 h of engine operation or whenever the filter condition indicator is alarming.

9.9.2 Device Pump Circuit Pressure Filter Change Filter location : Filter is mounted on the frame at left side of the unit. Filter is replaceable element inside the spin on type housing. Replacement information:

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CHAPTER 9 - MAINTENANCE

Work must be carried out when the engine is stopped and main switch in off position. Close the suction valves, located under the hydraulic tank. Undo the filter by turning the filter in counter clock wise. Dispose the used hydraulic filter according to country legislation

Figure 9.14 Lubricate the O-ring of the housing and spin the housing carefully on it's place Tighten the housing with 40 - 50 Nm torque.

Filter must be replaced every 1000 h of engine operation or whenever the filter condition indicator is alarming.

Figure 9.12 Undo the filter housing by turning the housing counter clockwise with 41 mm wrench.

9.9.3 Device Pump Circuit Return Oil Filter Change Filter location : Filter is mounted to the hydraulic tank. Filter is a replaceable element, under a cover. Replacement information: Work must be carried out when the engine is stopped and main switch in off position.Close the suction valves, located under the hydraulic tank.

Figure 9.13 Remove the filter element from the housing and install a new element to the filter support.

Figure 9.15 Undo the cover of the return filter. Open the four nuts ( 13 mm wrench ) and remove the cover.

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CHAPTER 9 - MAINTENANCE

Figure 9.16 Be careful when doing this as there is a spring under the cover. Figure 9.19 Clean the magnets before installing a new filter element (fig. 9.20). Use 20 - 25 Nm torque when securing the filter element. Insert the filter assembly on its place and close the cover.

Figure 9.17 Pull the filter assembly out from the filter housing.

Figure 9.20 Observe the O-ring condition and lubricate it before installation. Use 15 Nm torque for the cover mounting nuts.

Figure 9.18 Open the filter assembly by opening the 36 mm lock nut. Remove the filter element.

9-12

LOKOTRACK LT106 INSTRUCTION MANUAL

Filter must be replaced every 1000 h of engine operation or whenever the filter condition indicator is alarming. If the device pump pressure filter must be replaced due to alarm the return filter must be replaced at the same time.

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07/07

SERVICE INSTRUCTIONS

CHAPTER

10.1 GENERAL Only skilled and experienced mechanics must be allowed to service the plant. In any work related to the operation, adaptation to manufacture, conversion or adjustment of the LT and its safety equipment, as well as to inspection, maintenance and repair, observe starting and stopping procedures in accordance with the Instruction Manual and any indications relating to maintenance work! Secure extensively, as far as necessary, the area of maintenance works! In case the LT is completely switched off during maintenance and repair works, it must be safeguarded against unexpected switching-on. Lock-up main starting equipment, draw off keys and affix a hazard pictorial at the main switch. Smoking and any open flame is prohibited in the immediate area of the machine when refuelling or servicing the fuel system.

10

Service facilities must be kept clean. Oil and water can make floors slippery and highly dangerous. Avoid severely soiled clothing, they can be a fire hazard. Keep the LT and equipment free from oil spillage and dust. A clean machine reduces the fire risk and simplifies visual checks for components requiring attention. Be careful when using pressure cleaning equipment. Even low pressures and temperatures can damage wire insulation. Check wiring for signs of abrasion damage or kinks. This can cause short circuits and fire. Check hydraulic hoses for abrasion damage or kinks. Never weld or grind containers of inflammable liquids. Always have a fire extinguisher on hand when carrying out welding or grinding operations. Notify the location and use of fire extinguishers.

IMPORTANT!

10.2 BATTERY MAINTENANCE

In case of fire:

10.2.1 Fluid level check

–

Move the LT away from the dangerous area

–

Stop the engine

–

Turn off the main switch

–

Start fire fighting and give the alarm if necessary.

The fluid level in the batteries must be checked every 100 operating hours (figure 10.2.1). The level should be approximately 10 mm(1/4") above the plates. Add clean distilled water as required. Monitoring the fluid consumption will give an indication of the charge of the battery, but a separate test of the specific gravity of the acid will confirm the state of charge. If the fluid consumption is high it is possible for the alternator charging rate to be too high.

Diesel fuel is flammable - do not use as cleaning fluid. Use solvents of accepted quality only. Always stop the engine during maintenance unless it is mentioned in the instruction manual to keep the engine running. Do not check for leaks with a bare hand, use suitable cleaning cloth. Never adjust any hydraulic valve beyond the pressure recommended by the manufacturer. Always ensure adequate ventilation when running the engine in a confined area. Remember that some solvent qualities may cause skin irritation and may be extremely inflammable. Avoid breathing of solvent fumes.

07/07

10-28-EN

Figure 10.2.1 Check battery fluid level every 100 operating hours. Add clean distilled water in the accumulator as required

LOKOTRACK LT106 INSTRUCTION MANUAL

10-1

CHAPTER 10 - SERVICE INSTRUCTIONS

10.2.2 Battery check

10.2.3 Cleaning batteries, terminals and cables

The level of charge in the battery must be checked regularly using a hydrometer. Do not make this check immediately after adding any distilled water to the battery; the water and acid will be more evenly mixed after some charging has taken place. The specific gravity of a fully charged battery is approximately 1.28, and if only half-charged the reading will be about 1.2. These values relate to a battery temperature around +20ºC(68ºF).

Batteries and terminals must be cleaned at least once per year. The terminals and the cable ends should be cleaned with the special tools which will restore the contact area to the right form and size. After cleaning, the terminals and cable ends should be liberally covered with petroleum jelly to protect against oxidation. Check also the fastening of: battery earth cables to the main frame, engine starter cables, and electrical connections for the alternator. Clean and tighten as necessary. Keep battery cases clean and dry.

Batteries must always be maintained as far as possible at full charge. If the charge is allowed to remain low, the plates will become sulphated reducing the capacity and efficiency of the whole battery. Remember that a half-charged battery will freeze at a temperature of -25ºC(-13ºF) and a flat one at only -10ºC(14ºF).

10.3 OTHER ELECTRICAL EQUIPMENT 10.3.1 Charging circuit

Never use an open flame when checking the acid level of a battery. The gases given off by the chemical reaction during the recharging process are highly inflammable. The liquid used in lead-acid batteries is dilute sulf acid. This acid is corrosive, will cause severe burns to exposed skin and will damage clothing. Be very careful when handling a battery.

–

Check and tighten connections regularly.

–

The alternator requires only periodic attention.

NOTE: It is important to strictly follow the instructions for protecting the alternator: –

Do not remove battery cables or any other connections in the charging circuit while the engine is running.

–

Never start the engine if any wire in the charging circuit is disconnected or loose.

–

Whenever the batteries are charged using an external source, the earth lead to the frame must be disconnected from the battery. When reconnecting batteries, using jumper leads or a charger, be sure to identify the correct polarities.

–

Always disconnect the batteries when servicing the electrical equipment of the LT.

–

Do not cause a short circuit in any part of the system, nor take a test reading with an instrument with low internal resistance.

Always wear protection glasses and gloves while handling and maintaining.

NOTE: If auxiliary batteries are used to assist engine start, make sure that:

10-2

LOKOTRACK LT106 INSTRUCTION MANUAL

10-28-EN

–

batteries have the same voltage

–

the correct poles are connected

07/07

CHAPTER 10 - SERVICE INSTRUCTIONS

10.3.2 Starter circuit Normally the starter circuit requires little attention, but all components should be kept clean and electrical connections tight. The batteries are an essential part of the electrical system and are required to be kept fully charged, clean and topped up properly to maintain the acid level. Battery cables must also be checked for tightness and kept clean and greased.

10.3.3 Fuse List

IMPORTANT! Use only fuses with required size as oversize fuse can damage components in the electrical circuit.

Fuse ID 1F01

Fuse Size 10A

1F02

20A

1F03 1F04 1F05 1F06 1F07

10A 10A 15A 10A 10A

Description Control key Control fuse, secondary main Options Power for I/O-modules Optional water pump Radio control Not in use

Table 10-1 Fuse location in the control panel

Fuse ID 2F01 2F02 2F03 2F04 2F05 2F06 2F07

Fuse Size 30A 50A 10A 10A 10A 15A 10A

2F08

15A

2F09 2F10 2F11 2F12 2F13 2F14 2F15

15A 15A 15A 8A 8A 8A 10A

Description Control main fuse Start motor pilot Not in use Engine + bat Switched Optional drive lights Work lights Engine control Service light sockets + optional engine pre-heater Fuel cooler Oil cooler S- models Not in use Engine Engine Engine Engine

Table 10-2 Fuse location in the electrical panel next to the hydraulic tank

Fuse ID 2F20 2F21

Fuse Size 100A 100A

2F22

20A

2F23

10A

Description Main fuse Engine grid heater Engine control main fuse Main switch

Table 10-3 Fuse location next to the main switch

Fuse ID 3F01 3F02

Fuse Size 10A 20A

Description Screen module Fuel pump

Table 10-4 Fuse location in the electrical panel next to the hydraulic valves

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CHAPTER 10 - SERVICE INSTRUCTIONS

10.4 WELDING

10.6 CRUSHER SPEED SENSOR

If any welding is to be done on the machine, care must be taken to protect sensitive electrical equipment.

FUNCTION

–

Stop the engine.

The crusher is equipped with a speed sensor. The sensor controls the pitman rotation and gives one impulse per one pitman revolution.

–

Turn the main switch OFF.

MOUNTING

–

Disconnect the earth lead to the batteries.

–

Fasten the earth cable of the welding apparatus as close to the part to be welded, as possible and make sure that no welding current is able to pass through any bearings or electrical equipment.

The sensor is mounted at the back side of the pitman, close to the eccentric shaft. To locate the sensor, lift the rubber cover behind the pitman.

–

Disconnect engine wire harness sockets.

–

Disconnect control module sockets.

10.5 PRESSURE ACCUMULATOR

The sensor is mounted on its support with a plastic clamp. The correct distance from the sensor end to the pitman is 3-5 mm. (The minimum distance while the crusher is running). When replacing the sensor there is no need to adjust the sensor itself. Sensor has a LED-indicator. The function can be controlled from this led indicator. Possible reasons if the speed sensor is causing an alarm:

NOTE: Before removing / repairing any components from the hydraulic setting control circuit release the pre-charge pressure by opening the SHUT off VALVE. Make sure that the pressure gauge above accumulator indicates NO pressure. Make sure that the security valve of the gauge is open.

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–

Chocked fuel filter

–

Chocked air filter

–

V-belts are loose - slipping

–

The setting too small for the crushed material

–

Cavity worn out.

–

Hydraulic drive component failure

07/07

Symbol Identification

APPENDIX

A

1.General symbols

1. On/Start

2. Off/Stop

3. Connecting

4. Disconnecting

5. Increase

6. Decrease

7. Stepless adjustable movement

8. Warning

9. Warning: pressurized

10. Warning: electric danger

11. Grease lubrication point

12. Oil lubrication point

13. Running hours

14. Lifting point

15. Horn

16. Level

07/00

APPENDIX A

APPENDIX A - SYMBOL IDENTIFICATION

1.General symbols

17. Belt conveyor

18. Feeding

20. Check

2. Electric symbols

1. Remote control

21. Max. temperature

3. Lights

2. Battery charging indicator

1. Work light

2. Driving lights

4. Engine

1. Engine emergency stop

-2

2. Stopping of engine

3. Engine running speed

APPENDIX A

4. Combustion engine

07/00

APPENDIX A - SYMBOL IDENTIFICATION

4. Engine

5. Starting of engine

5. Fuel

1. Fuel volume

2. Fuel pressure

3. Fuel filter

5. Fuel refill

07/00

APPENDIX A

4. Fuel shut-off

APPENDIX A - SYMBOL IDENTIFICATION

6. Engine oil

1. Oil level

2. Oil refill

3. Oil pressure

4. Oil temperature

5. Oil filter

7. Cooler system

1. Coolant refill

-4

2. Coolant level indicator

3. Coolant pressure

APPENDIX A

4. Coolant temperature

07/00

APPENDIX A - SYMBOL IDENTIFICATION

8. Transmission oil

1. Oil refill

2. Oil level indicator

5. Oil filter

6. Testing point: oil pressure

3. Oil pressure

4. Oil temperature

9. Hydraulic oil

1. Hydraulic oil refill

07/00

2. Hydraulic oil level

3. Hydraulic oil pressure

APPENDIX A

4. Hydraulic oil temperature

APPENDIX A - SYMBOL IDENTIFICATION

9. Hydraulic oil

5. Hydraulic oil filter

6. Pressure testing

7. Shut-off valve

10. Air

1. Air intake

2. Air pressure

3. Air filter

11. Symbols not included in the ISO standard

1. Tensioning of power 2. Tightening of nuts and transmission belt bolts

-6

3. Remove / install transport locking

APPENDIX A

07/00

ADDITIONAL INFORMATION

CHAPTER

GUARDS AND PROTECTION DEVICES –

Belt drives are guarded.

–

The feed opening to the crusher is guarded.

–

Conveyor head and tail drum nip points are guarded.

–

Conveyors are equipped with emergency stop cables and safety switches or valves.

–

Emergency stop buttons are provided on the remote control box and service platform and in the electrical centre and cabin.

6

STORAGE OF THE MACHINES The machine must be stored in a dry and covered area. DISPOSAL OF THE MACHINE Whenever a machine is taken out of use, being dismantled or disposed of, all hazardous materials, such as oils, battery acids, fuels etc. must be carefully removed first to eliminate any danger to life and the environment. The hazardous materials must be removed to a suitable waste collection plant for disposal or recycling. Dispose of the machine so that there is no danger to life or the environment.

EMERGENCY STOP If a dangerous situation occurs, pull the nearest emergency stop cable or push an emergency stop button. After pulling an emergency stop cable, the trip switch will remain engaged and a signal light will show. To reset, push the button in the switch. To reset an emergency stop button, pull the red button to its outer position. Before restarting the machine ensure the area is clear around the unit and that no one will be endangered by your action. Start the machine according to the instruction manual. DISPOSAL OF WASTE Waste materials, such as oil, battery acids and cleaning fluids etc. must be removed carefully using suitable containers to prevent any hazard to people, animals or environment. The hazardous material must be removed to a suitable waste collection plant for disposal or recycling. FIRE The Manufacturer has not provided this machine with a fire extinguisher, and recommends that the user equips the machine with an extinguisher of a type approved by his local authorities. Inflammable materials used in the construction and use of this machine include: diesel and lubricating oils, conveyor belting and skirts, electrical cables and fittings, etc.

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Noise levels in excess of 85 dBA around the LT unit while running are shown in the diagram below. Ear protection must be worn in this area.

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RECYCLING

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0

If the machine is used for recycling, pay attention to the following: 1. Preprocessing of the feed material Break the feed material small enough and cut the metal bars to the length of 0.5 - 1 metres depending on the machine. Too long bars may damage the conveyor belt. 2. Feeding the material Remove the metal objects from the feed, if possible. At least remove the loose metal. The metal objects larger than the crusher setting must not enter the crusher. When removing the metal objects be very careful. Never go to the feeder when the machine is running. Observe the feed material. Never let uncrushable objects enter the crusher. 3. Block removal Be very careful when clearing the blocking. Stop the machine and use safety valve or switch during clearing.

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Factory test run in Metso Minerals (Tampere) Oy This document is only valid for products manufactured in Tampere, Finland. The machine has been test-run – i.e., its operation has been checked and adjusted to meet the requirements of the product specifications. During the test run, diesel fuel was used. This fuel may have in many countries a lowduty/tax or even duty/tax-free status and which may be categorised as red fuel in your country. There is this fuel left in the fuel tank and it may be subject to restrictions for use in certain countries.

NORDBERG C SERIES JAW CRUSHERS INSTRUCTION MANUAL 140588-EN

NORDBERG C SERIES JAW CRUSHERS

CHAPTER

0

This manual is valid for the Nordberg C Series Jaw Crushers manufactured by Metso Minerals. These crushers are high capacity jaw crushers, intented to be used in primary crushing applications.

Because of the continuous development of the products, the manufacturer reserves a right to alter the technical specifications written in this manual, without any advance information. This is the first edition published in April 2003 in Tampere, Finland .

Metso Minerals (Tampere) Oy P.O. Box 306 FIN-33101 Tampere Finland Tel. +358 (0)20 484 142 Fax +358 (0)20 484 143

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Nordberg C Series Jaw Crushers

Table of Contents NORDBERG C SERIES JAW CRUSHERS PREFACE 1.1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

SAFETY 2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.1.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.2 Warning signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.2.1 Warning sign codes and texts (ANSI). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2.2.2 Warning sign codes and texts (ISO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

GENERAL CRUSHER INFORMATION 3.1 CRUSHER TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 CRUSHER COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.3 SPARE PARTS BOOK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.4 ORDERING PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.5 ESTIMATING CRUSHER CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.6 ESTIMATING CRUSHER PRODUCT GRADATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3.7 CRUSHER SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3.8 CRUSHER SETTING LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 3.9 OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3.9.1 Intermediate Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3.9.2 Protection Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3.9.3 Conveyor Belt Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 3.9.4 Hydraulic Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 3.9.5 Automatic Lubrication Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

OPERATING INSTRUCTIONS 4.1 PREPARATIONS BEFORE STARTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.2 STARTING THE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.3 STOPPING THE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Nordberg C Series Jaw Crushers

Table of Contents 4.4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.4.1 Oversized Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.4.2 Tramp Iron/Uncrushables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.4.3 Packing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.5 RE-STARTING A CRUSHER STALLED UNDER LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.6 CRUSHER SETTING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.6.1 Mechanical Wedge Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.6.2 HYDRAULIC WEDGE SETTING ADJUSTMENT (OPTIONAL) . . . . . . . . . . . . . . . . . . . 4-6 4.6.3 ACTIVE SETTING CONTROL ADJUSTMENT (OPTIONAL). . . . . . . . . . . . . . . . . . . . . 4-8 4.7 TOGGLE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 4.8 SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 4.9 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

MAINTENANCE 5.1 SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.1.1 Spacer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.1.2 Spacer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5.2 TOGGLE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 5.2.1 Replacing the Toggle Plate And Toggle Seats (with wedge setting adjustment) . . . . . . 5-5 5.2.2 Replacing the Toggle Plate And Toggle Seats with Active Setting Control . . . . . . . . . . 5-7 5.3 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 5.3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 5.3.2 Grease Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 5.3.3 Eccentric Shaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 5.3.4 Eccentric Shaft Bearing Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 5.3.5 Jack-shaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 5.3.6 Jack-shaft Bearing Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 5.3.7 Thrust Bearing And Cap Nut Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 5.3.8 Electric Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 5.3.9 Toggle Seats And Toggle Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 5.3.10Setting Adjustment Wedges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 5.4 INSTRUCTIONS FOR LIFTING A JAW CRUSHER WHEN REPLACING CRUSHER SUPPORT BRACKET DAMPERS5-18 5.5 HYDRAULIC SETTING ADJUSTMENT POWER UNIT (OPTIONAL). . . . . . . . . . . . . . . . 5-20 5.5.1 Checking oil level and temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 5.5.2 Changing oil and filter (Figure 5.10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 5.5.3 Oil recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 5.5.4 Bleeding the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Nordberg C Series Jaw Crushers

Table of Contents 5.6 PERIODICAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 5.6.1 Daily maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 5.6.2 Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 5.6.3 Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 5.6.4 Twice a Year. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 5.6.5 Regularly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 5.7 MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 5.8 BOLT TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

REPLACEMENT OF WEAR PARTS 6.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.2 JAW SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.3 JAW WORK HARDENING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.4 CHEEK PLATE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.4.1 Cheek Plate Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.4.2 Cheek Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6.5 CHANGING OR ROTATING THE JAWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 6.5.1 One Piece Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 6.5.2 TWO-PIECE JAW REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 6.6 PITMAN EYE PROTECTION PLATE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 6.7 FEED HOPPER LINER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 6.8 TOGGLE PLATE SEAT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

Nordberg C Series Jaw Crushers

Table of Contents APPENDIX

1. 2. 3. 4. 5. 6. 7. 8. 9.

SAFETY, OPERATING AND MAINTENANCE INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . .A-1 Purpose of the jaw-lifting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Storage of the jaw-lifting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Safe use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Commissioning and operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 The jaw-lifting tool verification before first use and in service . . . . . . . . . . . . . . . . . . . .A-1 Handling the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3 Operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

APPENDIX

1. 2. 3. 4. 5. 6. 7. 8. 9.

SAFETY, OPERATING AND MAINTENANCE INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . .B-1 Purpose of the cheek plate lifting tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Storage of the cheek plate lifting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Safe use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Commissioning and operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2 The cheek plate lifting tool verification before first use and in service . . . . . . . . . . . . . .B-2 Handling the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3 Operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

PREFACE

CHAPTER

1

1.1 FOREWORD

1.2 SAFETY

This instruction manual provides guidance for first time operators of the crusher as well as technical procedures as a reference for the experienced crusher operator. Read, study, and keep it for future reference.

BASIC RULES REGARDING SAFETY IN AND AROUND A CRUSHING PLANT ARE OUTLINED IN THE SECTION ENTITLED "SAFETY."

The instructions given are for the operation and basic maintenance procedures only, as this instruction book is not a repair manual. Should maintenance procedures not covered in this manual be required, contact Metso Minerals. Illustrations and instructions guide the operator through correct procedures for checking, operating and maintaining the crusher and its accessories. Operating techniques outlined in this manual are basic. Operating skills and additional techniques will develop through experience as the operator gains knowledge of the crusher and its capabilities.

OPERATOR SAFETY AND THE SAFETY OF OTHERS DEPEND UPON REASONABLE CARE AND JUDGEMENT IN THE OPERATION OF THIS CRUSHER. A CAREFUL OPERATOR IS GOOD INSURANCE AGAINST AN ACCIDENT. MOST ACCIDENTS, NO MATTER WHERE THEY OCCUR, ARE CAUSED BY FAILURE TO OBSERVE AND FOLLOW SIMPLE FUNDAMENTAL RULES OR PRECAUTIONS. FOR THIS REASON RECOGNIZING HAZARDS AND TAKING STEPS TO AVOID THEM CAN PREVENT MOST ACCIDENTS. REGARDLESS OF THE CARE USED IN THE DESIGN AND CONSTRUCTION OF THIS TYPE OF EQUIPMENT, THERE ARE CONDITIONS THAT CANNOT BE COMPLETELY SAFEGUARDED AGAINST WITHOUT INTERFERING WITH REASONABLE ACCESSIBILITY AND EFFICIENT OPERATION. WARNINGS ARE INCLUDED IN THIS INSTRUCTION MANUAL TO HIGHLIGHT THESE CONDITIONS.

Continuing improvement and advancement of product design may result in changes to your new machine that may not be included in this publication. As required, each publication is reviewed and revised to update and include appropriate changes in the later editions. The descriptions and specifications in this manual were in effect at the time this manual was approved for printing. Metso Minerals reserves the right to discontinue models at any time and to change specifications and designs, without notice and without incurring obligation. Whenever a question arises concerning your crusher, or this publication, please consult your Metso Minerals representative for the latest available information.

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SAFETY

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2.1 GENERAL The instructions of the safety guide, these safety instructions and other manuals and safety labels for the equipment must be read, understood and used by each person who works with this equipment.

2

This manual uses the alert symbol, with words such as DANGER, WARNING or CAUTION, to alert you and other Crushing Plant personnel of actions or conditions that pose a potential safety hazard, with an attending risk of personal injury (including death) or property damage. The machine also displays safety signs, labels and tags at appropriate points to show safety risks that may exist.

WARNING! In addition to these unit-specific safety instructions, the operators of this equipment must also read the safety guide with instructions for general operational safety.

DANGER

The following symbol is used in this manual and on the machine to call attention to instructions, which will help prevent machine related injuries.

WARNING

When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.

CAUTION Sign

Figure 2.1 Alert Symbol

Description

Immediate hazards or unsafe practices DANGER that will result in severe personal injury or death. Hazards or unsafe practices that could WARNING result in severe personal injury or death Hazards or unsafe practices that could CAUTION result in minor personal injury or equipment damage Figure 2.2 Danger, warning, caution signs and their meaning

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2.1.1 General safety instructions

5. It is prohibited to stay in the danger area during the crushing process. The crushing material may be thrown into a few meters distance from the crusher. Always use helmet and safety glasses.

WARNING! Before performing any maintenance or repair work, make sure that the crusher is stopped and locked out.

6. Do not look into the jaw cavity during crushing. Material may be thrown from the crusher during crushing and cause injuries. Always use a helmet and safety glasses.

LOCKOUT PROCEDURE of the Lokotrack installed crushers

7. Because the crusher is installed on rubber dampers, it moves during crushing. This movement causes a crushing danger. Never put your hands or feet between the moving parts and the structure of the crusher during crushing. The movement may be as much as ± 10mm.

1. Switch off engine 2. Remove the ignition key and keep it on person during lockout 3. Place appropriate maintenance warning signs (TAG OUT)

8. Clearing a jammed cavity is extremely dangerous. Do not attempt to clear the cavity until the crusher has stopped completely.

LOCKOUT PROCEDURE of the electrical motor driven crushers

9. The crusher does not stop immediately after the motor has been turned off. Make sure that the crusher has stopped completely before opening any covers, performing any maintenance, or adjusting the crusher.

1. Switch off motor 2. Lock the main switch of the motor with a padlock or make sure in some other way that the engine cannot be started

10. The crushing plant and auxiliary equipment such as chutes, transfer stations, screens, etc. can create dust and, if not contained, the dust can escape into the air. Metso Minerals highly recommends that dust protective devices such as an appropriate respirator be worn by anyone exposed to airborne dust to prevent its inhalation. It is the responsibility of the Owner and Operator to determine the necessity and adequacy of protective devices and warnings, to provide them, and to ensure that they are used and followed!

3. Lock the main switch of the hydraulic adjustment power unit (if delivered) with padlock 4. Keep the keys on person during lockout 5. Place appropriate maintenance warning signs (TAG OUT). 1. Ignoring the safety instructions or the warning signs increases the risk of the severe injury or death.

11. The noise level is dangerously high near the crusher. All personnel working near the crusher must wear hearing protection. The noise level is typically about 102-110 dB next to the crusher during crushing.

2. Nordberg C series jaw crushers has been designed for safe operation when used by professional staff in the operating situations included in this instruction manual. All other service and repair procedures must be performed by specially trained personnel or authorized Metso service staff.

12. Before performing any maintenance or repair work, make sure that the crusher is stopped and locked out.

3. Never operate the crusher without proper covers and safety devices. 4. Before starting the crusher make sure that no one is near the crusher.

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NORDBERG C SERIES INSTRUCTION MANUAL

13. The surfaces of the crusher may become hot during crushing. Hot surfaces can cause severe burn injuries. Make sure that the

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CHAPTER 2 - SAFETY

surfaces have cooled before performing any maintenance work. 14. Before changing any wear parts of the crusher, read chapter 6: Replacement of wear parts and appendixes A and B carefully. 15. Before lifting any wear parts, check the weight of the component and ensure that lifting equipment being used is adequate to lift the weight. In addition, familiarize yourself with all the special tools provided with the crusher specifically for replacing the wear parts. 16. Read the instructions regarding the lifting tools and replacing wear parts carefully before replacing any wear parts. Make sure that the parts are adequately supported before lifting. Never go under a hanging part. The lifting tools delivered with the crusher are designed to be used only with original Metso Minerals wear parts. 17. The spring of the mechanical setting adjustment may accumulate significant amount of energy. Follow the instructions strictly and be extremely accurate when adjusting the spring. Never release the protective plate. 18. The pressure accumulator of the hydraulical setting adjustment may be charged only by a professional. If the pressure accumulator is charged incorrectly, it may explode. Do not charge the accumulator yourself. Release the pressure from the hydraulic system according to instructions before any maintenance to the system. 19. Keep the warning signs clean. Replace illegible and damaged signs before starting the crusher. Make sure that the warning signs are not hidden from sight when installing the crusher. If a part with a warning sign is replaced, make sure that the new part also has the required warning signs.

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2.2 WARNING SIGNS The warning signs attached to the equipment must always be kept readable and clean. Damaged or loose signs must be replaced at once before starting the crusher. Make sure that the warning signs are not covered during installation. If a part of the crusher attached a warning sign are replaced, always make sure that the warning signs needed are included in a new part.

IMPORTANT! There are two different sets of warning signs depending on the delivery country. You can check which set of warning signs is used on your machine from the side of the machine or the spare part manual.

Figure 2.3 The locations of the warning signs

The number and exact locations of the warning signs may vary according to options (for example, guards).

IMPORTANT!

The warning signs 1, 2, 3, and 4 are located on both sides of the crusher.

Warning signs 1, 2, 3 and 4 are not attached on crushers installed in Lokotracks or Nordwheelers.

The warning signs 3 are delivered only if the crusher delivery includes the drive guards. The warning sign 5 is delivered only with crushers that have a mechanical setting adjustment. The warning signs 6, 7, and 9 are delivered only with crushers that have a hydraulical setting adjustment.

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1

2

4

3

7

6

5

8 9

Figure 2.4 Warning signs (ANSI)

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2.2.1 Warning sign codes and texts (ANSI) 1. MM0229994 WARNING Read and understand instruction manual before using or maintaining this machine. Failure to follow operating instructions may result in death or serious injury. DANGER Lung disease hazard. Dust protection required. WARNING Risk of eye injury. Use of eye protection required. CAUTION Risk of head injury. Use of a helmet required. CAUTION Hazardous noise level. Use of ear protection required. 2. MM0229995 DANGER Moving parts can crush and cut. Do not insert tools in the crusher cavity when the motor is running. WARNING Material can fall out. do not stand in the vicinity of the crusher when the motor is running.

5. MM0229998 DANGER Spring in compression. Read and understand instruction manual before adjusting or servicing. Do NOT remove this protection plate. 6. MM0230002 WARNING Servicing while pressurized can cause severe injury. Lock out source and relieve pressure before servicing. 7. MM0230006 CAUTION Hot surface. Contact with skin may cause burns. Do not touch. 8. MM0230004 CAUTION Hot surface. Contact with skin may cause burns. Do not touch. 9. MM0230447 WARNING Pressurized device. Only authorized personnel should service this dev ice. See instruction manual for safety information.

3. MM0229997 WARNING Exposed moving parts can cause severe injury. Do not open drive guard before machine is completely stopped. 4. MM0229996 WARNING Exposed moving parts can cause severe injury. Do NOT operate this machine without proper guards.

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1

3 4

2

6

5

7

8

9

Figure 2.5 Warning signs (ISO)

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2.2.2 Warning sign codes and texts (ISO) 1. MM0250258 WARNING Read and understand instruction manual before using or maintaining this machine. Failure to follow operating instructions may result in death or serious injury. DANGER Lung disease hazard. Dust protection required. WARNING Risk of eye injury. Use of eye protection required. CAUTION Risk of head injury. Use of a helmet required. CAUTION Hazardous noise level. Use of ear protection required. 2. MM0250251 DANGER Moving parts can crush and cut. Do not insert tools in the crusher cavity when the motor is running. WARNING Material can fall out. do not stand in the vicinity of the crusher when the motor is running.

5. MM0250242 DANGER Spring in compression. Read and understand instruction manual before adjusting or servicing. Do NOT remove this protection plate. 6. MM0250241 WARNING Servicing while pressurized can cause severe injury. Lock out source and relieve pressure before servicing. 7. MM0250239 CAUTION Hot surface. Contact with skin may cause burns. Do not touch. 8. MM0251117 CAUTION Hot surface. Contact with skin may cause burns. Do not touch. 9. MM0250104 WARNING Pressurized device. Only authorized personnel should service this device. See instruction manual for safety information.

3. MM0250244 WARNING Exposed moving parts can cause severe injury. Do not open drive guard before machine is completely stopped. 4. MM0250244 WARNING Exposed moving parts can cause severe injury. Do NOT operate this machine without proper guards.

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GENERAL CRUSHER INFORMATION

CHAPTER

3

3.1 CRUSHER TERMINOLOGY Throughout this instruction manual, technical terms are used to describe the crusher, its components and its operation. These terms are defined herein with the intent of avoiding any confusion or misunderstanding.

Callout 1 2 3 4

Description Feed opening depth Moving jaw Stationary jaw Closed side setting (c.s.s)

Callout Description 5 Stroke 6 Nip angle 7 Feed opening width

Figure 3.1 Jaw crusher terminology

Feed: The raw material to be crushed, such as the rock type (limestone, basalt, granite, etc.) or man-made materials such as concrete and asphalt. The feed size is typically denoted in terms of a size distribution or based on an average top (maximum) size. Product size: The size of the material after it has been crushed. Similarly to the feed size, the product size is typically denoted in terms of a size

EN

distribution or based on an average top (maximum) size. Capacity: The output of the crusher in tons per hour. Feed Opening: The opening where the feed material is fed into the crusher. The feed opening has two dimensions: a width and a depth. The feed opening depth is a critical dimension because it dictates the maximum feed size a given jaw crusher model can accept.

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Maximum Recommended Feed Size: As a general guideline, the maximum average recommended feed size should be about 80% of the feed opening depth. Such measures will ensure that any bridging events resulting from oversized feed are kept to a minimum. A rock hammer is recommended for applications where the maximum feed size is regularly close to the feed opening depth.

Feed Opening

C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200

mm 800 X 510 930 X 600 1000 X 760 1060 X 700 1100 X 850 1150 X 800 1380 X 760 1250 X 950 1400 X 1070 1400 X 1100 1600 X 1200 2000 X 1500

inch 20 X 32 24 X 37 30 X 40 28 X 42 34 X 44 32 X 45 30 X 54 37 X 49 42 X 55 43 X 55 47 X 63 59 X 79

Stroke: The difference between the maximum and minimum distances at the bottom of the fixed and moving jaws during one revolution of the eccentric shaft.

Maximum Rec. Feed Size mm 408 480 608 560 680 610 608 760 856 880 960 1200

inch 16 19 24 22 27 24 24 30 34 35 38 47

Table 3-1 Maximum recommended feed sizes

Nip Angle: The angle between the fixed and moving jaws. The nip angle is often referred to as the "bite" angle as well. Jaws: The members that perform the crushing are commonly referred to as jaws. The jaws consist of a stationary and moving jaw, and depending on the model each one of these may consist of either 1 or 2 pieces. Different jaw profiles are available for different applications. Discharge Setting: The shortest distance between the bottom of the fixed and moving jaws as measured at the point where the jaws are at their closest relationship during their work cycle (i.e. the closed side setting, or c.s.s.). The method in which the setting is measured varies depending on the jaw profile. These differences are explained in detail in the CRUSHER SETTING section.

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3.2 CRUSHER COMPONENTS

Callout 1 2 3 4 5 6 7 8 9 10 11

Description Front frame Upper wedge Filling wedge Jaw bolt Disc spring package Cheek plate, upper Fixed jaw, upper Moving jaw, upper Center wedges Cheek plate, lower Fixed jaw, lower

Callout 12 13 14 15 16 17 18 19 20 21 22

Description Moving jaw, lower Frame bolt Fixed wedge Pitman eye protection plate Flywheel Eccentric shaft Pitman bearing Pitman Frame connecting rods Side plate Toggle seat

Figure 3.2 Jaw crusher main components

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Callout 1 2 3 4 5 6 7

Description Rear frame Adjustment wedges Spacer Toggle seat holder Toggle seat Locking nuts with thrust bearing Tension spring

Callout 8 9 10 11 12 13 14 15

Description Tension rod Toggle plate Piston rod Piston Pressure relief valve Pressure accumulator Tension cylinder Cylinder cover

Figure 3.3 Jaw crusher rear frame components

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3.5 ESTIMATING CRUSHER CAPACITY

3.3 SPARE PARTS BOOK A Spare Parts Book containing various assembly drawings pertaining to your crusher will be sent immediately after the crusher has been shipped. This book illustrates each and every part used in the assembly of the machine and is to be used when ordering spare or replacement parts.

3.4 ORDERING PARTS Metso Minerals endeavors to carry an ample supply of parts in stock to provide prompt and efficient service on all orders for repairs and replacements. To avoid delay and the possibility of incorrect parts being furnished, the following information should be given:

The capacity of the crusher depends on factors such as the type of feed (material type, size distribution, fracture characteristics, moisture content, etc.), type of operation (feed availability, feed arrangement) and discharge setting. To obtain an estimate of the capacity, refer to the following capacity table. These capacities are based on results obtained in actual practice with hard granite that has a bulk density of 1.6 t/m3 (100 lb/ft3), and are where the feed has been properly graded so that bridging does not take place. To obtain more accurate capacity estimates specific to your actual crushing application, contact your local Metso Minerals sales representative to request a computer simulation of your circuit's operating condition

1. Crusher size. 2. The serial number of the crusher which is stamped on the crusher nameplate. The serial number is also on the cover of the spare parts books. 3. Complete name and part code number as shown in the Spare Parts Book. 4. Exact quantity of each part ordered. 5. Complete shipping instructions. If your crusher Spare Parts Books have been lost, destroyed or misplaced, an additional set can be ordered. For proper operation, only genuine factory parts should be installed. These are guaranteed as to accuracy, workmanship and material. Using pirate parts may put your safety and that of your crusher at risk. Make sure you completely understand your crusher's Warranty conditions at all times.

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c.s .s .

C80

C96

C100

C106

C110

C116

C125

C140

C145

C160

C200 C3054

M tph M tph M tph M tph M tph M tph M tph M tph M tph M tph M tph M tph mm

in

40

Stph

Stph

Stph

Stph

Stph

Stph

150

171

190

175

Stph

Stph

Stph

Stph

Stph

Stph

65 1-5/8"

50

70 80

2"

90

2-3/8"

105

135

115

140

60

95

70 2-3/4" 80 3-1/8" 90 3-1/2" 100 4" 125 5" 150 6" 175 7" 200 8"

120 240

125

155

165

187

210

190

265

130

160

170

193

210

195

270

145

175

190

215

235

220

295

150

180

190

220

235

220

295

165

200

210

242

260

240

165

200

215

242

255

245

290

325

180

220

235

270

285

270

320

355

210

250

265

308

310

305

250

385

400

230

275

290

336

345

335

385

425

440

250

300

315

369

370

360

410

455

470

325

390 430 520

460

275

330

350

407

405

400

455

500

520

575

290

350

370

429

425

425

470

520

540

595

760

530

320

385

405

473

470

465

520

575

595

655

840

585

420

490

480

530

590

610

675

855

600

465

539

530

585

650

670

740

940

660

590

655

680

750

945

650

725

750

825

1045

650

725

750

825

1040

720

800

825

910

1145

820

900

1130

900

995

1250

225 9" 250 10" 275 11" 300 12"

510

980

1225

1080

1350

Table 3-2 Nominal jaw crusher capacities

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3.6 ESTIMATING CRUSHER PRODUCT GRADATION

These product gradations are based on results obtained in actual practice with hard granite. To obtain more accurate product gradation estimates, contact your local Metso Minerals sales representative to request a computer simulation of your circuit's operating conditions.

The crusher's product gradation depends on the same factors that affect capacity. The following figure gives an indication of the product gradation as a function of the closed side setting (c.s.s.).

1"

2"

4"

8"

16"

100

90 css

40 50

70

100 130 160 200 250

300

80

Percentage passing, weight %

70

60

50

40

30

20

10

0 1

10

100

1000

Product size

Figure 3.4 Crusher product gradation

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3.7 CRUSHER SETTING The Crusher setting is the most important Crusher parameter since it determines the Crusher's capacity as well as the top size of the Crusher product. It is therefore indispensable for everyone to understand how the Crusher setting is measured. The discharge setting is the shortest distance between the bottoms of the fixed and moving jaws during their work cycle. This distance is referred to as the closed side setting (c.s.s.), and it is a calculated distance as the Crusher setting is typically measured when the Crusher is at rest. The largest distance between the bottoms of the fixed and moving jaws is referred to as the open side setting (o.s.s.), and it is typically a distance that is directly measured when the Crusher is at rest.

The Crusher setting is measured in three different ways, first referring to the tooth groove (bottom) or crown (top) of the stationary jaw and then to the tooth groove (bottom) or crown (top) of the movable jaw. Thus, the setting is always measured from the Stationary (bottom or top) to the Movable jaw (bottom or top). The three alternatives are shown in Table 3-3. The measurement type depends on the profile as well as on the Crusher model. This information is also found in the Crusher Spare Parts Book.

Measurement Type 1 2 3

Reading Sequence (Jaws) Stationary Bottom Top Top

to to to to

Movable Top Top Bottom

Table 3-3 Measurement types

Figure 3.5 Crusher setting measurement

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For example, the setting of the C125, equipped with Quarry jaws, is measured from Top to Top (Type 2). However, with Standard jaws, the setting is measured from Bottom to Top (Type 1). IMPORTANT! The Crusher setting must always be measured in a straight line at the bottom of the crushing cavity. Measure the setting always from the least worn area.

Example Crusher: C140 Stroke: 42 mm (15/8” ) (Table 3-4) Jaw Profile: Quarry (top to top) O.S.S.: 230 mm (9") C.S.S.: 230 – 42 = 188 mm (9" – 1 5/8" = 7 3/8")

It is easiest to measure the setting when the Crusher is at rest with a device such as a block of wood of known dimensions (several blocks should be available if more than one setting is typically used). The distance measured this way is larger than the closed side setting (c.s.s.) because the pitman always stops at its lowest point. This value is close (±2mm/±0.08") to the open side setting (o.s.s.). As previously mentioned, the closed side setting is calculated by deducting the stroke from the open side setting (Table 3-4).

Model C80 C96 C100 C106

Stroke mm Inch 24 1 32 1¼ 32 1¼ 13/8 34

C110

36

17/16

C116 C3054

37 32

C125

41

1½ 1¼ 15/8

C140

41

15/8

C145

41

15/8

C160

41

15/8

C200

50

2

Table 3-4 Dimension (stroke) to be deducted from the open side setting (o.s.s.) to calculate the closed side setting (c.s.s.).

Dimension (stroke) to be deducted from the open side setting (o.s.s.) to calculate the closed side setting (c.s.s.).

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Figure 3.6 Measuring the setting

NOTE: The C.S.S does not have to be calculated if the user knows the Crusher setting limits in terms of the O.S.S. The C.S.S. is typically calculated because Crusher capacity is always denoted in terms of the C.S.S. only.

3.8 CRUSHER SETTING LIMITS All C-Series Crusher models have a maximum possible setting as well as a minimum allowed setting, and it is very important that the user understands why these are important to keep these in mind at all times. The maximum possible setting is simply the maximum setting that the Crusher is physically able to accommodate. Typically, such setting is indicated with new jaws, and the setting actually depends on the jaw profile as well as on whether a spacer is being used or not. This information is always found in the Crusher Spare Parts Book.

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The minimum allowed setting (c.s.s. or o.s.s.) is the minimum setting at which the Crusher can be used when the Crusher is operated according to Metso Minerals' recommendations. The minimum allowed setting is very important as it takes into account the design and operation limits of the Crusher. Not respecting these recommendations can lead to a poor utilization of the jaws (high scrap rate) as well as a shortened Crusher life. The minimum allowed setting varies depending on whether the application is a normal rock application (Normal), or a recycling application (Special), when materials such as concrete, asphalt and bricks are being crushed. Note that the minimum allowed setting does not depend on the jaw profile (it is always the same for a specific Crusher model). See Table 3-5.

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Crusher model

C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200

CSS Hard rock Soft Rock (>150 Mpa) ( 22 000 psi) (150 Mpa) ( 22 000 psi) (150 Mpa) ( 22 000 psi) (150 Mpa) ( 22 000 psi) ( 0.9d n

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JAW LIFTING TOOL

A-3

APPENDIX A

If any chain link within the leg of a chain sling is required to be replaced then the whole of the chain within that leg should be renewed.

Dimension L (4), measured between positions 2 and 3, must not exceed 10% of the value given in Table 2 below. If dimension L (4) exceeds 10% of the original value, the jaw-lifting tool must be replaced immediately. Lifting tool 582133 582151 585042

The repair of chain in a welded the jaw-lifting tool should only be carried out by the manufacturer using a resistance butt or flash butt welding process.

Check dimension L 382 +38 mm (15.04" +1.50") 367

+37 mm

395

+40 mm

(14.45"

Components that are cracked, visibly distorted or twisted, severely corroded or have deposits which cannot be removed should be discarded and replaced. Minor damage such as nicks and gouges may be removed by careful grinding or filing. The surface should blend smoothly into the adjacent material without abrupt change of section. The complete removal of the damage should not reduce the thickness of the section at that point to less than the manufacturers specified minimum dimensions or by more than 10 % of nominal thickness of the section.

+1.47")

(15.55” +1.57”)

Table 2 g. Check the condition of the locking mechanism (5). h. Lubricate the mechanism (6) with spray vaseline oil and turning the lever. i. Check the surfaces of the centre pin (7) and shoulder (8) visually.

A thorough examination should be carried out by a competent person at intervals not exceeding twelve months. This interval should be less where deemed necessary in the light of service conditions.

In the case of the jaw-lifting tool on which repair work has involved welding, each repaired chain sling should be proof tested following heat treatment using a force equivalent to twice the working load limit and thoroughly examined before it is returned to use. However, where repair is carried out by inserting a mechanically assembled component, proof-testing is not required providing that the component has already been tested by the manufacturer in accordance with the relevant European standard.

Records of such examinations should be maintained.

The accuracy of the tensile test equipment should be of class 2 as given in EN 10002-2.

j. The locking bolt (9) must be able to lock the lever during lifting. If worn or damaged replace the jaw-lifting tool immediately. Thorough examination

Chains slings should be thoroughly cleaned so as to be free from oil, dirt and rust prior to examination. Any cleaning method which does not damage the parent metal is acceptable. Methods to avoid are those using acids, overheating, removal of metal or movement of metal which may cover cracks or surface defects. Adequate lighting should be provided and the chain sling should be examined throughout its length to detect any evidence of wear, distortion or external damage. Repair Any replacement component or part of the chain sling should be in accordance with the appropriate European Standard for that component or part.

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JAW LIFTING TOOL

9. Operating instructions WARNING! Before lifting any wear parts, check the weight of the component and ensure that the lifting equipment being used is adequate to lift the weight. a. Clean the lifting hole of jaw in order to insert the jaw-lifting tool in. Make sure that there is not any material in the jaw-lifting hole, as it may prevent jaw-lifting tool's locking mechanism to function properly.

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APPENDIX A

b. Jaw-lifting holes can be kept clean by covering them with polyurethane. The polyurethane must withstand ambient temperatures and must be melted away with a torch prior to inserting the jaw-lifting tool. c. Turn the lever to the installation position so that the hinged tip of centre pin and the stationary part of the pin form a flush shape (Ref. Figure 2). The lever must remain locked in this position. d. Insert both hooks into the lifting holes and turn the levers 180 degrees in order to lock the pins to the jaw. The levers lock themselves to this position but as an additional safety precaution the locking mechanisms are secured by means of screwing in butterfly screws. e. Before beginning the hoist make sure that jaw is loose. f. Start the hoist slowly. If the jaw jams, stop lifting and unfasten jaw. g. Keep the hoisting zone free of people at all times. h. Never stand underneath a suspended load.

Figure 3 Lifting tool usage: A) Locked B) Unlocked

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APPENDIX A

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B

APPENDIX

NORDBERG C-SERIES JAW CRUSHER'S CHEEK PLATE LIFTING TOOL SAFETY, OPERATING AND MAINTENANCE INSTRUCTIONS

Load the lifting tool evenly and carry out the lifting and displacement of the cheek plate carefully. Keep the lifting zone free of people during lifting. Do not use the cheek plate lifting tool in a hurry.

1. Purpose of the cheek plate lifting tool The cheek plate lifting tool that is provided with Nordberg C Series jaw crushers is intended for the lifting of genuine Metso Minerals Nordberg C Series wear parts (cheek plates) only. The cheek plate lifting tool is not designed nor tested for the lifting of other types of objects.

4. Commissioning and operating conditions The cheek plate lifting tool is supplied fully assembled and it is ready for immediate use. The cheek plate lifting tool can be used in the same operating conditions as the jaw crusher.

2. Storage of the cheek plate lifting tool When not in use the cheek plate lifting tool should normally be stored carefully away from damaging materials, such as dirt or sand. They should not be left lying on the ground where they may be damaged. If it is likely that the cheek plate lifting tool will be out of use for some time they should be cleaned, dried and protected from corrosion, e.g. lightly oiled. 3. Safe use WARNING! Before lifting any wear parts, check the weight of the component and ensure that the lifting equipment being used is adequate to lift the weight. Read all instructions concerning the cheek plate lifting tool carefully and make sure that the tool is inspected regularly. Prior to lifting, make sure that the cheek plate lifting tool is locked and does not come out of the lifting hole. The cheek plate lifting tool is only meant for the lifting of genuine Metso Minerals Nordberg C Series cheek plates. It is neither designed nor tested for unfastening used cheek plates that may not readily come loose prior to lifting. Do not overload the cheek plate lifting tool. The maximum lifting load is found on the tag of the cheek plate lifting tool (see Table 1). Stop the lifting procedure immediately if the cheek plate is stuck to its location.

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CHEEK PLATE LIFTING TOOL B-1

APPENDIX B

5. Technical data The maximum lifting load is mentioned on the attached tag of the cheek plate lifting tool. Table 1 shows available lifting tools and the corresponding lifting hole sizes. Lifting tool MM0209800 MM0209814

Maximum lifting load (Working load limit, WLL) 1000 kg (2204 lbs) 500 kg (1102 lbs)

Diameter of lifting hole 80 mm (3.1”) 40 mm (1.6”)

Table 1 The cheek plate lifting tool should be clean enough to observe possible damages.

6. The cheek plate lifting tool verification before first use and in service

Adequate lighting should be provided and the cheek plate lifting tool should be examined throughout its length to detect any evidence of wear, distortion, or external damage.

Before first use Before first use of the cheek plate lifting tool it should be ensured that: a. the cheek plate lifting tool is precisely as ordered;

7. Handling the load Preparation

b. the manufacturer's certificate is at hand; c. the identification and working load limit marking on the cheek plate lifting tool correspond to the information on the certificate;

Attention should be given to any specific instructions provided for the handling of the load. Before starting the lift, it should be ensured that the load is free to move and is not bolted down or otherwise obstructed.

d. full details of the cheek plate lifting tool are recorded.

Mass of the load It is essential that the mass of the load to be lifted is known. If the mass is not marked, the information should be obtained from the consignment notes, manuals, plans, etc. If such information is not available, the mass should be assessed by calculation.

Before each use Before each use the cheek plate lifting tool should be inspected for obvious damage or deterioration (see paragraph 8 Maintenance / Inspection). If faults are found during this inspection, the procedure given in paragraph 8 Maintenance should be followed.

Centre of gravity

The cheek plate lifting tool must be inspected visually before every lift and more precisely at least once a year. See detailed instructions below. Inspections must be documented for own as well as authority audits. A damaged cheek plate lifting tool must be replaced or repaired immediately. Special attention should be paid to the condition of the threads, welds, and fasteners.

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CHEEK PLATE LIFTING TOOL

The position of the centre of gravity of the load should be established in relation to the possible points of attachment of the chain sling. To lift the load without tilting or toppling it, the following conditions should be met: a. For two leg chain slings the attachment points should be on either side of and above the centre of gravity. b. The hook to which the cheek plate lifting tool is attached should be directly above the centre of gravity.

N11456138_K

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APPENDIX B

Method of connection The cheek plate lifting tool is attached to the load and the lifting machine by means of terminal fittings such as hooks and links. Chains should not have any twists or knots. The lifting point should be seated well in the hook and the hook should be free to incline in any direction to avoid bending. For the same reason, the master link should be free to incline in any direction on the hook to which it is fitted. Straight leg

8. Maintenance Inspection During service, the cheek plate lifting tool is subjected to conditions which affect their safety. It is necessary therefore to ensure, as far as is reasonably practicable, that the chain sling should be safe for continued use. If the tag or label identifying the chain sling and its working load limit becomes detached and the necessary information is not marked on the master link itself, or by some other means, the cheek plate lifting tool should be withdrawn from service.

In this case the lower terminals are connected directly to the attachment points. The hooks and attachment points should be selected so that the load is carried in the seat of the hook and tip loading of the hook is avoided.

The chain sling should be withdrawn from service and referred to a competent person for thorough examination if any of the following are observed:

In order to prevent dangerous swaying of the load and to position it for loading, a tag line is recommended.

a. The chain sling markings (information on the chain sling identification and/or the working load limit) are illegible.

When loads are accelerated or decelerated suddenly, high dynamic forces occur that increase the stresses in the chain. Such situations, which should be avoided, arise from snatch or shock loading, e.g. from not taking up the slack chain before starting to lift or by the impact of stopping falling loads.

b. Distortion of the upper or lower terminals. c. Chain stretch.

Safety of lift Hands and other parts of the body should be kept away from the chain to prevent injury as the slack is taken up. When ready to lift, the slack should be taken up until the chain is taut. The load should be raised slightly and a check made that it is secure and assumes the position intended. This is especially important with basket or other loose hitches where friction retains the load. Landing the load The landing site should be prepared. It should be ensured that the ground or floor is of adequate strength to take the weight taking into account any voids, ducts, pipes, etc. which may be damaged or collapse. It should also be ensured that there is adequate access to the site and that it is clear of any unnecessary obstacles and people. It may be necessary to provide timber bearers or similar material to avoid trapping the chain sling or to

EN

protect the floor or load or to ensure the stability of the load when landed.

If the chain links are elongated or if there is any lack of free articulation between the links or noticeable difference in the leg length of multi-leg chain slings, the chain may have been stretched. d. Wear by contact with other objects usually occurs on the outside of the straight portions of the links where it is easily seen and measured. Wear between adjoining links is hidden. The chain should be slack and adjoining links rotated to expose the inner end of each link. Inter-link wear, as measured by taking the diameter indicated (d1) and one at right angles, (d2) may be tolerated until the mean of these diameters has been reduced to 90 % of the nominal diameter (dn) provided. (see Figure 1)

N11456138_K

d +d 2 1

2

> 0.9d n

CHEEK PLATE LIFTING TOOL

B-3

APPENDIX B

e. Cuts, nicks, gouges, cracks, excessive corrosion, heat discoloration, bent or distorted links or any other defects. f. Check the condition of the pin in position 1 (see Figure 2). If the pin is worn by 10% (or more) of its original dimension (MM0209800 = 10 mm, 0.39"; MM0209814 = 8 mm, 0.31”), it must be replaced immediately. Figure 1

Figure 2

Dimension L (4), measured between positions 2 and 3, must be within the values given in Table 2. If dimension L (4) is outside of the values given in the table, the cheek plate lifting tool must be replaced immediately.

B-4

CHEEK PLATE LIFTING TOOL

Lifting tool MM0209800 MM0209814

Min. length L 210 mm (8.3”) 182 mm (7.2”)

Max. length L 250 mm (9.8”) 222 mm (8.7”)

Table 2

N11456138_K

EN

APPENDIX B

the thickness of the section at that point to less than the manufacturer’s specified minimum dimensions or by more than 10 % of nominal thickness of the section.

g. Check the condition of the locking mechanism (8). h. Lubricate the mechanism (7) with spray vaseline oil and turning the lever. i. Check the surfaces of the centre pin (5) and shoulder (6) visually. j. The locking bolt must be able to lock the lever during lifting. If worn or damaged replace the cheek plate lifting tool immediately. Thorough examination A thorough examination should be carried out by a competent person at intervals not exceeding twelve months. This interval should be less where deemed necessary in the light of service conditions.

If the repair work of the cheek plate lifting tool has involved welding, each repaired chain sling should be proof-tested following heat treatment using a force equivalent to twice the working load limit, and thoroughly examined before it is returned to use. However, where repair is carried out by inserting a mechanically assembled component, proof-testing is not required providing that the component has already been tested by the manufacturer in accordance with the relevant European standard. The accuracy of the tensile test equipment should be of class 2 as given in EN 10002-2.

Records of such examinations should be maintained. Chains slings should be thoroughly cleaned so as to be free from oil, dirt and rust prior to examination. Any cleaning method which does not damage the parent metal is acceptable. Methods to avoid are those using acids, overheating, removal of metal, or movement of metal which may cover cracks or surface defects. Adequate lighting should be provided and the chain sling should be examined throughout its length to detect any evidence of wear, distortion or external damage. Repair Any replacement component or part of the chain sling should be in accordance with the appropriate European Standard for that component or part. If any chain link within the leg of a chain sling has to be replaced then the whole of the chain within that leg should be renewed. Any chain repairs that require welding should only be carried out by the manufacturer using a resistance butt or flash butt welding process. Components that are cracked, visibly distorted or twisted, severely corroded, or have deposits which cannot be removed should be discarded and replaced. Minor damage such as nicks and gouges may be removed by careful grinding or filing. The surface should blend smoothly into the adjacent material without abrupt change of section. The complete removal of the damage should not reduce

EN

9. Operating instructions WARNING! Before lifting any wear parts, check the weight of the component and ensure that the lifting equipment being used is adequate to lift the weight. a. Clean the lifting hole of the cheek plate in order to insert the cheek plate lifting tool. Make sure that there is no material in the cheek plate lifting hole, as it may prevent the cheek plate lifting tool's locking mechanism from functioning properly. b. Cheek plate lifting holes can be kept clean by covering them with polyurethane. The polyurethane must withstand ambient temperatures and must be melted away with a torch prior to inserting the cheek plate lifting tool. c. Turn the lever to the installation position so that the hinged tip of the centre pin and the stationary part of the pin form a flush shape (Ref. Figure 2). The lever must remain locked in this position. d. Insert the hook into the lifting hole and turn the lever 180 degrees in order to lock the pins to the jaw. The lever locks

N11456138_K

CHEEK PLATE LIFTING TOOL

B-5

APPENDIX B

to this position but as an additional safety precaution the locking mechanism is secured with a butterfly screw. e. Before beginning the hoist make sure that the cheek plate is loose. f. Start the hoist slowly. If the cheek plate jams, stop the lifting and unfasten the cheek plate. g. Keep the hoisting zone free of people at all times. h. Never stand underneath a suspended load.

B-6

CHEEK PLATE LIFTING TOOL

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EN

APPENDIX B

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B-7

7.9LEUDWLQJFKXWHV DQGVFUHHQV Instruction manual 140401

0HWVR0LQHUDOV

Instruction manual

Vibrating chutes

9LEUDWLQJFKXWHV This instruction manual is valid for vibrating chutes manufactured by Nordberg-Lokomo Oy.

Because of the continuous development of the product, the manufacturer reserves a right to alter the technical specifications written in this manual, without any advance information. This is the second edition published in may 1999 in Tampere, Finland.

Manufacturer: Metso Minerals (Tampere) OY PL 306 33101 Tampere Finland Tel. +358-204 84 142 Fax. +358-204 84 143

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Instruction manual

Vibrating Chutes

9LEUDWLQJ&KXWHV TABLE OF CONTENTS 1.

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WARNING SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTENDED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTRUCTION MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE AND REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OTHER SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1 2-1 2-1 2-1 2-2 2-3 2-3 2-4 2-6

3. 3.1 3.2 3.3 3.4 3.5 3.6

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Used terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nordberg vibrating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Uses of Nordberg vibrating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Principle of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare and ware parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1 3-1 3-1 3-2 3-2 3-3 3-4

4. 4.1 4.2 4.3 4.4 4.5 4.6

INSTALLATION, OPERATION AND TRANSPORT. . . . . . . . . . . . . . . . . . . . Foundation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting a hydraulic drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1 4-1 4-2 4-2 4-2 4-3 4-3

5. 5.1 5.2 5.3 5.4 5.5

OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring the stroke and the stroke angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1 5-1 5-1 5-1 5-1 5-2

6. 6.1

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Vibrating motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

7. 7.1 7.2 7.3

PERIODICAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Every three months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Vibrating Chutes

Instruction manual

8. 8.1 8.2

OTHER MAINTENANCE ACTIVITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Pre-tightening of screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Changing of grizzly cassettes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

9.

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

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Preface

 35()$&( This instruction manual is intended to assist owners and users of Nordberg products in the proper use of the equipment.

This instruction manual must be read and used by each person who works with the equipment, typically:

It includes important references to safe, proper and economical operation of the equipment. Following these instructions will help to avoid possible danger, reduce repair costs and breakdowns and to increase the reliability and life of the equipment.

— operations, including installation, startup, operation, application engineering, materials handling, site labour, environmental engineering and safety departments. — maintenance, including inspection and repair. — transport, materials handling and rigging.

This manual must be complemented by those instructions necessary because of existing national mandatory rules relating to accident prevention and environmental protection. A copy of this manual must be kept at the equipment’s location and made available to the operators as required. In addition to this manual and accident prevention regulations mandatory in the country of use and at the equipment’s place of operation, generally recognized rules for safe and professional operation must be observed.

Note that this instruction manual contains information and instructions on alternative and optional equipment. Normally the machines have only some of them. Before maintaining and servicing, find out which alternative and optional equipment your machine has. See separate instruction manuals for more detailed instructions when servicing the main components. There may be optional equipment which have separate instruction manuals. Those manuals must be read and used by each person who works with the equipment.

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1-1

SAFETY

SECTION

2

Please refer to the general Safety Instructions in Part A of this Instruction Manual folder.

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SAFETY

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SECTION 2 - SAFETY

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SAFETY

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General

Vibrating Chutes

 *(1(5$/ The operation manual deals with vibrating TK feeders and screens. Henceforth these will be generally called vibrating devices.

3.1 Used terms — Capacity = Transport ability of vibrator in tons per hour. — Sorting capacity = Sorting ability of vibrator in tons per hour. — Feeding end (F) = The end of the vibrator, where material is fed into. — Discharge end (D) = The end of the vibrator, where material is discharged from. — Vibrator = The mechanism in the vibrating device that makes the device vibrate. — Grizzly (G) = Grating structure in the vibrating device that separates the fine matter from the fed material. — Screen deck = Cloth structure in vibrating device that sorts the fed material into fractions. — Stroke length = Distance between vibration motion extreme positions of vibrating device. — Stroke angle = Direction of stroke movement in relation to horizontal.

3.2 Nordberg vibrating devices The Nordberg vibrating devices have either a closed bottom, or a screen deck and one or more grizzlies. There are different sizes of vibrating devices for various uses. The vibrating devices have either a direct squirrel-cage motor drive or a regulating drive with a frequency converter, some vibrating device types have a hydraulic drive. Grizzlies and screen cloths are available for different uses and they can be changed.

FIGURE 3.1.1 Terms used in the operation manual

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Vibrating Chutes

General

3.3 Uses of Nordberg vibrating devices The vibrating devices manufactured by Metso Minerals are used for feeding, transport and sorting of stone material, concrete and asphalt. 3.4 Principle of operation The body is supported on its base by springs, which the body vibrates on. Material is fed into the feeding end of the vibrating device and it is discharged from its discharge end.

The stroke angle of interconnected shafts is defined by the reciprocal position of the shafts and the position of the vibrator. The vibrating device can have a grizzly or a screen deck that lets the fine grain sizes through. The capacity (feeding efficiency) is regulated by altering the eccentric masses of the vibrator. The capacity can also be regulated by changing the speed of rotation of the vibrator by means of an optional frequency converter or a hydraulic drive, if needed.

Two identical rotating mechanisms revolving in opposite directions provide a rectilinear stroke movement. The material on the vibrating device moves due to the fact that the vertical movement of the base is quicker than that produced by the gravitational pull. Therefor the material comes off the bottom, continuing its movement in the direction of the movement of the moment of the base. The stroke angle of free synchronizing shafts is defined by the center of gravity and the position of the vibrator.

TYPE MARKING

TK 13 - 20 - 3V Vibrator Body width (dm) Body length (dm)

No marks = closed bottom S = with screen deck 2V = two stage grizzly 3V = three stage grizzly

FIGURE 3.2.1 Type marking of vibrating chutes

3-2

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General

Vibrating Chutes

3.5 Spare and ware parts Nordberg produces, with the same type marking, vibrating devices that differ from each other. In order to secure the right information concerning each vibrating device, the part number related to the device in question should always be quoted. The original Nordberg parts have precise measures and they are made out of the most appropriate material. Original parts make certain that your device works impeccably and they maintain the guarantee. The original Nordberg parts signify savings in your overall costs: — The parts are tested in practice — You can avail of the newest development changes at once — No sudden breakages — Reliable quick deliveries — All parts with one order — Parts also for older types

In order for the ordering of spare parts to be as quick and easy as possible, the order must include the following information: — Device type, part number and production number — Order number, title and amount of parts to be ordered — Official name and complete address of firm that pays the invoice — Precise delivery instructions, way of delivery and address If the original spare parts book has been lost, you can order a new one from Nordberg.

8VHRQO\ RULJLQDO 1RUGEHUJ VSDUHDQG ZHDULQJ SDUWV

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3-3

Vibrating Chutes

General

3.6 Optional equipment Grizzlies

Screen cloths

The grizzlies can be changed and there is a choice of different types of grizzlies with different grizzly openings.

The cloth can be changed and there are cloths with different hole size.

There are three different types of grizzlies in figure 3.6.1. On the left is a plate grizzly, in the middle a rod grizzly and on the right a bar grizzly. Measure G is the grizzly opening at the end, which is mainly used to identify the grizzlies. The choice of the grizzly depends on the feed to be used and the required sorting limit, among others. Contact a Nordberg specialist when you want to choose a grizzly.

The choice of the cloth depends on the feed to be used, the required sorting limit and the purity requirements of the fractions, among others. Contact a Nordberg specialist when you want to choose a screen cloth. The tightening of the screen cloth is done with tightening bars, hook screws and wedges. The tension of the screen cloth always depends on the cloth properties. The biggest recommended cloth screen hole size is 50-60 mm.

Figure 3.6.1 Different kinds of grizzlies.

3-4

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Installation

Vibrating Chutes

 ,167$//$7,2123(5$7,21 $1'75$163257 4.1 Foundation The vibrating device is mounted on springs, and the spring fixing plates are installed onto a firm foundation. The mounting surfaces for the fixing plates have to be horizontal. Vertical springs have to be in vertical position. If the upper spring support is adjustable, verify that it is parallel to the lower fixing plate. See if the springs on both sides are compressed an equal amount, you will notice the distortion of the base from the compression. Spacer plates can be used underneath the fixing plates, if needed.

stroke movement of the vibrating device becomes vague decreasing the output. Observe that you also have to pay attention to the horizontal rigidity of the base. The support forces of the vibrating device can be found in the information related to each type. No undue parts may be fixed onto the body of the vibrating device, e.g. feeding funnels, chutes, etc. These have to be fixed onto their own support structures, apart from the vibrating device.

Figure 4.1.1 Straightness requirements of the vibrating device foundation Figure 4.1.1 shows the straightness requirements for the foundation. The spring bases of the vibrating device have to be on the same level with each other up to a precision of 10 mm. The supporting structures have to be placed directly below the springs. Verify that the lower structures of the vibrating device are not elastic. If the lower structure is elastic, the

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If extra masses are fixed onto the body, the center of gravity moves downward and the body movement becomes uneven. Besides, feeding output decreases due to the increase in weight. — sideways15 mm — lengthwise30 mm — vertical direction50 mm

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4-1

Vibrating Chutes

Installation

The vibrating device should be installed in such a way that the distances between the vibrating device and other structures (e.g. supporting structures, funnels, chutes, silos), when loaded, are at least as follows. This relatively large free space between the body and other structures is needed for the momentary irregular swinging motion when starting and stopping the device. Eventual beams under the body have to be installed in such a way that the material that gathers on top of them does not touch the body. Correspondingly, the fixing points of the springs have to be such that there is no possibility for sufficient material to gather near to them as to cover the springs and damage them. If the body hits the funnel, or another fixed structure, when the vibrating device is running, loading increases to a multiple of the designed loading, leading to a device failure. The discharge opening of the funnel that feeds material onto the vibrating feeder may not be essentially smaller than the body width. This way the whole transversal area of the body can be utilized. Nevertheless, movement gaps of the previously mentioned size have to be left between the body side plate and the side of the funnel. The sides may not extend too far down into the body in order for fed material not to get squeezed between the lower edge of the funnel and the bottom of the vibrating device. The sides have to reach, however, to at least 70 mm below the top edge of the vibrating device body. Chains or a hatch may be used to conduct the material flow discharging from the feeding funnel onto the vibrating device. The hatch may not extend too near to the bottom of the vibrating device. Especially in connection with vibrating devices with a closed bottom, the feeding funnel discharge opening has to be designed and placed in such a way that material cannot have a free flow over the discharge end when the vibrating device is not running. When designing feeding funnels, it has to be observed that the pressure caused by material

4-2

does not exceed the maximum allowable value of the vibrating device (see specifications, chapter ASupport loads and AMinimum measure of springs, loaded). The design of the feeding funnel has to be such that it carries part of the feed mass. When installing funnels, channels or other structures near to the feeder body, the gaps between the structures have to be guarded according to safety regulations of the country of operation (e.g. EN 294).

4.2 Service level There has to be a service level around the vibrating device in order to make maintenance and operation easy. If the service level has not been ordered and delivered together with the device, it has to be built by the user. The service platform of crushing equipment has to comply with the safety regulations valid in the country of operation. All instructions on crushing equipment service levels in force in the country of operation of the vibrating device must observed.

4.3 Transport During transport, the vibrating device must be firmly fixed onto the trailer. Most vibrating chute types have transport supports designed for this purpose. Turn the device into the most appropriate position according to the way of transport (e.g. vibrators upwards and the body downwards).

4.4 Welding The body and other parts of the vibrating device may not be welded without the consent of the manufacturer.

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Installation

Vibrating Chutes

4.5 Electrification It has to be noted that the separate vibrators of electrically driven vibrating devices have to be connected to turn in opposite directions. Safety regulations of the country of operation of the vibrating device have to be observed in electrification. When the operation frequency of the device changes, the vibrators’ regulating values have to be set to correspond to the new frequency. Especially when connecting a spare part vibrator, the regulating values have to be checked. The regulating values can be found in the specification annex.

4.6 Connecting a hydraulic drive It has to be observed that the separate vibrators in hydraulically operated vibrating feeders must be connected to turn in opposite directions.

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140401

4-3

Operation

Vibrating Chutes

 23(5$7,21 5.1 Before starting

5.4 Operation

NOTE! Remove eventual transport supports and inspect the device as indicated in point 7.1.

Do not drop big stones into an empty vibrating device, the bottom might get damaged. Try to keep material on the bottom of the device in order to soften the blows of falling big stones. Stones may not be dropped onto the grizzly of the vibrating device. Stones stuck into grizzly openings must be removed in order not to damage the grizzly.

Make sure that the electric connections are properly done and that the cables etc. are in condition of operation. Operate the device only when all necessary safety devices are installed (e.g. covers, emergency stop devices, etc.) and they are in condition of operation.

Material should be fed correctly onto the vibrating device, this conserves the device and gives it a longer service life.

Make sure before starting the device that startup puts nobody in danger. Walk around the device and make sure that nobody is on top of, beside or under it. Warn those in the vicinity before starting.

Check at least once during a shift, as indicated in point 7.1, that the device works properly and for possible failures. Report changes (also in the operation of the device) immediately to the person responsible at the job-site. The device has to be stopped and safety measures have to be taken, if needed.

5.2 Starting When starting the process, the devices removing material from the vibrating feeder have to be started before starting the vibrating device, and the feeding devices after the vibrating device.

Do not climb onto the device when it is running. Also, do not touch moving parts on the device when it is running. When the device is running, do not approach it so much that feed material may pose a risk.

Make sure that in a vibrating device with two vibrators, both vibrators start. Using the vibrating device only with one vibrator (e.g. in a failure situation) leads quickly body damage.

5.3 Stopping The vibrating device and the peripheral devices are stopped in the opposite sequence in respect to starting.

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140401

5-1

Vibrating Chutes

Operation

5.5 Measuring the stroke and the stroke angle There are stickers on the device, where the stroke and stroke angle can be read on during operation. There are black circles of a diameter of 1...20 mm on the sticker. The difference between the diameters is one millimeter. When the body vibrates, the eye perceives two circle rows underneath each other. The stroke is indicated by the circles below each other that are tangent to each other. The diameter of the circle concerned is the stroke. In order to help the determination of the diameter, there is a circular ring in the circles of 5, 10, 15 and 20 mm.

In order to determine the stroke angle, there is a dot in the sticker and lines at 15° intervals. The line, the direction of which the dot seems to move, determines the stroke angle. If the dot moves between the lines, the stroke angle can be estimated according to the nearest lines. In the example of figure 5.5.2 the stroke is 13 mm and the stroke angle is 55°.

FIGURE 5.5.1 Sticker that is to be used when defining the stroke and stroke angle

FIGURE 5.5.2 The stroke of the feeder in the figure example is 13 mm and the stroke angle 55°

5-2

140401

2/99

Lubrication

Vibrating Chutes

 /8%5,&$7,21 6.1 Vibrating motor The instructions for vibrator lubrication are in a separate vibrator operation instruction. NOTE! Excessive lubrication may damage the bearings and other parts of the device.

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140401

6-1

Periodical maintenance

Vibrating Chutes

 3(5,2',&$/0$,17(1$1&( 7.1 Daily

7.2 Monthly

Check all safety devices and that they work properly. Repair revealed faults at once.

Check that nothing touches the moving body (sufficient free space around)

Check the state and fixing of wearing parts, change or tighten them if needed. If there is a screen cloth in the device, its tension has to be regularly checked. Check the electric devices, especially the connection and condition of the cables leading into the vibrators. Listen to the sound of the vibrating device. The cause of all extraordinary sounds has to be determined.

7.3 Every three months Check the condition of the vibrating device. All screws, nuts and connections have to be checked and tightened, if needed, in order to avoid damages. See pretightening torque of screws in chapter 8.1 "Pretightening of screws". Check the springs (wear, corrosion, breaks, protections).

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140401

7-1

Other maintenance

Vibrating Chutes

 27+(50$,17(1$1&( $&7,9,7,(6 8.1 Pre-tightening of screws

8.2 Changing of grizzly cassettes

The torques in the table have to be used to tighten all screws. In order to achieve the right pre-tightening tension in the screws, the threads have to be clean, dry and zink-plated.

When ordering a grizzly, make sure that it suits the vibrating feeder and the application in question.

The tightening instructions of the vibrator fixing screws are in the vibrator operator’s manual.

Special attention has to be paid to safety at work when changing the grizzly (see chapter 2). The working levels have to be sturdy and the lifting devices appropriate for the purpose. The lifting ropes have to be fixed properly. When lifting, nobody may be underneath the load to be lifted or too near to it.

Torque

Screw M 10

47 Nm

4,8 kpm

35 ft lbs

M 12

81 Nm

8,3 kpm

60 ft lbs

M 14

129 Nm

13 kpm

95 ft lbs

M 16

196 Nm

20 kpm

145 ft lbs

M 18

270 Nm

27 kpm

199 ft lbs

M 20

382 Nm

39 kpm

281 ft lbs

M 22

519 Nm

53 kpm

383 ft lbs

M 24

662 Nm

67 kpm

488 ft lbs

M 27

975 Nm

99 kpm

719 ft lbs

M 30

1320 Nm

135 kpm

973 ft lbs

2/99

The tightening torques of the screws are explained in the previous point.

The grizzlies are described more in detail in the Specifiactions annex.

140401

8-1

Troubleshooting

Vibrating Chutes

 7528%/(6+227,1* In spite of careful operation of the vibrating device according to instructions, as well as of careful quality control in the production of the vibrating device, different failures may turn up in the vibrating device and the process associated with it.

The following presents some possible failures and their corrective procedures. FAILURE

CAUSE

Small feeding capacity.

Feeding funnel or discharge opening too small and they vault.

Uneven vibration.

2/99

PROCEDURE

Body touches fixed structure or material.

Change structures so that body has sufficient swinging room. (point 4.1)Design structures so that no material can gather on top of them.

Feed material is wet or unclean.

Choose feed again or prepare it to be suitable, e.g. by mixing.

Grain size of feed is too big and it vaults.

Reduce grain size of feed.

Wrong vibrator speed of rotation.

Check vibrator control circuit and speed of rotation.

Uneven vibration

See following point.

Material in feeding funnel weighs too much on the vibrating device.

Change structure of funnel.

The strokes at the different ends of the body are remarkably unequal in size.

Contact Nordberg specialist.

Wrong stroke angle.

Contact Nordberg specialist.

Lower structure of vibrating device or ground gives in.

Reinforce structure and place better foundation under support structures.

Extra structures have been fixed onto the body.

Remove extra structures from body and fix them on other structures.

Material has stuck onto the body.

Remove stuck material.

Broken springs.

Replace them with new springs.

140401

9-1

Vibrating Chutes

Troubleshooting

FAILURE

CAUSE

PROCEDURE

Vibrating device vibrates sideways

Only one vibrator works.

Device may not be operated with only one of the vibrators working. Contact Nordberg specialist.

Both vibrators turn in same direction.

Check vibrator control circuit.

Operation base gives in.

Make better foundations according to manufacturer’s instructions.

Loose screws in body.

Tighten screws.

Body touches other structures.

Verify that spacings are according to chapter 4. point 1.

Air does not circulate enough around vibrator.

Improve air circulation.

Insufficient lubrication in bearings.

Lubricate bearings.

Too much grease in bearings.

Stop device, let it cool down and start again.

Grease has become stiff due to cold weather.

Warm the vibrator.

Fault in vibrator control circuit.

Check vibrator control circuit.

Too high speed of rotation of hydraulic driven vibrator.

Only one vibrator is working.

Device may not be operated with only one of the vibrators working. Contact Nordberg specialist.

Hydraulic oil leaks from hydraulic vibrator.

Shaft packing of hydraulic motor leaks.

Contact Nordberg specialist.

The body clatters.

Vibrator becomes too hot.

Vibrators will not start.

9-2

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Instruction manual, V150 hydraulic drive

APPENDIX

2

Terms used

General instructions

Fixed side = the side of the fixed bearing, A side

The cooling openings on the sides of the vibrator must not be covered. Covering the openings prevents air from circulating and can cause the bearings to overheat. The cooling openings are shown in the figure 946893 (marked with number 1). Also, avoid covering the slots on the circle of the vibrator.

Free side = the side of the moving bearing, B side Drive axle = the axle containing the drive motor Driven axle = the axle being rotated via the gear assembly Half = the frame is made of two, identical halves

The tightness of the fixation screws of the vibrator (shown in the figure 946893, marked with number 2) must be checked in connection with other maintenance operations of the device. One indication of loose screws is a rusty streak coming from the screw joints. The loose screws must be re-tightened at the torque of 662 Nm. The frame of the vibrator is made of ball graphite cast iron which must not be subjected to physical force. This is especially important in cold weather.

946895

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V150 HYDRAULIC DRIVE

INSTRUCTION MANUAL

2-1

APPENDIX 2 - INSTRUCTION MANUAL, V150 HYDRAULIC DRIVE

Checking the oil level and changing the oil The oil level is checked by opening the cap shown in figure 946894 (7) while the machinery is in the angle of 45 degrees. Some oil should drip from the cap. The oil level indication is reliable when the machinery has been stopped for at least 30 minutes. The oil is changed for the first time at 200 running hours. In the future, oil must be changed every 1,000 running hours and at least twice a year. For oil change, drain the machinery of oil by opening the cap (2) in figure 946894 while the machinery is in operational position. Oil is filled through either of the two caps (3). The recommended oil volume is 4 litres (allowable range is 3.5 to 4.5 litres, this corresponds to oil level of the cap (1) with the angle of 42.5º to 47.5º). Absolute cleanliness is imperative when changing the oil. Recommended oil qualities: For summer use (temperature above -10 ºC): Manufacturer BP ESSO FINA MOBIL NESTE SHELL TEBOIL TEXACO

2-2

INSTRUCTION MANUAL

Oil Energol GR-XP 150 Spartan EP 150 Giran 150 Mobilgear 629 Vaihteisto 150 EP Omala Oil 150 Pressure Oil 150 Meropa Lubricant 150

For winter use and for cold conditions (temperature below -10°C): Manufacturer BP ESSO FINA MOBIL NESTE SHELL TEBOIL TEXACO

Oil Energol GR-XP 100 Spartan EP 100 Giran 100 Mobilgear 627 Vaihteisto 100 EP Omala Oil 100 Pressure Oil 100 Meropa Lubricant 100

The recommended temperature of use with oil is -30 to 95 ºC. NOTE: The above recommendations are for reference only. To ensure the optimal lubrication efficiency for the bearings, the viscosity of the oil has to be 30 to 40 cST in the temperature of use. An adhesive label with more details is attached on the side of the machinery. The label has space for the first few oil change dates.

V150 HYDRAULIC DRIVE

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APPENDIX 2 - INSTRUCTION MANUAL, V150 HYDRAULIC DRIVE

Breather A blocked breather causes the internal pressure of the machinery to rise which causes increased wear of the seals and leads to oil leaks. If the feeder is turned (during transportation) so that oil can travel to the breather, the breather should be removed and the connection should be closed using the cap in the aluminium cover. The breather is screwed in to replace the cap. Make sure no dust or dirt enters the connection threads and the oil cavity. When the machinery is taken into use, the breather is reinstalled in the operational position and the cap is reinstalled in the cover. The breather MUST be in operational position whenever the device is in use. Pay special attention to making sure that the cup spacer (shown with number 1 in figure 946894) is always installed correctly. The breather must always be replaced in connection with changing the oil (see above).

946894

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V150 HYDRAULIC DRIVE

INSTRUCTION MANUAL

2-3

APPENDIX 2 - INSTRUCTION MANUAL, V150 HYDRAULIC DRIVE

Adjusting the angle of stroke Adjusting the angle of stroke influences the flow speed of material and the accuracy of the grizzling operation. See the table below Change in the Flow speed of angle of stroke material Raising Lowering

Slower Faster

Accuracy of the grizzling operation Better Worse

The angle of stroke is adjusted as indicated in figure 946895. Both the aluminium covers must be removed to adjust the angle of stroke. 1. Open the retaining screw (1) of the weight. Loosen the tightening screw (3, 4) of the driven axle. Consequently, loosen the screw (2) at the end of the axle. Beware of rotating axles when loosening the weights.

2. Position the weight as desired using the retaining screw (1). Both sides must be positioned the same way, and symmetrically in relation to the centre line of the feeder. 3. Tighten the weight axially using the screw (2) at the end of the axle at the torque of 196 Nm (20.0 kpm). Use Loctite 270 to lock the screw. 4. Tighten the tightening screw (3, 4) of the weight, and use Loctite 270 to lock. 5. Finally, check that the tightness of the retaining screw is 24 Nm (2.4 kpm). Use Loctite 270 to lock. 6. Install the aluminium covers and the hydraulic motor. NOTE: The vibrator must not be used without the aluminium covers due to risk of accidents! Instead of Loctite 270, the screws can be locked using similar products from other manufacturers.

946895

2-4

INSTRUCTION MANUAL

V150 HYDRAULIC DRIVE

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APPENDIX 2 - INSTRUCTION MANUAL, V150 HYDRAULIC DRIVE

Replacing the seal Instructions for changing the seal in the fixed side (the side indicated in the figure) of the drive axle (the axle with the drive motor):

1. Open the vibrator cover (1).

1. Open the vibrator cover (1). 2. Loosen the screws (2) of the weight. Refer to section "Adjusting the angle of stroke". Beware of rotating axles when loosening the weight. 3. Open screw (3) and remove the flange (4) and the coupling half (5). The coupling half can be heated to max. 100ºC to facilitate removal. 4. Remove the weight (6) and pull the sleeve off together with the O rings (7). 5. Replace the seal (8). The detailed pictures T and U indicate the correct position of the seal and the sleeve. Make sure that the spacer ring (17) is placed in between the bearing and the sleeve (7) on the fixed side. 6. Reinstall the sleeve (7). 7. Reposition the weight (6) using the retaining screw. 8. Reinstall the coupling half (5) and the flange (4). 9. Tighten the weight axially using the screw (3) at the end of the axle at the torque of 196 Nm (20.0 kpm). Use Loctite 270 to lock the screw. 10. Tighten the tightening screw of the weight (2). Use Loctite 270 to lock. 11. Finally, check that the tightness of the retaining screw is 24 Nm (2.4 kpm). Use Loctite 270 to lock. 12. Reinstall the vibrator cover (1).

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The seal on the free side of the drive axle is changed similarly. The procedure with the driven axle (the axle being rotated by the drive axle via the gear assembly): 2. Loosen the screws (11). 3. Open screw (9) and remove the flange (10). 4. Remove the weight (12) and the sleeve (13). 5. Pull the sleeve out together with the O rings (14). 6. Replace the seal (15). The detailed pictures T and U indicate the correct position of the seal. 7. Reinstall the sleeves (14 and 13). 8. Reposition the weight (12) using the retaining screw. 9. Reinstall the flange (10). 10. Tighten axially using the screw (9) at the end of the axle at the torque of 196 Nm (20.0 kpm). Use Loctite 270 to lock the screw. 11. Tighten the tightening screw of the weight (11). Use Loctite 270 to lock. 12. Finally, check that the tightness of the retaining screw is 24 Nm (2.4 kpm). Use Loctite 270 to lock. 13. Reinstall the vibrator cover (1). Fluorocarbon seals (e.g. VITON etc.) may leak when cold. This is a normal phenomenon and does not necessitate any corrective actions. If the axle is corroded at the location of the O ring (7) of the sleeve or in the countersurface of the lip seal, the sleeve can be turned so that the O ring meets a non-corroded spot of the axle and the lip surface gets a new countersurface.

V150 HYDRAULIC DRIVE

INSTRUCTION MANUAL

2-5

APPENDIX 2 - INSTRUCTION MANUAL, V150 HYDRAULIC DRIVE

2-6

INSTRUCTION MANUAL

V150 HYDRAULIC DRIVE

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APPENDIX 2 - INSTRUCTION MANUAL, V150 HYDRAULIC DRIVE

2.1 Hydraulic motor

Reassembling:

Remove the hydraulic motor (marked with number 1 in figure 931145) from the cover (2) so that you can inspect the coupling for wear and tear. If the coupling halves are not worn, only the spacer (8) needs to be changed. If the coupling halves, too, are worn, follow the procedure detailed below. Coupling half of the axle 1. Remove the cover (2) of the machinery. 2. Open the screw (3) at the end of the drive axle and remove the flange (4). 3. Remove the coupling half (5) from the drive axle. The half can be heated up to max. 100ºC to facilitate removal. Coupling half of the motor Open the retaining screw (6) and remove the coupling (7) from the motor axle. The half can be heated to max. 100ºC to facilitate removal. Beware of overheating and damaging the motor seals.

1. Install the coupling half (5) and the flange (4). The coupling half can be heated to max. 100ºC. 2. Tighten the screw (3) at the end of the axle and lock with Loctite 270. 3. Reinstall the cover (2) of the machinery. Make sure that the guiding surface of the hydraulic motor is aligned with the coupling half of the vibrator. Make sure the guide pins of the cover are properly in place. 4. Install the spacer (8) of the coupler at the end of the coupler in the axle side. 5. Install the coupling half (7) in the axle of the hydraulic motor. The coupling half can be heated to max. 100ºC. 6. Fix the coupling half with the retaining screw (6) and lock with Loctite 270. Make sure the axial position of the coupling is within the allowable range given by the manufacturer. 7. Install the hydraulic motor. Note the position according to the operational position

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V150 HYDRAULIC DRIVE

INSTRUCTION MANUAL

2-7

APPENDIX 2 - INSTRUCTION MANUAL, V150 HYDRAULIC DRIVE

2-8

INSTRUCTION MANUAL

V150 HYDRAULIC DRIVE

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APPENDIX 2 - INSTRUCTION MANUAL, V150 HYDRAULIC DRIVE

Additional weights Many additional weight options are available for the vibrator: Identification

Mass torque

N11897099

5.34 kgm

N11897100

6.10 kgm

N11897101

6.87 kgm

N11897103

7.58 kgm

N11897106

8.35 kgm

N11897111

9.12 kgm

N11897557

9.12 kgm

10/00

The procedure for installing additional weights is device specific. Installing additional weights is agreed on separately. Install the additional weights according to the instructions in the document 926418.

V150 HYDRAULIC DRIVE

INSTRUCTION MANUAL

2-9

TK11-42-2V Hydraulic drive V150

Technical specification

Specifications TK11-42-2V Hydraulic operation Part No.,

Vibrator

Revolutions of vibrator max [ rpm ]

Max. capacity (volume weight1,6 t/m3) [ t/h ]

Weight[ kg ]

First installation grizzly *)

Transport deck / Screen deck

N11902871

V150/ A2FM23/61W

1150

500

2900

5

Screen deck

N11902870

V150/ A2FM23/61W

1150

500

2950

4

Screen deck

N11902869

V150/ A2FM23/61W

1150

500

3300

1

ZICZACScreen deck

N11902868

V150/ A2FM23/61W

1150

500

2900

3

Screen deck

N11902867

V150/ A2FM23/61W

1150

500

2850

3

Transport deck

N11902866

V150/ A2FM23/61W

1150

500

2950

2

Screen deck

N11902865

V150/ A2FM23/61W

1150

500

2850

2

Transport deck

N11902864

V150/ A2FM23/61W

1150

500

3300

1

Screen deck

N11902863

V150/ A2FM23/61W

1150

500

3200

1

Transport deck

N11902873

V150/ A2FM23/61W

1150

500

2800

6

Screen deck

N11902872

V150/ A2FM23/61W

1150

500

2883

7

Screen deck

*) Numbering in connection with grizzlies.

10/02

A-1

Technical specification

TK11-42-2V Hydraulic drive V150

Main dimensions

Support loads / corner Static [ kN ]

Dynamic [ kN ]

A-2

Measures of springs F1

5,5

Free length [ mm]

270

F2

10,2

Allowed min. length [ mm ]

180

F1, hor.

±0,3

Wire diameter [ mm ]

18

F1, vert.

±1,0

Spring outside diameter [ mm]

116

F2, hor.

±0,4

F2, vert.

±1,6

10/02

TK11-42-2V Hydraulic drive V150

Technical specification

Transport supports The device has transport supports that are fastened during transport. The transport supports have to be removed for operation.

Lifting

The lifting lugs in the device have to be used when lifting the machine. These are marked in the figure below with letter Z. Verify that the lifting devices and instruments are appropriate for the lifting.

10/02

A-3

Technical specification

TK11-42-2V Hydraulic drive V150

Grizzlies Grizzly 1 Two adjustable bar grizzly cassettes. Part no. 912977-A Grizzly opening [ mm ] 47 - 96 Weight [ kg ] 894

Follow these instructions when adjusting the grizzly. 1.Clean the grizzly so that the bars can move sideways, and no sand goes between the wedge surfaces. 2.Loosen the screw at the end of the bar. Do not loosen too much, because the counterpart may fall into the funnel or it can come off its loop. If the screw is damaged, it can be changed into a new one. There is a normal nut in the counterpart.

grizzly openings at regular intervals are 47, 54, 62, 71, 82 and 96 mm. The bar should always be added to or removed from the border; this way the packing rubbers overlap the right way. 4.Adjust the outermost openings to the desired size and the bars in the right direction. 5.The bars in the middle are adjusted into regular intervals, or if a larger opening is required, every second opening is left bigger. 6.Tighten the screws (M20), beginning from the outermost, with a torque of 382 Nm (281 ft lbs). Tightening is repeated several times, because when a bar is tightened, it always loosens the adjacent bars. 7.The screws are retightened after 50 service hours and after that when need be, if you notice that the grizzlies have moved.

3.Choose the new grizzly opening area and add or remove a bar or bars (observe the overlapping packing rubbers at the end). The

A-4

10/02

TK11-42-2V Hydraulic drive V150

Technical specification

Grizzly 2

Grizzly 5

Two plate grizzly cassettes with a grizzly opening of 52 mm.

Sloped ZICZAC grizzly cassette with two changeable grizzly plates with opening of 38 mm.

Grizzly cassette Part no. 913480 Grizzly opening [ mm ] 52 Weight [ kg ] 238 Grizzly cassette Part no. 913481 Grizzly opening [ mm ] 52 Weight [ kg ] 240

Grizzly Part no. 926619 Weight [ kg ] 528 Grizzly plate Part no. 926567 Weight [kg] 94

Grizzly 3

Grizzly 6

Two plate grizzly cassettes with a grizzly opening of 70 mm.

Two plate grizzly cassettes with a grizzly opening of 50 mm.

Grizzly cassette

Grizzly cassette

Part no. 918039 Grizzly opening [ mm ] 70 Weight [ kg ] 220

Part no. 941161 Grizzly opening [ mm ] 50 Weight [ kg ] 175

Grizzly cassette

Grizzly cassette

Part no. 918040 Grizzly opening [ mm ] 70 Weight [ kg ] 221

Part no. 941162 Grizzly opening [ mm ] 50 Weight [ kg ] 175

Check before starting that the clearance of the grizzly end support is 3±2mm.

Grizzly 7

Grizzly 4 Two ZICZAC grizzly cassettes with a grizzly opening of 38 mm. Part no. N11893496

Sloped ZICZAC grizzly cassette with two changeable grizzly plates with opening of 60 mm. Grizzly Part no. 939096 Weight [ kg ] 54

Weight [ kg ] 585 Grizzly plate

Grizzly

Part no. 922894

Part no. 939093

Weight [kg] 95

Weight [kg] 90

10/02

A-5

Technical specification

TK11-42-2V Hydraulic drive V150

Grizzly 5 & 7 Changing the grizzly When changing grizzlies, the parts indicated in the picture have to be detached in numerical order in order to remove the grizzly cassette. Grizzlies 2-4 & 6

A-6

10/02

TK11-42-2V Hydraulic drive V150

Technical specification

Screen deck

4.Loosen the cotter bolts in point 3.

The screen deck of the device has to be opened in order to help remove stuck material.

5.Open the bolts in point 4.

Part no. 913839 Weight [ kg ] 178 Steel screen cloth (bent ends) Part no. 386928-21 (See spare parts book for more detailed information). The wire thickness and the aperture size is defined on a case by case basis. Opening the screen deck 1.Fasten a lifting tackle between points 1 and 3 and use it to lower the screen deck safely onto the ground. Never open the screen deck without the help of a lifting tackle, because you might get squeezed due to the weight of the deck (88 - 214 kg). 2.Remove the obstructing structures from the opening area of the screen deck. NOTE! It is prohibited to go under the deck.

6.Lower the screen deck calmly down with the lifting tackle. Changing the screen cloth 1.Loosen the screen cloth tightening screws. The screen cloth fixing plate is moved into its end position. 2.Remove the old screen cloth. 3.Check the condition of the protection rubbers of the screen cloth support deck, because the curvature of the cloth has to remain right. The protection rubbers are changed into new ones, if needed. 4.Install new screen cloth with the hook ends into their places. Tighten the screen cloth by means of the screws in point 5. Do not tighten the screen cloth too much in order not to damage it.

3.Open the bolts in point 2.

10/02

A-7

Technical specification

TK11-42-2V Hydraulic drive V150

Plate reinforced ends are always recommended to be used in the screen cloth in order for the screen cloth wires not to dig into the tightening plates. Closing the screen deck — Lift the screen deck up with the lifting tackle. — Tighten the bolts in point 4. — Tighten the screws in points 2 and 3 (M20).Tightening torque 382 Nm(281 ft lbs). NOTE! Never operate the device when the screen deck is open.

A-8

ZICZAC Screen deck The ZICZAC screen deck of the device has to be opened in order to help remove stuck material. Part no. N11892331 Weight [ kg ] 214 ZICZAC-Finger grizzly group Part no. N11892330 (See spare parts book for more detailed information

10/02

TK11-42-2V Hydraulic drive V150

Setup and opening of the ZICZAC screen deck grizzlies Opening the ZICZAC screen deck

Technical specification

Transport deck The transport deck of the device has to be opened in order to help remove stuck material.

See opening of the screen deck.

Title 913338 Weight [ kg ] 88

Setup of the ZICZAC screen deck grizzlies

Opening the transport deck

Before beginning to change or to setup the grizzlies, open first the rubber plate from the feeding end in order to get hold of the grizzlies at the feeding end.

See opening the screen deck. Closing the transport deck See closing the screen deck.

Screw C tightens the grizzly group into its place. The grizzly group position is adjusted with screws A and B so that height H is at least as big as the grizzly opening. Closing the the ZICZAC screen deck See closing the screen deck.

10/02

A-9

HYDRAULIC DRIVEN CONVEYORS INSTRUCTION MANUAL 140638-EN

PREFACE

CHAPTER

0

Hydraulic conveyors are operated hydraulically and used widely in Metso Minerals’ applications. They are available in several configurations for specific applications, both fixed position and with hydraulic raise and lower. This Instruction Manual is valid for hydraulic driven belt conveyors manufactured by Metso Minerals for the year 2006.

Due to the continuous development of the product, the manufacturer reserves the right to make changes to the product and/or manual without prior notice. This is the first edition of the Instruction Manual, published in November 2006 in Tampere, Finland. Metso Minerals (Tampere) Oy P.O. Box 306 FIN-33101 Tampere Finland Tel. +358 (0)20 484 142 Fax +358 (0)20 484 143

11/06

EN

CONVEYOR INSTRUCTION MANUAL 0-1

CHAPTER 0 - PREFACE

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TABLE OF CONTENTS 1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1 TYPE IDENTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 CONVEYOR PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 POINTS OF DANGER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1 2-1 2-2 2-2

3 CONVEYOR BASICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 CONVEYOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 CONVEYOR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 DRIVE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 TAIL DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 CARRYING ROLLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 RETURN ROLLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 BELT PLOUGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 BELT SCRAPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 IMPACT BEAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11 SIDE BEAMS / PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12 SIDE SKIRT RUBBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1 3-2 3-2 3-2 3-2 3-2 3-2 3-2 3-2 3-2 3-2 3-2 3-2

4 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 OPERATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.2 Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.4 If the conveyor suddenly stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.5 Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 REMOVING A BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Clearing of a jammed main conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1 4-1 4-1 4-1 4-1 4-2 4-2 4-3 4-3

5 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 BELT TRACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.1 Squaring the pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.2 Adjusting the idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 BELT SCRAPER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 BEARING LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1 5-1 5-1 5-2 5-3 5-4 5-5

CONVEYOR INSTRUCTION MANUAL

6 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.1 CONVEYOR REMOVAL AND MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.2 CONVEYOR BELT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.2.1 Punched belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.2.2 Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.3 CONVEYOR ROLLER RENEWAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 6.3.1 Carrying rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 6.3.2 Return rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 6.4 CONVEYOR DRIVE MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 6.5 DRIVE DRUM BEARING RENEWAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 6.6 TAIL DRUM BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 6.7 CONVEYOR BELT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 6.8 TRIP WIRE SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 6.9 DRIVE DRUM LAGGING RENEWAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 6.10 PRE CLEANER (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 6.11 PLOUGH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 6.12 TEST RUN AFTER REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

7 REFERENCE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.1 TIGHTENING TORQUES, UNITS OF MEASUREMENT AND CONVERSION TABLES . . . . . 7-1 7.2 CONVEYING TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

CONVEYOR INSTRUCTION MANUAL

GENERAL

CHAPTER

1

1.1 TYPE IDENTIFIER Example of type identifier: H6,5-15 H = Belt conveyor 6,5 = Belt width (0,65 m / 25,59 in) 15 = Length of conveyor (15 m / 49,2 ft) The conveyor's type identifier is given on the machine plate mounted to the conveyor frame.

Figure 1-1 Machine plate

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CHAPTER 1 - GENERAL

1.2 CONVEYOR PURPOSE The belt conveyor is intended to transfer the process material in recycling crushing or screening applications in crushing plants. Any other use is not considered as intended. The directions right and left are defined from the direction of travel of the material from the feed heading perspective.

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SAFETY

CHAPTER

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2.1 POINTS OF DANGER •

Drive end

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Tensioning end

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Nip points of pulleys

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Nip points of idlers

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Loading and discharging locations

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Material flow

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Electric equipment and cables

Figure 2-1 Conveyor's points of danger

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CHAPTER 2 - SAFETY

2.3 INSPECTIONS

2.2 GENERAL

The list of inspection items below can easily be included as part of the daily walk-around. Operating personnel should be alert to most of these items any time the plant is operating. At a minimum, these checks should be performed once a week.

NOTE: PERSONNEL SHALL NOT BE ALLOWED TO OPERATE, MAINTAIN OR BE NEAR THE CONVEYOR WITHOUT RECEIVING THOROUGH CONVEYOR SAFETY TRAINING AND REVIEWING THIS MANUAL.

1. Check belt location on troughing and return idlers and train if necessary. 2. Check belt tension and tighten if belt is slipping on drive pulley or sagging enough between troughing idlers to allow spillage.

The operator must be acquainted with the following: •

Structure and operation of the conveyor

•

Points of danger

•

Safe working and moving near the conveyor

•

Emergency stop functions and the locations of the emergency stop switches

3. Inspect lagging on drive pulley and replace if necessary. 4. Inspect troughing and return idlers under load. They should be in contact with the belt and running free.

The safety, operating, and maintenance instructions of the conveyor should always be easily available near the conveyor.

5. Check material loading area to make sure material is loaded evenly onto the center of the belt.

The instructions on safety etc. must be observed.

6. Check for spillage and eliminate the cause by adjusting side skirt rubbers, etc.

Unauthorized persons are not allowed to be near the conveyor.

7. Check, in several locations, that conveyor frame is level side-to-side.

The conveyor should only be used for it’s purpose and in the conditions jointly agreed upon by the user and the manufacturer.

8. Check belt cleaners to make sure that scraper blades are in good condition and properly adjusted.

The conveyor belt should not be used as an access or maintenance walkway.

9. Inspect belt fasteners for wear and replace as necessary.

No changes are allowed to be made on the conveyor without the manufacturer's written consent.

10. Run belt empty, and check for tears or other damage. Repair and eliminate cause(s) of damage.

All those moving near the conveyor must use the marked walkways, service platforms, stairs, and ladders, and these must always be kept clear.

11. Check conveyor belt travel area to make sure that nothing is interfering with or rubbing on the belt.

The conveyor must not be used for carrying persons.

12. Clean frame and guards. 13. Remove any material from around troughing and return idlers.

Caution must be observed when the conveyor is running. The conveyor area must have sufficient lighting.

NOTE: ONLY AUTHORIZED PERSONNEL MAY PERFORM THESE DUTIES.

No safety device are allowed to be removed.

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CONVEYOR BASICS

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Figure 3-1 The main components of the conveyor

Reference 1 2 3 4 5 6 7 8 9 10 11 12

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Description Frame Tail pulley Joint Return roller Finger guard Hydraulic folding Belt Snub roller Scraper Drive drum bearing Drive motor Drive drum

Reference 13 14 15 16 17 18 19 20 21 22

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Description Plough Impact beam Dust cover Skirt rubber Roller assembly Roller assembly wedge Belt tension mechanism Pinch guard Lifting lugs Locking bolts

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CHAPTER 3 - CONVEYOR BASICS

3.1 CONVEYOR BELT

3.6 RETURN ROLLERS

•

Consist of different layers

•

Rubber disc rollers

–

Top layer

•

Finger guards

–

Fabric layer

•

Speed sensor

–

Reinforced layer

•

Belt tracking

3.2 CONVEYOR FRAME

3.7 BELT PLOUGH

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Plate structural

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Polyurethane cleaner

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Modular, bolted, pinned

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Internal cleaner

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V-shape

3.3 DRIVE DRUM •

Single drive motor

3.8 BELT SCRAPER

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Dual motor drive

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Pre cleaner

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Friction coating

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Polyurethane or steel tip

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Bolted coating

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Rubber strap or spring tensioning

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Bearings 3.9 EMERGENCY STOP

3.4 TAIL DRUM

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Trip wire switch

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Self cleaning drum

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Push button

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Solid shaft design (bearings inside of the drum )

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Standard design

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Bearings

3.10 IMPACT BEAM

3.5 CARRYING ROLLERS •

Fixed rollers

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Hanging rollers

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Shock rollers

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Anti magnetizing rollers

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Shock absorber

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Polyethylene coated for low friction

3.11 SIDE BEAMS / PLATES •

Roller mounting

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Skirt rubber mounting

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Dust cover mounting

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Standard profiles

3.12 SIDE SKIRT RUBBERS •

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Spill prevention

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OPERATING INSTRUCTIONS

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4

4.1 OPERATING

4.1.2 Before starting

4.1.1 General

•

Check that the conveyor is free from foreign objects.

•

Make sure that the conveyor belt, the drive and tensioning pulleys, and the idler assemblies are free to rotate. Wet belts can freeze to the pulley so firmly that the rubber will tear loose from the fabric when the conveyor is started. A thin coating of ice on an inclined belt surface can cause a load to slide.

•

Make sure that the mechanical parts and guards of the conveyor are in place, and the inspection and service doors closed.

IMPORTANT! Only persons with a proper training on the operation of the conveyor are allowed to operate the conveyor during a test run and normal work. The operator must be well acquainted with the following: – Structure of the conveyor –

Operating functions

–

Points of danger

•

–

Safe working and moving near the conveyor

Check that all personnel are clear of the conveyor and the discharge area.

•

Give a starting alarm.

–

Removing a block WARNING! Before starting the conveying process and during the operation, make sure that the restricted area is clear of people.

Normal starting and stopping are done with the operating switch, or with the IC panel. (IC = Intelligent control) Further information about using the IC control system is provided in the separate IC instruction manual. When the conveyor is in operation, working and moving in its immediate surroundings must be done with caution. If the conveyor stops by itself, the reason for this must be determined and corrected before attempting to restart the conveyor. A running conveyor must be constantly monitored. The safety switch (Located in the main panel) should not be used to stop the conveyor in normal operation. This can cause unnecessary wear on the switch or a blockage of overflowing material. When the conveyor is running, any cleaning, maintenance, and block removing operations are strictly forbidden. When the diesel engine is running, operations such as cleaning, maintenance, and removing blockages are strictly forbidden.

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4.1.3 Operation •

Start the conveyor (process) with the operating switch, or with the IC panel.

•

The conveyor is a part of the crushing process. If the conveyor is used by a forced control, please consult separate IC instruction manual.

•

Check that the conveyor belt runs centrally on the idlers.

•

Check that the drive and tensioning pulleys, as well as the idler assemblies and the idlers rotate normally.

•

Make sure that the material feeds onto belts properly and that the load does not exceed rated capacity.

•

Observe the operation of the conveyor during running.

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CHAPTER 4 - OPERATING INSTRUCTIONS

4.1.4 If the conveyor suddenly stops •

Detect the reason for stopping: overloading, device fault, emergency stop, slipping drum etc.

•

Shut down the diesel engine before attempting to clear any blockage. Lock and tag controls.

•

Remove the cause that prevents operation.

•

Restart the conveyor according to the starting procedures.

•

Allow the conveyor to empty before stopping it.

•

Stop the conveyor with the operating switch, or with the IC panel to insure proper operation.

•

Resume crushing process.

4.1.5 Emergency stop •

The emergency stop push button or trip wire will stop the conveyor in the event of an emergency.

•

Test function regularly, every 40 hours.

•

The emergency stop push button or trip wire should not be used to stop the conveyor in normal operation. This can cause unnecessary wear on the switch.

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CHAPTER 4 - OPERATING INSTRUCTIONS

4.2 REMOVING A BLOCK

4.2.1 Clearing of a jammed main conveyor

CAUTION! Never try to clear the blockage with an excavator. This will cause severe damage to your Lokotrack. If the conveyor stops, follow these instructions: • Stop the process and the feeding equipment. Shut down the engine. Wait until the process has stopped completely. •

Lock the safety switch/valve into the off or disabled position to make sure that the conveyor cannot be accidentally started while the block is being removed.

•

Make sure that material feed to the conveyor cannot start while the block is being removed. Make sure also that the primary Lokotrack is not feeding your LT. Alert loader/excavator operator that maintenance is in process. When removing the block, use suitable equipment and wear appropriate personal protection.

•

If guards or other structures have to be removed, install them back into place when the block has been cleared. Unlock the safety switch/valve.

•

Start the conveyor according to the starting procedures.

Stop the process immediately.

•

Shut down the engine. Wait until the process has stopped completely.

•

Lock the safety switch/valve into the off or disabled position to make sure that the conveyor cannot be accidentally started while the block is being removed.

•

Clear the jammed main conveyor as well as possible. Do not use the excavator. When most of the material is removed, start the main conveyor by using a manual start on the IC panel. If necessary, the main conveyor can be driven in both directions (This is an optional feature in some models).

NOTE: The opposite direction drive is not used with the vibrating chute. •

•

•

•

Observe the belt running direction. Do not reverse the conveyor more than 0,5 m (1’6”). Do NOT use this method, if the rock is too big to pass under the magnetic separator.

For more information please consult separate IC and LT instruction manuals. WARNING! Do NOT use this method, if the rock is too big to pass under the magnetic separator! Use a hook to remove iron bars and wires. Be very careful not to hurt yourself. Never use the hook when the machine is running.

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CHAPTER 4 - OPERATING INSTRUCTIONS

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MAINTENANCE

CHAPTER

5

5.1 BELT TRACKING A properly trained conveyor belt will travel over the center of the troughing rolls, pulleys and return rolls, resulting in lower maintenance costs and improved operation. Conveyor belts can be trained to track properly, unless they are warped or curved from improper manufacture, use or storage. Before any belt adjustment is done, make sure that the conveyor is in level. To inspect that the conveyor is levelled correctly, refer to the unit level indicator for the unit straightness. When adjusting the belt, the following items can be used to control the belt tracking: –

Drive drum position

–

Return roller position

–

Carrying rollers

–

Tail pulley position

Before adjustment, make sure that the conveyor belt is undamaged. A damaged belt will not track properly.

5.1.1 Squaring the pulleys In short conveyors the belt tracking is heavily affected by the position of the drive drum and tail pulley. Before making tracking adjustments, check that the head and tail pulleys are both square to the conveyor frame.

Figure 5-1 Squaring the tail pulley

Squaring the head pulley - Repeat the above process for the head pulley. When adjusting the drive drum location, remember always to loosen the slide beam locking bolts on both sides of the conveyor. This function allows the parts to move without causing any torsion on the drive motor. Adjust until the belt is properly tensioned and the drive pulley is square to the conveyor frame. Tighten the slide beam locking bolts slightly on both sides of the conveyor to the proper torque (30 Nm).

Squaring the tail pulley - Mark the frame member close to the tail pulley (Point A). Use a large square (1) to mark (Point B) on the opposite frame member so that a line between the two points is at a 90° angle to the imaginary centerline of the frame. Adjust tail pulley bearing blocks so that the distance C (the distance between marks A and B and the ends of the tail pulley shaft) is equal on both sides of the frame (fig. 5.1).

Figure 5-2 Loosen the slide beam locking bolts on both sides of the conveyor.

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CONVEYOR INSTRUCTION MANUAL

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CHAPTER 5 - MAINTENANCE

5.1.2 Adjusting the idlers Adjust for run off by finding the point of maximum run off (D) and adjusting the idler or idlers (E) "ahead" of it. "Ahead" means those idlers which the belt contacts before the point of run off. Roller position exaggerated for illustration purposes in figure 5.3. 1.

Before adjustment

2.

After Adjustment

a. Return roller adjustment is used to center the belt on the tail pulley. Run the conveyor with the belt empty. Loosen the bolts (indicated with arrows in the figure 5.2) and displace the roller assembly. Tighten bolts and test for run off again.

Figure 5-4 Return idler adjustment

b. Carrying idler adjustment is used when the belt does not center with material. Each end of the carrying idler fits into an elongated hole that provides two mounting locations. See figure 5.5. Determine which direction the idler must turn and turn the idler by moving one end to the alternate location.

Figure 5-3 Eliminating run off

Loosen bolts and pivot roll (E) around its mid point the way you would turn a steering wheel to bring a car back into the center of its lane. Make small adjustments, retighten bolts and test for run off after each adjustment. If point of creep changes, adjust idler ahead of the new creep point. Figure 5-5 Carrying roller adjustment

Do not attempt to adjust idlers with the conveyor running. Lock out and tag controls while making adjustments.

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CHAPTER 5 - MAINTENANCE

c. If the belt adjustment method a & b have not corrected the belt tracking completely, adjust the tail pulley slightly to make the final correction.

5.2 BELT TENSION The conveyor belt tension is adjusted by relocating the drive pulley position. When adjusting the drive drum location, remember always to release the slide beam locking bolts from both side of the conveyor. This function allows the parts to move without causing any torsion to the drive motor. A belt is properly tensioned when the sag of the loaded belt between two adjacent return rollers is 0,5 - 3% of the distance between the rollers when an empty belt is operating. Sag can be difficult to measure accurately, because of the small distances involved. The practical rule of thumb is, "The proper tension is the lowest possible tension that will prevent the drive pulley from slipping on the belt."

Figure 5-6 Tail pulley adjustment

If the conveyor has a vertical curve, the conveyor belt should remain touching all carrying rollers with material.

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CONVEYOR INSTRUCTION MANUAL

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CHAPTER 5 - MAINTENANCE

5.3 BELT SCRAPER ADJUSTMENT The scraping force is done by spring force. Rubber, steel or gas springs are generally used methods. Belt scraper tension and condition must be checked daily. Observe the scraper wear daily and replace the scraping element when nesessary. The tension mechanism can be jammed or frosen in muddy / icy conditions and due to this the scraper operation must be checked in the beginning of every shift or daily.

Figure 5-8 Adjusting the rubber spring type pre-cleaner

Use tensioning screw Z to adjust the scraper with a rubber element tensioner.

Figure 5-7 Steel spring type pre-cleaner

Adjust the spring to set the scraper’s pressing force so that the belt becomes properly cleaned.

Figure 5-9 Scraper with rubber strap tensioning

The belt scraper in the picture above is adjusted by a rubber strap.

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5.4 BEARING LUBRICATION The bearing size will affect the needed grease amount. In the following table the amount of grease (in grams) is proportined to shaft diameter (in millimeters). Table 5-1 Shaft diameter / mm 40 55 60 80

Amount of grease / g 4 6 6 9

In practice an appropriate amount of grease to each bearing is about 5-10 grams (0.17....0.35 ounch) in every 40 - 50 hours. Use a multi-purpose grease with an NLGI-class 2 rating and a good resistance to water, cold (-30 C/ 22 F) and hot (continuous operating temperature + 100×C/212×F). The grease must have rust and oxidation (RO) inhibitors and it must contain EP-additives. Don't use grease containing molybdenium. The minimum viscosity of the base oil must be 160 mm2/s ( cSt ) in 40×C / 104×F and minimum viscocity index 80.

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6

6.2 CONVEYOR BELT REPAIR

6.1 CONVEYOR REMOVAL AND MOUNTING

6.2.1 Punched belt When it is sensible to repair a punched belt?

DANGER! Always use conveyor’s lifting lugs and approved lifting equipment with adequate capacity when removing or mounting the conveyor.

As a rule of thumb, when a tear is larger than 15% of the belt’s width, it might be more reasonable to renew it. In case the belt is quite new and the tear is small, there are usually 3 possibilities to repair it –

Mechanical connector Repair like this is recommended only for a temporary solution. To avoid damage to the belt scraper, pick the correct fastener, set it properly and grind the bolt ends.

–

Surface patch Repair like this is recommended only for small areas. The patch material is available from belt distributors.

–

Fabric patch A glue-bonded layered patch of rubber and fabric is the recommended way of repairing the belt. The patch material is available from belt distributors.

DANGER! Never attempt to maintain or service the conveyor until the conveyor has stopped completely.

WARNING! Always use appropriate protective equipment (e.g. protective helmet, goggles) when operating, maintaining or servicing the conveyor.

If the conveyor is removed for a maintenance or a repair, ensure that the replacement structure is identical to the original one. If the conveyor’s supporting structure is damaged, the new repaired structure must always be equivalent to a new one. Use only genuine Metso spare parts. The warranty does not cover if either non-Metso or non-conforming parts are used. Never attempt to operate, maintain or service the conveyor unless you understand all procedures necessary to safely and properly perform the task. If you are unsure at any stage, please do not hesitate to contact the nearest authorized Metso Minerals’ service or dealer.

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6.2.2 Renewal

–

DANGER!

Find out the most appropriate bonding method; hot vulkanizing, cold vulcanizing or mechanical splicing. If electricity is needed, find out the power requirement.

Always use conveyor’s lifting lugs and approved lifting equipment with adequate capacity when removing or mounting the conveyor.

The power requirement depends on the equipment; e.g. Almex 1400 mm vulcanizing press with 32 A three-phase current operates in 400 V voltage.

Although they may look alike, all belts are not the same. Differences in carcass construction and covers will affect belt life and belt tracking. Use only genuine Metso spare parts.

The power requirement in this case: 400V x 32A x 1,73 = 22,5 kW –

The conveyor belt needs to be replaced when: –

The surface rubber is worn out

–

The edges are ripped, the belt is punctured, or the surface has bulged [indicating delamination].

–

When the belt can not be made to track properly.

WARNING! Hot vulcanizing press can cause burn injury. Follow manufacturer instructions. Use protective gloves and avoid contact with hot surfaces. Keep unauthorized personnel away from work area.

A worn belt might damage other parts of the conveyor. Replace the belt promptly when these conditions are observed. When ordering a new belt, notice the following –

Part number

–

Belt width, number of plies, cover thickness and length. If the belt will be field vulcanized, allow enough extra length to make the splice.

Whether you are using mechanical fasteners, hot vulcanizing or cold vulcanizing, always follow manufacturers instructions precisely.

WARNING! The vulcanizing process may release poisonous vapours with a narcotising effect. The vapours irritates eyes and skin, may cause cancer, have a possible risk of irreversible effects and may cause drowsiness and dizziness.

NOTE: If you are unsure at any stage, please do not hesitate to contact maker of the splice.

When preparing for a belt renewal, proceed as follows. –

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WARNING!

Lower the conveyor into a working level or build an appropriate stand

Danger of fire. The vulcanizing material can become highly flammable in use.

–

Loosen the belt, remove the scrapers. Remove or alternatively loosen the skirts.

–

Inspect pulleys, bearings, idlers, impact beds, skirts and scrapers. Repair or replace as needed.

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For further information concerning safety, see separate General Safety Instructions.

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The following table describes the main dimensions needed for using the hot-vulcanizing press. B = Belt width W = Width of the bars L = Length of the bars H = Height of the bars I = Current needed G = Weight of the tools Table 6-1 Need for space on conceyor and needed current B (mm) 600 1000 1200 1400 1600

W (mm) 1500 1500 2000 2000 2500

L (mm) 1500 1500 1500 1500 2000

H (mm) 600 600 700 700 1000

I (A) 32 32 32 32-63 63

G (kg) 200 300 400 400 600

The figures in table above is for reference only, based only on one supplier of hot-vulcanizing presses.

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Cold vulcanizing When bonding a belt by cold vulcanizing, always consult the supplier of the vulcanizing adhesives to select the most appropriate way for the task in hand.

WARNING! Cold vulcanizing adhesives are toxic and have a narcotising effect. The adhesive irritates eyes and skin, may cause cancer, has a possible risk of irreversible effects and its vapours may cause drowsiness and dizziness.

WARNING! Danger of fire. Cold vulcanizing adhesives can become highly flammable in use.

FIRST AID MEASURES INHALATION Supply fresh air. Consult a doctor in case of drowsiness, dizziness or difficulty breathing. SKIN CONTACT Wash immediately with water and soap and rinse throughly. Consult a doctor if skin is burned. EYE CONTACT Rinse the opened eye for several minutes using an emergency eye wash station or under running water. Then consult a doctor. SWALLOWING Contact a doctor. Have package or MSDS sheet (Material Safety Data Sheet) available. The chemical makeup of the specific compound will determine whether dilution or vomiting are appropriate.

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6.3 CONVEYOR ROLLER RENEWAL

d. Thread a wire through the roller’s link (fig. 6-3).

6.3.1 Carrying rollers Proceed as follows a. Remove the service hatch (1) (fig. 6-1). b. Remove the locking pin (2) (fig. 6-1).

3 6 2 1

Figure 6-3 Thread a wire

e. Pull the wire and remove the wedge (3) (fig. 6-1). Figure 6-1 Remove the service hatch

f. Remove the roller assembly.

c. Insert a wooden support (4) through the service hatch and support the roller assembly (5) (fig. 6-2).

g. Install a new roller assembly according to the direction of the travel of the belt into the front edge of the elongated hole (6). See figure 6-1. h. Install the wedge from the top. i. Install the locking pins. j. Check that the belt runs in the middle of the conveyor. Adjust if needed.

5 4

Figure 6-2 Support the roller assembly

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6.3.2 Return rollers

e. Install a new roller assembly into the groove of the support bracket. See figure 6-6 (Indicated with an arrow).

Proceed as follows a. Remove the finger guard (2) (fig. 6-4). b. Remove the lock plate (3) (fig. 6-4).

3

2 4 4 1

Figure 6-6 Install a new roller assembly

Figure 6-4 Remove the finger quard

f. Install the lock plate (3) (fig. 6-4). g. Install the finger guard.

c. Loosen the supports (4) (fig. 6-4).

h. Align the supports with the marks you made on the frame. Tighten the supports (4) (fig. 6-4). i. Position the finger guard and adjust it. The guard should be as close as possible to the belt and return roller without touching (