Instruction Manual LT1213 With IC Contol

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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METSO MINERALS SAFETY INSTRUCTIONS

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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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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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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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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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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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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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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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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.


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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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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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



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

•


•

Verify lockout

•


•


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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– 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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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

•


•

Verify lockout

•


•


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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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.



– 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 LT1213 INSTRUCTION MANUAL 140554-EN

Lokotrack LT1213

Table of Contents

PREFACE SAFETY MAIN COMPONENTS 3.1 MAIN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

3.2 DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

3.3 TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

3.4 CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

3.5 FEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

3.6 MAIN CONVEYOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

3.7 OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

3.8 ENGINE MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3

3.9 HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4

CONTROL PANELS 4.1 OPERATING PANEL SWITCHES/BUTTONS AND CONTROL LEVERS . . . . . . . . . . . . . . . .

4-1

4.2 DRIVE CONTROL BOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2

4.3 REMOTE CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3

4.4 HYDRAULIC MODULE CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4

4.5 RADIO CONTROL (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5

4.6 IC500 CONTROL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5

4.7 CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6

STARTING AND STOPPING 5.1 BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1

5.2 STARTING THE DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2

5.3 STOPPING THE DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2

5.4 ADJUSTING DIESEL ENGINE RPM SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2

5.5 EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3

Lokotrack LT1213 Table of Contents TRANSPORT 6.1 SAFETY IN THE TRACK DRIVE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

6.2 SELECTING THE DRIVING SPEED RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

6.3 DRIVING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

6.4 TRANSPORTING THE UNIT FROM ONE LOCATION TO ANOTHER. . . . . . . . . . . . . . . . . .

6-3

6.5 DRIVING ONTO/OFF THE TRANSPORT PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4

CRUSHING 7.1 CRUSHING SITE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1

7.2 FEEDING MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2

7.3 DISCHARGE MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3

7.4 CRUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-6

7.5 BY-PASS CHUTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-9

7.6 CRUSHER SPEED SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-10

7.7 FEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-10

7.8 CRUSHER SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-11

7.9 CLEARING OF THE JAMMED MAINCONVEYOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-12

7.10 REMOVAL OF THE STEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-12

7.11 RECYCLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-13

7.12 DISCHARGE CHUTE IMPACT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-14

Lokotrack LT1213

Table of Contents MAINTENANCE 8.1 PERIODICAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1

8.2 RUNNING-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4

8.3 HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4

8.4 FINAL DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5

8.5 FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5

8.6 FILLING VOLUMES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-6

8.7 TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-7

8.8 LUBRICANT RECOMMENDATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-8

8.9 CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-8

8.10 FEEDER / SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-8

8.11 TRACK GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-8

8.12 GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-8

8.13 ADDING HYDRAULIC FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-8

8.14 ENGINE FILTER CHANGE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-10

8.15 REPLACING THE HYDRAULIC OIL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-12

SERVICE INSTRUCTIONS 9.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1

9.2 BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1

9.3 OTHER ELECTRICAL EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2

9.4 WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3

9.5 SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-4

TROUBLESHOOTING APPENDICES

Lokotrack LT1213

SECTION

0

This Instruction Manual is valid for diesel engine driven Lokotrack LT1213 primary crushing unit manufactured by Metso Minerals. Lokotrack LT1213 is a portable impact crusher unit, which is intended to be used in recycling crushing applications in crushing plants.

Due to the continuous development of the product, the manufacturer reserves the right to make changes to the manual without prior notice. This is the second edition of the Instruction Manual, published in October 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

10/03

0-27-EN

LOKOTRACK LT1213 INSTRUCTION MANUAL 0-1

SECTION 0 - LOKOTRACK LT1213


0-2

LOKOTRACK LT1213 INSTRUCTION MANUAL

0-27-EN

10/03

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.

01/95

1-00-EN

INSTRUCTION MANUAL

1-1

SECTION 1 - PREFACE


1-2

INSTRUCTION MANUAL

1-OO-EN

01/95

SAFETY

SECTION

2

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

02/05

2-00-EN

SAFETY 2-1

SECTION 2 - SAFETY


2-2

SAFETY

2-00-EN

02/05

MAIN COMPONENTS

SECTION

3

3.1 MAIN ASSEMBLY

Callout 1 2 3 4

Description Diesel engine Tracks Crusher Feeder

Callout Description 5 Main conveyor 6 Side conveyor (optional) 7 Magnetic separator (optional) Figure 3.1 Main assembly

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SECTION 3 - MAIN COMPONENTS

3.2 DIESEL ENGINE

onwards to a separate pile located next to the machine.

Lokotrack LT1213 crushing unit has a Caterpillar C-12 diesel engine. The engine runs hydraulic pumps.

3.7.3 Extended Main Conveyor Total length of 13 m (43 ft) will allow discharge height of 4,2 m (14 ft). Conveyor will fold to a transport position.

3.3 TRACKS

3.7.4 Hydraulic Output

The Lokotrack LT1213 crushing unit moves on a set of tracks. The tracks ensure a safe and speedy operation of the machine even in rough terrain.

The hydraulic output can be set on, off or “on with the process”. The selection is done by the process option selection page. Refer to the IC500 Instruction Manual for further information on hydraulic output.

3.4 CRUSHER The Lokotrack NP1213 impact crusher is the heart of the Lokotrack LT1213 unit. The materials fed into the crusher are crushed into smaller pieces by the machine.

3.7.5 Intermediate Cable For Secondary Unit

3.5 FEEDER

3.7.6 Large Hopper

The feeder ensures an even and uninterrupted flow of materials into the crusher. Any feed material smaller than the opening of the feeder grizzly goes through the grizzlies, bypassing the crusher. This increases feed capacity and prevents materials from accumulating and obstructing the crusher.

Large hopper will enlarge the hopper volume from 6m3 to 9m3.

The unit can be equipped with a socket assembly by allowing intelligent controls between primary and / or secondary unit.

3.6 MAIN CONVEYOR The main conveyor transfers the crushed material from the crusher to the stock pile or onwards for further processing. Free distance to ground 2800 mm (110”).

3.7 OPTIONAL EQUIPMENT 3.7.1 Side Conveyor The optional side conveyor transfers the material that has bypassed the crusher through the feeder grizzlies and on to the stock pile located next to the machine. 3.7.2 Magnetic Separator The optional magnetic separator is installed above the main conveyor. It separates magnetic objects from the crushed material and transfers them

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3.8 ENGINE MODULE

Callout Description 1 Crusher circuit filter 2 Hydraulic pressure filter 3 Oil filter

Callout 4 Oil fill port 5 Dipstick 6 Charger

Description

Figure 3.2 Engine module

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3.9 HYDRAULIC TANK

Callout 1 2

Description Hydraulic return filter Breather

Callout Description 3 Hydraulic oil sight glass Figure 3.3 Hydraulic tank

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CONTROL PANELS

SECTION

4

4.1 OPERATING PANEL SWITCHES/BUTTONS AND CONTROL LEVERS

Callout 1 2 3 4 5

Description Emergency stop Lubrication unit Radiol ¨control key Water pump Display

Callout 6 7 8 9 10

Description Process ON Key switch Signal horn Process OFF Work light

Figure 4.1 Operating panel

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LOKOTRACK LT1213/1213S INSTRUCTION MANUAL 4-1

SECTION 4 - CONTROL PANELS

4.2 DRIVE CONTROL BOX

Callout Description 1 Track, left-hand 2 Track, right-hand

Callout Description 3 RPM of diesel engine 4 Emergency stop

Figure 4.2 Drive control device

4-2

LOKOTRACK LT1213/1213S INSTRUCTION MANUAL

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4.3 REMOTE CONTROL

Callout Description 1 Emergency stop 2 Feeder stop 3 Feeder start

Callout Description 4 Feeder speed 5 Feeder speed + 6 Feed gate opening

Figure 4.3 Remote control

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4.4 HYDRAULIC MODULE CENTER

Callout Description 1 Safety switch for conveyors 2 Fuel pump (optional) 3 Socket for screen module

Callout Description 4 Emergency stop 5 Hand valves 6 Socket for service light

Figure 4.4 Hydraulic module center

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4.5 RADIO CONTROL (optional)

l Callout Description 1 Engine rpm UP-DOWN/ feeder ON-OFF 2 Battery 3

Remote STOP

4 5

Feeder speed increase/decrease Left track forward-backward

Callout Description 6 Battery voltage level indicator 7 Selector switch tracking/crushing (a/b) a) Right track forward-backward 8 b) Feed gate open 9 Key switch

Figure 4.5 Radio control

4.5.1 Radio components Transmitter, receiver, two batteries, charging device for the batteries, two key switches. For functions of radio control refer to Chapter 7.10.

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4.6 IC500 CONTROL SYSTEM 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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4.7 CONTROL LEVERS 4.7.1 Hydraulic Module

Callout 1 2 3 4 5

Description Screen module connect socket Fuel filling pump (optional) Safety switch for conveyors Emergency stop Hand valves

Callout 14 15 16 17 18

6

Main conveyor on/off (with manual lever)

19

7 8 9 10 11 12 13

Main conveyor Hydraulic outlet Magnetic separator Left track Side conveyor turning up/down Side conveyor in/out Not in use

20 21 22 23 24 25

Description Pressure gauge of the device pump Crusher frame opening Crusher setting control Extended discharge conveyor up/down Hydraulic oil drainage port Side conveyor driving/operations of cylinder Feed gate opening Feeder Right track Hydraulic outlet Hydraulic outlet Direction valve of the main conveyor

Figure 4.6 Location of the hydraulic valves

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STARTING AND STOPPING

SECTION

5

5.1 BEFORE STARTING IMPORTANT! Check the condition of the machine.

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.

Turn the light pole up (figure 5.1), if necessary.

IMPORTANT! Do not initiate the process before the feeder side panels have been raised in order not to damage the rubber rams! (figure 5.2)

LT1213

vmy1213.eps

Figure 5.1 Turn the light pole up

Check the tension of the crusher V-belts. The belt deflection is 30 mm (1,2”) for a force value of 110 N (25 lb) . 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.

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Figure 5.2 Do not initiate the process before the feeder side panels have been raised.

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SECTION 5 - STARTING AND STOPPING

5.2 STARTING THE DIESEL ENGINE

5.3 STOPPING THE DIESEL ENGINE

Start the diesel engine as follows:

Stop the diesel engine by turning the key switch to "OFF" position.

1. Turn the key switch in the main control panel to ignition ON-position (ref. fig 4.1).

NOTE: Before stopping the diesel engine, make sure that the engine idles for few minutes.

2. Wait until the unit centre display is visible. Reset possible display messages with F1 function key.

5.4 ADJUSTING DIESEL ENGINE RPM SPEED

3. Turn the key switch to START position and hold it that way until the engine is running. NOTE: Hold the key switch at start position until the diesel engine starts. If you use manual control, be especially careful. The fact is that manually activated device will not run until the diesel engine is running. But the device will start to operate immediately when the engine is started, if the manual control is on.

The automatic control of the machine monitors and adjusts the diesel engine RPM during the start and the crushing process. During this time, the user cannot adjust the RPM speed. When the process is not running, the RPM speed of the diesel engine can be controlled with the RPM control switch located in the drive control box (ref. fig. 5.3) If the machine has radio control (optional), the RPM speed of the diesel engine can be adjusted with radio control in the same way as with the drive control box.

Figure 5.3 RPM speed of the diesel engine can be controlled with the RPM control switch located in the drive control box.

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5.5 EMERGENCY STOP In the event of an emergency, press the emergency stop button to stop the machine or the conveyor (figure 5.4). For instructions on operation of the emergency stop relay, see Chapter 10.

Emergency stop button A B C

Function Stops the machine Stops the discharge conveyor Stops the main conveyor Figure 5.4 Emergency stop buttons

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ENSURE THAT THE SUCTION VALVES OF THE HYDRAULIC TANK ARE FULLY OPEN If the suction valves are not fully open, the position switch of the suction valves will cause emergency stop function.

Figure 5.5 Ensure that the suction valves of the hydraulic tank are fully open.

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TRANSPORT

SECTION

6.1 SAFETY IN THE TRACK DRIVE MODE

6

words, it is recommended for distances over 500 m when there is no need to turn the unit.

Be especially cautious when transporting or moving the unit because of its large size and weight.

6.3 DRIVING THE UNIT

Normally the unit can be moved to its working position on the site by driving it in track drive mode. Before starting to drive, make sure that –

the driving route is sufficiently even.

–

differences in altitude and road inclination do not prevent driving.

In the track drive mode, the maximum inclination allowed for the machine is 5 degrees in lateral direction and 15 degrees in longitudinal direction.

Drive the unit with the help of the drive controls located in the drive control box. If the machine is equipped with a radio control feature (optional), it is also possible to drive the unit with the help of the radio control feature. Drive with the radio control in the same manner that you would drive if you were using the drive control box. Connect the drive control cable into one of the cable connecting sockets (figures 6.1 and 6.2). The LT unit can now be moved in either direction using the drive control levers located in the remote control unit (figure 6.2).

Make sure that the load-bearing capacity of the underlying ground is at least 15,000 kg/m2 (3,072 lbf/sq f). Start the engine according to the instructions provided in Chapter 5.2.

IMPORTANT! Always check the surroundings of the LT unit before attempting to move it.

6.2 SELECTING THE DRIVING SPEED RANGE It is possible to use three different speed ranges for driving the machine; fast, slow and normal. Select the required speed range with the engine rpm control switch. Recommended driving speeds shown in Table 6-1: Engine speed Idle - 1199 1200 - 1999 2000 -2100

Drive speed Slow Normal Fast

Table 6-1 Recommended drive speeds

•

•

•

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Figure 6.1 Connect the drive control cable to one of the cable connecting sockets

Slow: When driving the LT onto/off a trailer, or when precise and careful handling of the machine is called for. Normal: The most effective speed range for moving the unit. Crawl speed is used in regular daily operations. Fast: The fast speed range is used when the tracking distance is relatively long. In other

NOTE: Make sure that no-one is near the unit before attempting to drive it. Avoid making any sudden moves while driving. NOTE: In the case of longer driving distances (over 100 m / 328 ft), the unit must be driven with its feeder end first. This ensures that the track chain

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SECTION 6 - TRANSPORT

NOTE: When driving on an uneven surface or in the event that the LT unit is connected to Lokolinks, moving the LT requires extreme caution.

remains tight and prevents the chain from skipping over the drive pulley teeth. NOTE: In the case of longer driving distances, monitor the temperature of the hydraulic oil continuously. The oil temperature should not exceed 90°C (194°F). If the oil is too hot, it may damage the seals. If no crushing is required, stop the engine according to the instructions provided in Chapter 5.3.

•

Avoid turning the machine in situations where the upper segment of the crawler chain acts as the driving end. The crawler chain may loosen if the tightening spring located inside the crawler chassis gives way, which in turn may cause the traction wheel to skip over the chain.

•

Always select an appropriate surface for turning the LT unit. Only attempt to turn the LT in a location where the ground surface supports the whole length of the unit's tracks. This ensures that the traction force is concentrated on the lower section of the crawler chain.

If crushing is required, refer to section 5.2 for instructions. A few tips to make turning the unit unit easier: •

It is easier to turn the unit on hard surfaces than on soft surfaces.

•

If the unit cannot be turned while driving uphill, drive downhill for a short distance, turning the unit at the same time.

NOTE: If manual valves are active it will prevent track driving.

Figure 6.2 The unit can be moved in either direction with the help of the drive controls

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6.4 TRANSPORTING THE UNIT FROM ONE LOCATION TO ANOTHER REQUIRED EQUIPMENT IMPORTANT!

–

When transporting the unit on public roads, make sure that you have received the permits required for special transports from the appropriate authorities. Check the local regulations, as they vary from one country to another.

Low loader, minimum load-bearing capacity 45t (49,5 st).

REQUIRED PRE-TRANSPORT MEASUREMENTS

1. A) Undo the feed hopper of the feeder. Remove all wedges. Lower the real wall. (see also 7.4) B) Lower the side walls.

3. Place the light pole into transport position. 4. See 7.10 Extended discharge conveyor if necessary

2. Turn the side conveyor up (see also 7.4)

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6.5 DRIVING ONTO/OFF THE TRANSPORT PLATFORM

The unit can be driven onto the transport platform by driving it either straight or in reverse, depending on the type of transport platform in question.

NOTE: Drive the unit onto/off the trailer with great care.

Always make sure the hydraulic oil surface level is right before driving the unit onto/off the trailer.

Fix a suitable ramp against the trailer so that its maximum inclination does not exceed 1:4 when driving the unit onto the trailer.

Figure 6.3 Driving the unit onto a trailer

WEIGHT OF THE BASE UNIT (WITHOUT FUEL): 37500 KG / 82500LBS Weight of LT1213 optional equipment kg Side conveyor H 5-5 600 Magnetic separator STD 2200 Feed hopper (9m3) Long conveyor H10-15

lbs 1320 4800

570

1255

1900

3890

Table 6-2 Weight of LT1213 optional equipment

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

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CRUSHING

SECTION

7.1 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 (figure 7.1).

Figure 7.1 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 (figure 7.2).

Figure 7.2 General measures taken on the site.

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7

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 (figure 7.3). Next, harden the underlying ground by driving the unit back and forth over the site (figure 7.4).

Figure 7.3 Spread some fine-grained material on the ground and even it out.

Figure 7.4 Strengthen the underlying ground by driving the unit back and forth over it.

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SECTION 7 - CRUSHING

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 (figures 7.5 and 7.6). For purposes of maintenance, it is recommended that you dig a hole under the unit unit (figure 7.7).

7.2 FEEDING MEASURES 7.2.1 Loading Equipment The unit can be loaded with the help of either an excavator or a wheel loader.

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

•

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 (figure 7.8).

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

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

Figure 7.7 Dig a hole under the unit for maintenance purposes.

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Load the material into the rear end of the feeder, on top of the solid base (figure 7.9).

7.3 DISCHARGE MEASURES •

ALTERNATIVES –

Wheel loader

–

Stack conveyor

–

Secondary process

–

Lokotrack (secondary)

Check the height and volume of the discharge pile. Do not let the pile grow so high that it reaches the conveyor. The distance between the pile and the conveyor must always be at least 200 mm (8") (figure 7.10). Figure 7.9 Load the material into the rear of the feeder, on top of the solid base.

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 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.

Figure 7.10 The distance (h) between the pile and the conveyor must be always at least 200 mm (8").

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 unit unit. 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.

NOTE: Do not drive the excavator bucket into the material or try to force the material into the jaw cavity. NOTE: Keep feed gate closed during operation.

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7.3.1 Extended Discharge Conveyor •

FROM TRANSPORT TO CRUSHING 1. Activate conveyor control lever (*). 2. Release transport locking. Lift the conveyor slightly to allow the removal of locking pins. 3. Turn the conveyor drivehead to crushing position 4. Mount locking pins at their places. The head of the pin must be inside the conveyor frame. 5. Reset trip wire switches.Adjust tightness if necessary. 6. Secure side rubber position at both of the joints. 7. Deactivate conveyor control lever (*).

Figure 7.11 Transport position

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•

FROM CRUSHING TO TRANSPORT IMPORTANT! 1. Activate conveyor control lever (*). 2. Remove crushing position locking pins from their places. Lift the conveyor slightly to ease the removal of the locking pins. 3. Lower the conveyor drivehead to transport position. 4. Mount transport locking at their place. 5. Deactivate conveyor control lever (*).

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

IMPORTANT! The discharge conveyor can only be folded on top of an even surface. (*) Ref. 4.4 # 4.5

Figure 7.12 Crushing postion

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7.4 CRUSHING

2. Turn up the side walls of the feed hopper and lock them in place with the help of the wedges (ref. fig. 7.16).

1. 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 (figures 7.13 and 7.14).

–

Lift both of the side walls (1 and 2) into their uppermost position.

–

Lift the rear wall (3) into its uppermost position and lock it in place with the help of the wedges (4). The upper wedges are easiest to lock in place from the direction of the feeder.

–

Remove the transport locking of the feeder (fig. 7.15).

Figure 7.13 Turn the side conveyor down with the help of the control levers

Figure 7.15 Remove the transport locking of the feeder.

NOTE: Turn off the diesel engine before moving over to the feeder. – Callout Description 1 Side conveyor up / down 2 Side conveyor in/out 3 Not in use Figure 7.14 Control lever for the side conveyor located in the hydraulic valve section (2). NOTE! Control switch for the hand valves, see Chapter 4.4.

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Lock the side and rear walls in place with the help of the locking wedges (5).

3. Lower the walls in reverse order. When removing the wedges, install and tighten the lifting ropes of the crane first. Once you have done this, you can proceed to remove the wedges in reverse order.

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IMPORTANT! 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.

IMPORTANT! 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.

Figure 7.16 Turn the rear wall of the feed hopper upwards.

BEFORE STARTING THE MACHINE, MAKE SURE THAT NO-ONE IS ON, NEXT TO OR UNDER THE CRUSHER. CAUTION EVERYBODY IN ITS VICINITY THAT YOU ARE ABOUT TO START THE CRUSHER.

If the additional side walls of the machine are not lifted with hydraulic cylinders, you must be extremely careful when lifting or lowering them. In this case, the side walls must be lifted and lowered using a crane. Make sure that there is no-one below the side walls, or too near them, as it may cause an accident risk. 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 LT. When the side wall is lifted vertically against the joint hinge, the mass of the entire LT may apply to the lifting instrument. When you lift the side walls, first lift the side wall to its upper 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.

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7.4.1 Starting the Crushing Process Before starting the crushing process, always make sure that the crusher cavity is empty. If there is material in the cavity, clear the cavity. 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. NOTE: Initiate the crushing process by pressing the “Process ON” button (figures 4.1 and 4.2). IMPORTANT! Only initiate the crushing process once you have made sure that the feeder side panels have been raised and locked in place with the help of wedges.

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NOTE: When starting the crushing process, the automatic control function takes care of starting the devices, 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.

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. NOTE: 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 enter the crusher.

Stop the crushing process by pressing the “Process STOP” button. NOTE: When stopping the crushing process, the automatic control function takes care of turning off the equipment, monitoring any possible problems and adjusting the RPM level of the diesel engine. The termination of the crushing process takes approximately 1 minute. Process options: –

side conveyor

–

magnet separator

–

hydraulic power take off (PTO)

–

crusher speed (an application) Figure 7.17 "Emergency stop" - buttons (for more information, refer to Chapter 5.5

must be selected before the process start. Load some material into the feed hopper while the vibrating chute is running. For further instructions, refer to Chapter 7.6 "Feed control". 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.

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

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

IN CASE OF EMERGENCY, PRESS "EMERGENCY STOP"-BUTTON TO STOP THE UNIT (FIG. 7.17).

Do not attempt to crush stones that are too large to fit inside the cavity. Having to reposition rocks

7-8


Figure 7.18 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 7.19) or towards the optional side conveyor (figure 7.20). With the optional screen deck, materials larger than the mesh openings can be directed towards the main conveyor (figure 7.21). 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 7.21 The flow of materials has been screened and directed either to the side conveyor (pass-through) or to the main conveyor.

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

Figure 7.20 The chute has been directed towards the side conveyor.

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7.6 CRUSHER SPEED SELECTION

1. Stop the feeder during the crushing process by pressing the "feeder stop" button.

Use correct speed for the rotor as too high rotor speed can cause unnecessary wear.

2. Restart the feeder after it has stopped completely by pressing the "feeder start" button.

Too low speed with some hammer combinations may cause wear to the rotor. Check wear daily to prevent rotor damages. Crusher speed is a process option. Table 7-1 explains factory set crusher speeds. FACTORY SET SPEEDS (Drive pulley dia 250mm) Crusher Hammer Speed Feed speed/rpm speed m/s Asphalt/ 1 Abrasive 450 28 metal Recycling/ Medium 520 32 2 abrasive material Rock feed/ 3 Non-abrasive 600 37 material

FACTORY SET SPEEDS (Drive pulley dia 315mm) Crusher Hammer Speed Feed speed/rpm speed m/s 1 570 36 Non-abrasive 2 660 42 material 3 760 48 Table 7-1

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. 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. 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.

It is possible to change the factory preset speeds for a secondary application. Crusher speed change is explained in the IC500 Instruction Manual.

An overfilled feeder will reduce the capacity and cause unnecessary wear.

7.7 FEED CONTROL

The feeder control mode can be either manual or automatic. The selection is done in the feeder parameter F5. Refer to the IC500 Instruction Manual for the parameter change.

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:

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7.7.1 Feeder Automatic Control

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

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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. 7.7.2 Feed Material Refer to the NP1213 Instruction Manual for the feed material.

7.8 CRUSHER SETTING

Figure 7.22 Measuring the setting (X)

7.8.1 Measuring the setting 1. Stop the engine.

7.8.2 Changing the setting

2. Open the inspection door of the crusher.

1. Stop the process.

3. Rotate the Rotor to position as show in the drawing.

2. Stop the engine. Measure the setting. 3. Start the engine.

4. Measure setting (x) between the hammer and the breaker plate liner. (Measurement from the middle of the hammer to the closest breaker plate.

4. Activate hand valves. 5. Remove protection plate 1 (Fig. 7.23). 6. Remove the spring tension with setting assistant lever 2. (Install the safety block to prevent on accident risk).

NOTE: Observe the hammer wear while measuring the setting. Hammers must be renewed if the hammer wears on the hammer wear limit. (Ref. NP1213M Instruction Manual).

7. Turn the adjustment nut lever 3 to desired direction:

NOTE: Observe the rotor while measuring the setting. Rotor should not wear during crushing. Inspect the speed of the crusher and hammers if rotor wear is detected.

–

cw: open setting

–

ccw: close setting

8. Release spring tension with setting assistant 2. 9. Stop the engine. 10. Check the setting. 11. Close the inspection door 12. Mount protection plate 1 on it's place. NOTE: Observe that the setting assistant cylinders will return completely in after use.

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removed, the main conveyor can be started by using a manual lever in the hydraulic valve manifold. The main conveyor can be driven in both directions with the manual lever and the directional valve. Observe the belt running direction. Do not reverse the conveyor more than 0,5 m (1’6”). 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.

7.10 REMOVAL OF THE STEEL

Figure 7.23 Changing the setting

Always stop the machine (feeder, crusher, conveyors and engine) before removing metal from it. Ensure that it can not be started during removing metal from it.

7.8.3 Minimum setting Ref. NP1213M Instruction Manual for setting ranges. MINIMUM SETTING mm 360x600x960 180x300x320 120x200x160 60x100x160

mm 60 50 40 30

Table 7-2 Minimum settings

7.8.4 Maximum setting All material 90 mm. 7.9 CLEARING OF THE JAMMED MAINCONVEYOR NOTE: Never try to clear the blockage with the excavator. If the conveyor stops, follow these instructions:

7-12

–

Stop the process immediately.

–

Clear the jammed main conveyor as well as possible. When most of the material is


7-16-EN

10/03


7.11 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 LT1213. The optional magnetic separator can be used for the removal of small metal objects.

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

10/03

7-16-EN



7.12 DISCHARGE CHUTE IMPACT PLATE Plate is designed to reduce the wear of the conveyor belt. Impact plate is designed to be used with hard rock & asphalt application. Impact plate can be used in recycling application if the steel in the feed material is precut enough short.

Callout

Description

Impact plate is mounted to discharge chute. Impact plate can be lifted to/from it's place with the impact crusher hoist.

Callout

1

Impact plate

3

2

Upper mounting - hook

4

Description Lower mounting - bolt/overload protection Rotor of the crusher

Figure 7.25 Discharge chute impact plate

Overload protection is designed to cut off the mounting bolts if uncrushable object enters through the crusher.

7-14


7-16-EN

10/03

MAINTENANCE

SECTION

DIESEL ENGINE Change engine oil every 200 operating hours. Change oil filter every 200 operating hours. Drain water from fuel. Change the primary fuel filter every 200 operating hours. Change fine fuel filter every 200 operating hours. Check the service indicator of the air filter. Change the cartridge if necessary. Change X the safety cartridge every third time. See the engine operating manual for other maintenance. IMPACT CRUSHER Check locking of frame and access doors. X Remove accumulations of material from the frame. Check crusher V-belt tension. Check condition of adjustment systems. Check that frame opening sensor works correctly. Lubricate the bearings 45g/40h Check condition of feed box curtains and dust protection (option). Lubricate the setting adjustment components 5g/100h. Check eventual bearing noise. Check condition of frame opening cylinders and setting adjustment hydraulic assistance jacks (option). Check tightness of breaker plate liners. Check tightness of frame liners. Check locking of hammers. Tighten hammer locking wedges. Check condition of wear parts for abrasive X materials and recycling applications.

10/03

When needed

Every 12 months

Daily

Weekly

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

Every 6 months

NOTE: Grease lubrification specification NLGI EP 2.

Monthly/200 h

8.1 PERIODICAL MAINTENANCE

8

X X X X X

X

X X X X X X X X X X X X X

8-15-EN LOKOTRACK LT1213/1213S INSTRUCTION MANUAL

8-1

8-2

When needed

Every 6 months

Monthly/200 h

Weekly

Daily Check condition of wear parts for average abrasive materials. Check condition of wear parts for non-abrasive materials. Lubricate jackshaft 10g/40h. Open discharge chute access door and observe the chute condition. Check condition of the discharge chute impact plate wear rate. Check/Adjust the sealing of the discharge chute and conveyor belt. VIBRATOR Oil change (1000h) Check oil level Replace breather 1000 h 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. Discharge chute impact plate mounting. Check the conveyor belt condition and leakages. HYDRAULICS Check the oil level. Check the oil temperature (max 90ºC / 194ºF). Check the fixing bolts of all components. Check pipes and hoses. Change hydraulic oil filters every 2000 operating hours. Clean the hydraulic tank every 2000 operating hours. Check the breather of the hydraulic tank. Replace every 6 months.

Every 12 months

SECTION 8 - MAINTENANCE

X X X

X

X X X X X X X X X X

X X X X X X


X X X X X

8-15-EN

10/03

10/03

When needed

Every 6 months

Monthly/200 h

Weekly

Daily 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)

Every 12 months


X X X X X X X X X X


8-3


8.2 RUNNING-IN

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).

See the Crusher Instruction Manual for further details. 8.3 HYDRAULICS Basic requirements for the hydraulic oil quality: –

viscosity index should be min. 150

–

min. viscosity 16 cSt at operating temperature

–

Attached some examples of oil brands meeting these requirements:

max. viscosity 1000 cSt at starting temperature

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 46

–

Esso Univis N 46

–

Shell Tellus Oil T 46

–

Teboil Tebo Hydraulic Oil 46

–

Mobil DTE 15

8-4

–

Esso Univis N 32

–

Mobil DTE 13

–

Shell Tellus Oil T 32

–

Teboil Tebo Hydraulic Oil 32 S


Mobil DTE 16

–

Teboil Tebo Hydraulic Oil 68

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

Crusher

Attached some examples of oil brands meeting these requirements: BP Energol SHF 32

–

Oil amount is 520 litres (140 gal) .

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 (86ºF).

–

BP Energol SHF 68

Factory set speeds:

Attached some examples of oil brands meeting these requirements: –

–

8-15-EN

450-600 rpm

Main conveyor

1,7-2,0 m/s (5,6-6.6 f/s)

Side conveyor

2,4-2,6 m/s (7,7-8,5 f/s)

Magnet conveyor

1,5-1,7 m/s (4,9-5,6 f/s)

Engine speed

2100 rpm

Feeder speed

500-1150 rpm

10/03


8.4 FINAL DRIVE Change the final drive oil after every 2000 engine operating hours. Oil amount is 4.5l (1.2 gal). Oil quality is ISO VG 220.

8.5 FUEL LEVEL The fuel level can be checked from the fuel amount indicator in the display (figure 8.1). Fuel tank capasity 600l (160gal). 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 8.1 Checking the fuel level

10/03


8-5


8.6 FILLING VOLUMES

LT1213 DEVICE

AMOUNT

Hydraulics

520 l / 140 gal

Final drive

4,5 l / 1,2 gal

Fuel tank

600 l / 160 gal

Feeder vibr. unit

4 l / 1 gal

ENGINE CATERPILLAR C12 Engine oil Water

28,5 l / 7,6 gal 36 l / 9,5 gal

Table 8-1 Filling volumes

8-6


8-15-EN

10/03


8.7 TRACKS

Frame

Tension

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

–

–

Check that the track chains are properly tensioned. Adjust as necessary. See the correct chain deflection in fgure 8.2. 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 LT if needed.

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.

X

Figure 8.2 Check that the track chains are properly tensioned. The correct deflection (X) is 25 mm (1")

10/03


8-7


8.8 LUBRICANT RECOMMENDATION

–

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 crusher 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.

Recommended brands are e.g.: •

•

Blasia 220

8-8

Varter EP 220

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

8.13 ADDING HYDRAULIC FLUID

–

•

open the oil addition plug in the top of the return filter (refer to 3.11)

•

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

Degol BG 220

AVIA Gear RSX 220

BP Enersyn HTX 220

CASTROL –

•

–

Adding hydraulic oil:

– •

TOTAL

ARAL

– •

Syngear 220

AGIP –

•

EP Gear Synth 220

TEXACO –

•

Mobilgear 630, SHC 220

PANOLIN –

•

Q8 Goya 220, El Greco 220

MOBIL –

8.11 TRACK GEAR

Lamora 220

KUWAIT –

See further instruction in your feeder/screen manual.

Renolin AWD 220

KLÜBER –

8.10 FEEDER / SCREEN

Giran L 220

FUCHS –

8.9 CRUSHER

Reductelf SP 220, Elf Epona Z 220

FINA –

•

Trion EP 220, Intor HCLP 220

Alphasyn T 220, Aplha ZN 220

DEA


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

8-15-EN

10/03


8.13.1 Adding Engine Fluids Add the engine oil through plug 4. Check the amount of oil with dipstick 5 (see chp 8.6. Filling volumes).

Callout Description Crusher circuit filter 1 Hydraulic pressure filter 2

Callout 4 Oil fill port 5 Dipstick

Description

Figure 8.3 Adding engine fluids

10/03


8-9


8.13.2 Removing Engine / Hydraulic Fluids

8.14 ENGINE FILTER CHANGE INFORMATION

Observe the following instructions: –

remove the plug

8.14.1 Replacing the Engine Fuel Filter

–

open the valve

Engine fuel filter 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 Chp. 8.6 Filling volumes).

For more information, refer to the Caterpillar C-12 Operation Manual. 8.14.2 Replacing the Engine Oil Filter Engine oil filter must be replaced every 200 h of engine running hours or at least once a year 8.14.3 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. 8.5) in every third primary filter replacement.

Callout Description Coolant valve (under the cooler) 1 Engine oil 2 Hydraulic oil 3 Figure 8.4 Draining engine fluids

Figure 8.5 The safety cartrigde

8-10


8-15-EN

10/03


Figure 8.6 Undo the filter housing latches to remove the cover.

Figure 8.8 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 8.7 Draw the primary cartridge out from it's place. If needed draw the safety cartridge out from it's place. Figure 8.9 Close the air filter housing cover correctly on it's place and make sure that all latches are properly closed.

10/03


8-11


8.14.4 Fuel tank Breather change.

8.15.1 Crusher Drive Pump Filter Change

Breather is located side by the engine cover (fig. 8.10). 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 8.10 Fuel tank breather

8.15 REPLACING THE HYDRAULIC OIL FILTERS First hydraulic oil filter change should take place at 2000 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

Figure 8.11 Crusher drive pump filter

Replacement information: 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. Tighten the housing with 20 Nm torque. Filter must be replaced every 2000 h of engine operation or whenever the filter condition indicator is alarming. 8.15.2 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.

8-12


8-15-EN

10/03


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. Undo the filter by turning the filter in counter clock wise. Dispose the used hydraulic filter according to country legislation.

Figure 8.14 Lubricate the O-ring of the housing and spin the housing carefully on it's place Tighten the housing with 40 - 50 Nm torque.

Figure 8.12 Undo the filter housing by turning the housing counter clockwise with 41 mm wrench.

Filter must be replaced every 2000 h of engine operation or whenever the filter condition indicator is alarming. 8.15.3 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 8.13 Remove the filter element from the housing and install a new element to the filter support.

Figure 8.15 Undo the cover of the return filter. Open the four nuts ( 13 mm wrench ) and remove the cover.

10/03


8-13


Figure 8.16 Be careful when doing this as there is a spring under the cover.

Figure 8.19 Clean the magnets before installing a new filter element (fig. 8.20). Use 20 - 25 Nm torque when securing the filter element. Insert the filter assembly on its place and close the cover.

Figure 8.17 Pull the filter assembly out from the filter housing.

Figure 8.20 Observe the O-ring condition and lubricate it before installation. Use 15 Nm torque for the cover mounting nuts.

Filter must be replaced every 2000 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. Figure 8.18 Open the filter assembly by opening the 36 mm lock nut. Remove the filter element.

8-14


8-15-EN

10/03

SERVICE INSTRUCTIONS

SECTION

9.1 GENERAL

Remember that some solvent types may cause skin irritation and may be extremely flammable. Avoid breathing in any solvent fumes.

Only skilled and experienced mechanics must be allowed to service the plant.

Service and maintenance facilities must be kept clean. Oil and water can make floors slippery and therefore hazardous. Avoid using severely soiled fabrics, as these can be highly flammable.

When carrying out any work related to the operation, application and modification or adjustment of the LT and its safety equipment, as well as when carrying out the inspection, maintenance and repair of the crushing unit, observe the starting and stopping procedures outlined in the Instruction Manual and monitor the unit to see if there are any indications that maintenance work is required!

Keep the LT and its equipment free of oil spills and dust. A clean machine reduces the risk of fires and makes the visual inspection of the machine easier.

Secure the area of maintenance work as thoroughly as possible! In the event that the LT unit is switched off completely during maintenance and repair work, it must be safeguarded against accidental re-ignition. Lock the main start-up device, remove the keys and fasten a caution plate on the main switch. Smoking and lighting fires is prohibited in the vicinity of the machine when refuelling or servicing the fuel system. IMPORTANT! In the event of a fire:

9

Be careful when using the pressure cleaning equipment. Even low pressures and low temperatures can damage the wiring insulation. Check the wiring for signs of abrasion damage or kinks. These can cause short circuits and fires. Check the hydraulic hoses for abrasion damage or kinks. Never weld or whet tanks that contain flammable materials. Always have a fire extinguisher on hand when carrying out welding or whetting operations. Familiarise yourself with the location and use of the fire extinguishers. 9.2 BATTERY MAINTENANCE

Move the LT unit away from the hazardous area Switch off the engine

Fluid level inspection

Turn off the main switch

The battery fluid level must be checked every 100 operating hours (figure 9.1). The level should be at approximately 10 mm (1/4") above the plates. Add clean, distilled water as required. Monitoring the fluid consumption rate will give an indication of the charge status of the battery, but a separate test indicating the amount of acid present will provide a more reliable picture of the charge status. If the fluid consumption rate is high, it could be an indication that the alternator charging rate is too high.

Begin extinguishing the fire and sound the fire alarm if necessary.

Diesel fuel is highly flammable - do not use it as a cleaning fluid. Use solvents of accepted quality only. Always switch the engine off during maintenance work unless the Instruction Manual specifically directs you to keep the engine running. Do not check for leaks with your bare hands. Instead, use a suitable cleaning cloth. Never adjust any hydraulic valve beyond the pressure reading recommended by the manufacturer. Always ensure adequate ventilation when running the engine in a confined area.

10/03

9-14-EN


SECTION 9 - SERVICE INSTRUCTIONS

Always wear protective goggles and gloves when handling the batteries. Cleaning batteries, terminals and cables Batteries and terminals must be cleaned at least once a year. The terminals and cable ends should be cleaned with the help of special tools that help maintain the correct size and shape of the contact surface. After cleaning, the terminals and cable ends should be covered with petroleum jelly to protect them against oxidation. Also inspect the following: fastening of the battery earth cables to the main frame; engine starter cables; and electrical connections to the alternator. Clean and tighten the wiring as required. Keep the battery cases clean and dry. Figure 9.1 Check battery fluid level every 100 operating hours. Add clean distilled water in the accumulator as required.

Battery inspection The battery charge level must be checked regularly using a hydrometer. Do not carry out this inspection immediately after adding distilled water to the battery; the water and the acid will have mixed more evenly after some charging has taken place. The specific gravity of a fully charged battery is approximately 1.28, and the reading for a half-charged battery is approximately 1.2. These values correspond to a battery temperature of around +20°C(68°F).

9.3 OTHER ELECTRICAL EQUIPMENT 9.3.1 Charging Circuit –

Check and tighten the connections regularly.

–

The alternator requires only periodic maintenance.

NOTE: It is important that you follow the instructions for protecting the alternator closely:

Batteries must always be maintained fully charged for as long as possible. If the charge level is allowed to remain low, the cells will become sulphated, reducing the capacity and efficiency of the whole battery.

–

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 has come 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 or when using jumper leads or a charger, make sure that the cables are connected to the correct terminals.

–

Always disconnect the battery cables when servicing the electrical equipment of the LT unit.

–

Do not cause short circuits in any part of the system or take a test reading with an instrument that has a low internal resistance.

Remember that a half-charged battery will freeze at a temperature of -25°C(-13°F), while an empty one will freeze at only -10°C(68°F). Never use an open flame when inspecting the acid level of a battery. The gases given off by the chemical reaction that occurs during the recharging process are highly flammable. The fluid used in lead-acid batteries is diluted sulphuric acid. This acid is corrosive, and it may cause severe burns to exposed skin as well as damage clothing. Be very careful when handling batteries.

9-2

LOKOTRACK LT1213 /1213S INSTRUCTION MANUAL 9-14-EN

10/03


NOTE: If auxiliary batteries are used to assist the ignition of the engine, make sure that: –

the batteries are of the same voltage

–

the terminals have been correctly connected

9.3.2 Starter Engine Circuit Under normal conditions, 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 they must be kept fully charged, clean and properly filled to maintain the correct acid level. Battery cables must also be checked for tightness and kept clean and well-greased.

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

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 9-1 Fuse location in the control panel

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

10/03

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

Fuse Size 30A 10A

2F08

15A

2F09 2F10 2F11

15A 15A 15A

2F12

8A

2F13

8A

2F14

8A

2F15

10A

Description Control main fuse Engine control Service light sockets + optional engine pre-heater Fuel cooler Oil cooler S- models Not in use Cummins Engine/ Cat - Not in use Cummins Engine/ Cat - Not in use Cummins Engine/ Cat - Not in use Cummins Engine/ Cat - Not in use

Table 9-2 Fuse location in the electrical panel side by the hydraulic tank

9.3.3 Fuse List

Fuse ID 1F01

Fuse ID 2F01 2F07

Description Control main fuse Start motor pilot Not in use Engine + bat Switched Optional drive lights Work lights

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 9-3 Fuse location side by the main switch

Fuse ID

Fuse Size

3F01

10A

3F02

20A

Description S- Module + Fuel pump control Fuel pump

Table 9-4 Fuse location in the electrical panel side by the hydraulic valves

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

9-14-EN

–

Switch off the engine.

–

Turn off the control voltage.

–

Disconnect the earth lead to the batteries.



–

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

–

Disconnect engine electronics wire harness plugs from the engine control computer.

9.5 SENSORS 9.5.1 Crusher Speed Sensor 9.5.1.1 Operation The crusher is equipped with a speed sensor. Sensor can be deactivated from rusher parameters (Refer to the IC500 Instruction Manual). 9.5.2 Pressure Sensors 0 - 600 bar (8700 PSI) / 4 - 20 mA.

9-4

–

component pump

–

crusher drive pump

LOKOTRACK LT1213 /1213S INSTRUCTION MANUAL 9-14-EN

10/03

SECTION 10 TROUBLESHOOTING LICENSE TO START ENGINE

No

Main switch ON

Check: Fuse 2F03 Key switch contact Battery voltage

Key switch ON

Yes All modules not up

No No Yes Remote stop

Module missing alarm 37, 38 or 39 Check function of the emergency relay

Remote stop alarm 26 or 27: Check ECM XM1 input 15 with radio control Check DCM XM3 input 22 with cable control

No High Hydraulic oil temp

Alarm 17 Check: ECM XM3 input 13 Check cooler and hydarulic oil temperature

OK Closed

Alarm 16 Check : ECM XM2 input 18 Check suction valve position

Down

Alarm 10 Check: ECM XM2 input 17 Check actual oil level at hydraulic tank add oil if needed

Main valve

Open Oil level

OK Engine stop solenoid output ON

ENGINE READY FOR START

LT1213

1

SECTION 10 TROUBLESHOOTING ENGINE START

Key switch to start position

Check DCM XM1 input 4 Check the key switch contact

Signal horn output ON for 3 sec.

Check ECM XM2 output 7 Check fuse 2F04 & relay 2K06

Engine start output ON max 30 sec.

Check ECM XM2 output 5 Check fuse 2F02

Engine to min rpm

Engine to max rpm

Yes All modules not up

Engine stopping Module missing alarm 37, 38 or 39 Check function of the emergency relay

No Yes Remote stop

Engine stopping Remote stop alarm Check ECM XM1 input 15 with radio control Check DCM XM3 input 22 with cable control

No High Hydraulic oil temp

Engine stopping Alarm 17 Check: ECM XM3 input 13 Check cooler and hydarulic oil temperature

OK

Engine start continue

LT1213

2

SECTION 10 TROUBLESHOOTING

Engine start continue

Closed Main valve

Engine stopping Alarm 16 Check : ECM XM2 input 18 Check suction valve position

OK Down Engine stopping Alarm 10 Check: ECM XM2 input 17 Check actual oil level at hydraulic tank

Hydraulic oil level

OK Yes Engine stopping Alarm 11 Check fuse 2F07 Check fuse 2F06 Check ECM XM2 output 6 & relay 2K03

J1939 bus fault

No No

Engine start motor running

Check ECM XM2 output 5 Check fuse 2F02

Yes ENGINE RUNNING

Yes Releasing key switch from start position

LT1213

No

Engine start motor is running but engine does not start: Check fuel amount , Fill and bleed fuel system Manifold preheater function: Check fuse for preheater – side by the engine. Check active diagnostic code from the DCU page 5.3.2

3

SECTION 10 TROUBLESHOOTING ENGINE CONTROL WHILE ENGINE RUNNING

Engine stopping Module missing alarm 37, 38 or 39 Check function of the emergency relay

Yes

All modules not up

Yes

Yes

Radio selected

Engine stopping Alarm 27 Check ECM XM1 input 15

Radio remote stop

Yes

Yes

Drive box connected

Engine stopping Alarm 26

Drive box remote stop

Check DCM XM3 input 22

Yes

Yes

Hydr oil temp high

Process running

Disable process Alarm 1

No

Yes Hydr oil main valve closed

Yes Hydr oil level down

Yes Emergency stop

Engine running

LT1213

Engine stopping Alarm 16 Check : ECM XM2 input 18 Check suction valve position

Engine stopping Alarm 17 Check: ECM XM3 input 13 Check cooler and hydarulic oil temperature

Engine stopping Alarm 10 Check: ECM XM2 input 17 Check actual oil level at hydraulic

Engine stopping Alarm 28 ES from control panel Check HUB XH4 input 11! repair wiring or contact Alarm 29 ES Service platform Check HUB XH4 input 12 ! repair wiring or contact Alarm 30 ES from engine module Check HUB XH4 input 13 ! repair wiring or contact Alarm 31 ES from hydraulic center Check HUB XH4 input 14 ! repair wiring or contact

4


SCREEN ENABLE

Alarm 22 Check HCM XM1 input 19 If not active repair wiring or switch

Yes Safety switch (over size) off

Yes Alarm 23 Check HCM XM1 input 20 If not active repair wiring or switch

Safety switch (under size) off

Yes Force screen conveyors on from display

Yes Force screen on from display

Yes Process running

Screen enable

LT1213

Screen not enable Forced control of screen and screen conveyors is possible from display.

5


MAIN CONVEYOR ENABLE

Main conveyor left safety switch

Main conveyor right safety switch

Conveyor maintenance safety switch

Alarm 18 Main conveyor not enable Reset trip wire switch Check steel cable tension HCM XM1 input 23 - "1" ok ( "0" not ok ) - Check wiring & contact Alarm 19 Main conveyor not enable Reset trip wire switch Check steel cable tension HCM XM1 input 22 - "1" ok ( "0" not ok ) - Check wiring & contact

Alarm 21 Main conveyor not enable Check position of the maintenance switch Check contacts - 1 – 2 feed back contact - 5 – 6 solenoid

Main conveyor enable

LT1213

6

SECTION 10 TROUBLESHOOTING CRUSHER START UP AND STARTING BY PROCESS

Fault

Crusher not enable Contact to Metso Minerals service dept.

Engine control

Yes

Crusher not enable Alarm 41 Check wiring if ok Replace sensor

Crusher drive pressure probe failure

Yes Clamping pressure not between limits

No Crusher start from process ?

Crusher not enable Alarm 4 Low Alarm 5 High Alarm 36 Probe failure Check charging circuit operating charging valve manually. ! does the pressure change at UCD page 1.2 ! if not check sensor Check HCM XM2 output 22 if on check the voltage in the Danfoss valve plug if ok the danfoss valve control head failured

Yes Yes

No High over allowed delay

Pressure OK ?

Yes Yes Low over allowed delay

Yes

No Speed OK ?

Low over crusher starting time

Crusher Stopping Alarm 3 Material in the cavity Start crusher from service platform Crusher Stopping Alarm 6 Crusher not enable Check: V-belts, pressure sensor

Crusher Stopping Alarm 7 Crusher not enable Material in the cavity Start crusher from service platform

No Start OK ?

Yes Crusher running

LT1213

7


CRUSHER START FROM SERVICE PLATFORM

Fault Engine control

Crusher Stopping

Yes Forced control from display ?

No No

Crusher stopped by process ?

Yes Yes

No Swing reverse direction ? 1)

Swing normal direction ?

No

Swing reverse direction ?

Yes No

Yes

Run crusher to reverse direction

Stop crusher

Run crusher to normal direction

1) If swing normal direction and reverse direction are activated simultaineously LT1213

8

SECTION 10 TROUBLESHOOTING CRUSHER CONTROL IN RUNNING MODE


Crusher stopping

Yes Crusher stop request from process ?

Alarm 4 or 5 Crusher stopping

Clamping pressure not between limits

Yes

Yes

Yes Crusher speed low

Crusher pressure high

Crusher running

LT1213

Alarm 41 Crusher stopping Crusher not enable Check wiring if ok Replace sensor

Crusher drive pressure probe failure

Main conveyor not running

Crusher not enable. Check charging circuit operating charging valve manually. ! does the pressure change at UCD page 1.2 ! if not check sensor Check HCM XM2 output 22 if on check the voltage in the Danfoss valve plug if ok the danfoss valve control head failured

Yes

Yes

Alarm 8 Crusher stopping Crusher not enable Check crusher V-belt tension Check used setting ! open if nesessary Check / adjust the crushing speed ! Parameter C1 ! increase the mA value Crusher should run 300 rpm (avg.) with the material Alarm 18, 19 or 21 Crusher stopping Crusher not enable Check main conveyor trip wire switches reset if nesessary. Check conveyors maintenance switch position

Alarm 2 Crusher stopping Crusher not enable Check used setting ! open if nesessary Check / adjust the crushing speed ! Parameter C1 ! increase the mA value Crusher should run 300 rpm (avg.) with the material

9

SECTION 10 TROUBLESHOOTING SETTING CONTROL WHEN OVERLOAD PROTECTION TYPE IS TOGGLE PLATE

Yes Process running

Yes

No Crusher stopped

Yes Increase setting

Process control mode: DO Return rod pre relief valve OFF DO Setting increase valve OFF DO Setting decrease valve OFF DO Return rod pre valve ON, if pressurization needed else OFF

No DO Return rod pre relief valve ON DO Setting increase valve ON DO Return rod pre valve OFF

Yes Decrease setting

No DO Return rod pre relief valve ON DO Setting decrease valve ON DO Return rod pre valve OFF

DO Return rod pre relief valve OFF DO Setting increase valve OFF DO Setting decrease valve OFF DO Return rod pre valve ON, if pressurization needed else OFF

LT1213

10

SECTION 10 TROUBLESHOOTING SETTING CONTROL WHEN OVERLOAD PROTECTION TYPE IS HYDRAULIC

Yes Increase setting

No DO Return rod pre relief valve ON DO Return rod pre valve OFF

Yes Decrease setting

No DO Return rod pre relief valve OFF DO Setting decrease valve ON DO Return rod pre valve ON, if pressurization needed else OFF

DO Return rod pre relief valve OFF DO Setting increase valve OFF DO Setting decrease valve OFF DO Return rod pre valve ON, if pressurization needed else OFF

LT1213

11


CRUSHER OVERLOAD: DETECTION AND SETTING CONTROL

No Ultrasonic sensor in range

Alarm 33

Yes

Ultrasonic sensor movement over 8 mm

Yes Crusher load normal

Crusher overload

No Crusher pressure high

Alarm 2 Crusher stopping, Page 9

LT1213

DO Return rod pre relief valve OFF DO Setting decrease valve ON DO Return rod pre valve ON, if pressurization needed else OFF

12


SIDE CONVEYOR ENABLE

Side conveyor left safety switch

Alarm 24 Side conveyor not enable Reset left side safety switch HCM XM1 input 21 - "1" ok ( "0" not ok ) - Check wiring & contact

Side conveyor right safety switch

Alarm 25 Side conveyor not enable Reset right side safety switch HCM XM1 input 4 - "1" ok ( "0" not ok ) - Check wiring & contact

Conveyor maintenance safety switch

Alarm 21 Side conveyor not enable Check position of the maintenance switch Check contacts - 1 – 2 feed back contact - 3 – 4 solenoid

Side conveyor enable

LT1213

13

SECTION 10 TROUBLESHOOTING FEEDER START UP


Yes Feeder stop ?

Yes ( radio contrtol on & active ) Feeder start from radio ?

Yes Feeder start from service platform ?

Yes Feeder start from process ?

Yes Feeder start forced from dislay ? Feeder power & control ON

No Feeder running

Check: feeder power HCM XM2 output 5 ( "1" = ok "0" not ok ) Measure voltage at terminal 3X3 – 81 Check: feeder control measure voltage at terminal 3X3 – 43 ( 17 – 19 V ok if Udc 27,5 V). Check manually valve operation. Replace valve control head if nesessary. LT1213

Yes

Feeder not able to start

Feeder ready for material feed

14

SECTION 10 TROUBLESHOOTING FEEDER STOP

Feeder start from process ?

Yes Yes Device pump probe failure

Yes Device pump pressure high ?

Alarm 35 Check: sensor & wiring // HCM XM3 analog input 7 ( 4 – 20 mA = "ok" ) Replace sensor if nesessary

Alarm 40 Check the reason for high pressure. Material leakage under the conveyor. If hydraulic pto is "on" are the hoses connected. If magnet selected "on" is it running.

Yes Alarm 10 Add fuel Check fuel sensor operation & wiring

Fuel level below alarm level ?

Yes Feeder stop from process

Yes Feeder stop from radio

Feeder stop from service platform

Second LT alarm stop

Yes

Yes Feeder power OFF

LT1213

15 Feeder stopped

SECTION 10 TROUBLESHOOTING Feeder running


Yes Feeder stop ?

Yes Secondary LT level high ?

Yes Crusher speed low

Check crusher V-belt tension Check used setting ! open if nesessary Check / adjust the crushing speed ! Parameter C1 ! increase the mA value Crusher should run 300 rpm (avg.) with the crushed material

Yes Check the cleanness of the sensors Check the function of the crusher level detector

Crusher level high


Hydraulic oil temperature high

Yes

Check used setting ! open if nesessary Check / adjust the crushing speed ! Parameter C1 ! increase the mA value Crusher should run 300 rpm (avg.) with the crushed material

Yes Check hydraulic cooler cleanness Check function of the hydraulic return oil circuit thermostat Yes

Crusher overload

Feeder paused

LT1213

Feeder stopped

16

SECTION 10 TROUBLESHOOTING Feeder paused

Fault Engine control ?

Yes Feeder stop ?

No Yes

Secondary LT level high ?

No Yes Crusher speed low

No Yes Crusher level high

No Yes


No Yes Hydraulic oil temperature high

No Yes Crusher overload

No Feeder running

LT1213

Feeder stopped

17

SECTION 10 TROUBLESHOOTING Process start up


Return rod pressure not correct: - manual valve position ? Cruher drive circuit pressure sensor not in range.

No Crusher enable

No Main conveyor enable

Page 6

Yes Screen module connected

No Screen enable

No

Yes Side con.veyor connected

Process stop

Page 5

Side conv.eyor enable

Page 13

Yes

No Process enable to start

LT1213

Process not enable to start

18

SECTION 10 TROUBLESHOOTING Process start

Fault Process stopping

Engine control

Signal horn

Engine to max rpm

No

Yes

Screen module connected

Process stopping

Screen enable

Yes Screen conveyors hydr. valve ON Screen hydr. valve CW/ CCW ON

Magnetic separator present

Yes

Yes Hydraulic outlet on mode

No Main conveyor enable

Magnetic separator output ON

Hydraulic outlet valve ON

Process stopping

Yes Main conveyor hydraulic valve ON

LT1213 Process start continue

19

SECTION 10 TROUBLESHOOTING Process start continue

No

Process stopping

Crusher enable

Yes Start crusher

No

Process stopping

Crusher enable

Yes No

Yes Side conveyor present


Process stopping

Yes Side conveyor hydraulic valve ON

Yes Crusher pressure rise too fast at start

No Start feeder

Yes Process stopping

Process stop

No Process running

LT1213

20

SECTION 10 TROUBLESHOOTING Process stopping procedure

Yes Stop feeder

Feeder running ?

Side conveyor present

Yes

Stop side conveyor

Yes Stop crusher

Crusher running ?

Stop main conveyor

Yes Stop hydraulic outlet

Hydraulic outlet on mode ?

Yes Magnetic separator present ?

Stop magnetic separator

Yes Screen module connected ?

Stop screen and conveyor

Engine to min rpm

Process stopped

LT1213

21


Process control in running mode


Yes Crusher enable

Yes Main conv. enable

Yes Screen module connected

No Screen enable

No

Yes Side conveyor connected

Process stop

Process running

LT1213


Yes

Process stopping

22

SECTION 10 TROUBLESHOOTING Track drive from radio


Yes Hand valve on

Yes Screen connected

Yes Process running

No

Track drive not enabled

Radio selected

Yes Radio or process control

Yes Radio left track forward

No Radio left track backward

No Radio right track forward

No Radio righttrack backward

No LT1213

Track control

23

SECTION 10 TROUBLESHOOTING Track drive from drivebox


Yes Hand valve on

Yes Screen connected

Yes Process running

No


Radio selected

No Drivebox connected

Yes Drivebox left track forward

No Drivebox left track backward

No Drivebox right track forward

No Drivebox righttrack backward

No LT1213

Track control

24

SECTION 10 TROUBLESHOOTING Track drive from display


Yes Hand valve on

Yes

Yes Process running

Screen connected


No

Yes Radio selected

No

Radio process or control

No

Display left track forward

No Display left track backward

No Display right track forward

No Display righttrack backward

No Track control LT1213

25


Track control

Yes

Yes Process running

Normal driving: Track speed according to engine RPM.

LT1213

Driving with slow speed.

26

$'',7,21$/,1)250$7,21

&+$37(5 6725$*(2)7+(0$&+,1(6

*8$5'6$1'3527(&7,21'(9,&(6 –

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.

The machine must be stored in a dry and covered area. ',6326$/2)7+(0$&+,1( 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.

(0(5*(1&<6723 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. ',6326$/2):$67( 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. ),5( 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.

%

$

&+$37(5$'',7,21$/,1)250$7,21


6-2

$

%

RECYCLING

CHAPTER

6

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 0.5 - 1 metres long 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 the uncrushable objects enter the crusher. 3. Removal of the blocking Be very careful when clearing the blocking. Stop the machine and use safety valve or switch during clearing.

08/95

CHAPTER 6 - RECYCLING

6-2

08/95

SAFETY PLATES ANSI

10/04

APPENDIX

0

SAFETY PLATES ANSI 0-17

APPENDIX 0 - SAFETY PLATES ANSI

0-18

SAFETY PLATES ANSI

10/04


10/04



0-20

SAFETY PLATES ANSI

10/04


10/04



0-22

SAFETY PLATES ANSI

10/04


10/04



0-24

SAFETY PLATES ANSI

10/04

Instruction manual

NP1110M - NP1213M IMPACT CRUSHERS

CONTENTS

NP1110M - NP1213M IMPACT CRUSHERS CONTENTS

Preface - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Section 0 Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Section 1 General information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Section 2 Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Section 3 Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Section 4 Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Section 5 Replacing wear parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Section 6 Scheduled maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Section 7 Servicing- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Section 8 Trouble shooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Section 9 Optional equipement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Section 10 Hydraulic power unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Section 11

Section 0 PREFACE

Preface

SECTION

This instruction manual is intended to assist owners and users of Metso minerals products in the proper use of the equipment. 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. This manual must be completed if necessary by those instructions related to of existing local or national mandatory rules for 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 recognised rules for safe and professional operation must be observed. This instruction manual must be read and used by each person who works with the equipment, typically:

0

– 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. Note that this instruction manual contains information and instructions on several 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.

BROYEURS À PERCUSSION SÉRIE NP1110M - NP1213M

0-1

Section 1 SAFETY 1.1 - Warning symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 - Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.3 - Instruction manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.4 - Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.4.1 - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.4.2 - Do you know your employer’s safety program ? . . . . . . . . . . . . . . . . . . . . 1-2 1.4.3 - Are you dressed properly for the job ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.5 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.5.1 - Do you understand your machinery ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.2 - Do you know the places where you work ? . . . . . . . . . . . . . . . . . . . . . . . . 1.5.3 - Are you prepared for emergencies ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.4 - Open frame crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.5 - Start up safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.6 - Report a defective machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.7 - Stopping safely. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

1.6 - Tips for safe maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1.6.1 - Read and understand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.2 - Warning tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.3 - Lockout electrical service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.4 - Clothing - Safe practice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.5 - Alcoholic beverages and medication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.6 - Work area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.7 - Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.8 - Fire hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.9 - Pressurized systems - hydraulic or air . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.10 - Use quality parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.11 - Report necessary repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4 1-5 1-5 1-5 1-5 1-5 1-5 1-6 1-6 1-6 1-6

1.7 - Plant safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 1.7.1 - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.2 - Drive guards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.3 - Operator’s platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.4 - Electrical lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.5 - Hoist gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.6 - Mobile cranes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.7 - Welding equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.8 - Conveyor belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.9 - Backing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.10 - Sound level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.11 - Open frame crushers and access doors . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.12 - Clearing the crusher if it stalls when loaded. . . . . . . . . . . . . . . . . . . . . . . 1.7.13 - Crushing plant dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.14 - General maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6 1-6 1-7 1-7 1-7 1-7 1-8 1-8 1-8 1-8 1-8 1-9 1-9 1-9

Safety The principales rules concerning safety in and around a crushing plant are shown in the chapter entitled SAFETY. The safety of operators and others depends on care and judgement when using the machine. Attentive operators do not have accidents! The majority of accidents are caused by failure to observe and respect simple fundamental rules and precautions. Most accidents can be avoided by identifying the risks and by taking measures to prevent them before an accident occurs. Althought great care is taken when designing and building this type of equipement, there are conditions in which safety cannot be 100% without inhibiting reasonable accessibility and effective use. To underline these conditions, warnings are included in this instruction manual.

1.1 Warning symbols The following symbols for particularly important instructions are being used in the instruction manual: Reference

Refers to economical operation of the equipment. Attention

Particular attention must be given to prevent possible incorrect or dangerous operating situations from occuring.

SECTION

1

Danger

Particular attention must be given to prevent accidents or damage to personnel and/or property.

1.2 Intended use Metso minerals’s products are designed with safety as a major criteria and also manufactured according to the state of art principals in engineering and safety. Nevertheless, improper or careless operation can be dangerous. Operating personnel and others must be made aware of the inherent dangers in operating this type of equipment. The equipment shall be used only when in proper mechanical condition, according to its «intended use», and careful consideration given to safe operation and possible danger. Strict attention must be paid to this instruction manual. Poor mechanical or site conditions that would prejudice safety must be corrected immediately. The equipment is intended to be used in ore, rock or rock-based materials handling exclusively. Any application different from above or exceeding the design limitations of the equipment will not be considered as intended. The manufacturer will not be liable for any consequential or inconsequential damages resulting from the product’s misuse. The user only, shall incur these risks. The «intended use» must also include : adherence to all instructions in this manual, proper and safe operation, and the observing of responsible inspection and maintenance procedures.

NP SERIES IMPACT CRUSHERS

1-1

SECTION 1 - SAFETY

1.3 Instruction manual Keep the instruction manual permanently accessible at the equipment’s location. In addition to the following advise provided in the instruction manual, observe and provide instruction regarding all general legal and mandatory regulations relating to safety, accidental prevention and environmental protection. Such responsibilities also include : handling and disposal of dangerous materials or consumables, wearing of personal protection apparel and other protective equipment, and transport regulations. Read the instruction manual completely. Initiate and institute proper training procedures for: operator instruction and education, reporting and control procedures, supervision guidelines and procedures, personnel supervision, etc... DANGER Before starting assembly or site preparation, personnel in charge must read the instruction manual and in particular the chapter on safety. This is imperative. Particular attention must be paid to the activities or safety of personnel not familiar with the equipment and its application, for example those involved in assembly, startup or maintenance.

1.4 Personnel 1.4.1 General This portion of the instruction manual is intended to illustrate only basic safety procedures. Additional precautions may be necessary for the safe operation of a crusher. The information contained in this manual is not intended to replace safety codes, insurance requirements, federal, state and local laws, rules and regulations. SAFETY of the operator and maintenance personnel is of prime concern. These paragraphs are presented as a helpful guide to construction equipment personnel and shows

1-2


some of the daily work problems which they may encounter. It is the responsability of the operator to know what specific requirements, precautions and work area hazards exist and to discuss them with his supervisor. A common understanding should be reached by all personnel to assure safe performance in operating the equipment. The operator is the key to safe job performance and should study these safety tips to be aware of basic safety precautions to help prevent serious injury and damage to property. Even the safest machines must be used carefully and with full knowledge of all operating restrictions. This implies the introduction of an in-depth safety program. Point out that in every job, the operator is central to safety. Good safety practices not only protect the people around you but are also the best way to protect yourself. IMPORTANT! Make sure your co-workers are aware of the dangers before problems occur and remember that the safety depends on you.

1.4.2 Do you know your employer’s safety program ? Company safety records show that the greatest percentage of accidents are caused by disregard of simple safety rules. Know-observe!- the overall program... and consult your supervisor for specific instructions when starting a job.

SECTION 1 - SAFETY

1.4.3 Are you dressed properly for the job ?

1.5.3 Are you emergencies ?

You may need any number of special items : safety hat, safety shoes, safety glasses, goggles, heavy gloves, ear protective devices, etc...for your own protection. Find out what items are required and wear them! Loose clothing can catch in moving parts. Keep sleeves buttoned, jackets belted and wear your special safety equipment. Keep warm without restricting your movement. Wrist watches and rings can be dangerous. Keep your pockets free of objects which may fall out.

Plan ahead - stay alert - operate sensibly - and you will avoid both having and causing personal injury and accidental equipment damage. If a careless moment does cause an emergency - react quickly with the tools and skills at hand. Know the location of and how to use a fire extinguisher and a first aid kit. Know where to get prompt assistance. An emergency calls for fast action. DON’T STOP YOUR SAFETY PROGRAM WITH THESE GENERAL RULES. BE EQUALLY CONSCIOUS THAT SPECIFIC WORKING CONDITIONS - AND YOUR PARTICULAR EQUIPMENT - CAN REQUIRE ADDITIONAL PRECAUTIONS.

1.5 Operation 1.5.1 Do you machinery ?

understand

your

READ THE MANUAL furnished with your equipment to learn its operating and maintenance characteristics, capacities and limitations. Learn the location and function of ALL controls, indicators, warning devices and caution instructions.

1.5.2 Do you know the places where you work ? Learn as much as possible about your workplace in advance. Keep it clean. Clean the ground, eliminate grease, oil, rags, cables, chains, buckets, stones and other hazards. Keep spare parts in a toolbox. Only use non flammable detergents and solvents. Find out which spaces the operating area must remain unencumbered. A little time spent checking the height and width of open spaces as well as power line positions, if any, can avoid difficulties subsequently. Watch out for dust, smoke and fog which could prevent you from seeing what you are doing.

prepared

for

1.5.4 Open frame crushers DANGER Open frame crushers must be fitted with a system to prevent the frame from being opened when crushing components are moving and to prevent crusher components from being started up when the frame is open.

Equipment not properly prepared for operation is unsafe equipment. Run a careful check at the beginning of your shift. If you find something that needs attention, THINK TWICE before deciding to «let it go this time». Even minor mechanical defects can lead to personal injury and accidents. 1. DO NOT allow unauthorized personnel to operate the crusher! 2. MAKE SURE all guards and other protective devices are in place, secured and not damaged. 3. CHECK fluid systems: Are they at the correct level and completely leak free ? 4. CHECK every drain cock, valve and fitting to be sure it is in place and secure. 5. Loss of pressure from low fluid levels may lead to serious hydraulic failures.


1-3

SECTION 1 - SAFETY

6. CRUSHER SEIZURE from lack of oil or grease is a problem that may cause accidents. 7. NEVER CHANGE the settings of pressure relief valaves to obtain higher operating pressures than those recommended by the manufacturer are the original settings have been optimized for reliable operation and prolonged service life. 8. NEVER tamper with safety devices. 9. CHECK the crusher thoroughly for visual defects, such as leaks, worn hoses or loose parts. 10.INSPECT your machine according to the operator’s manual and your supervisor’s instructions. 11.BEFORE STARTING walk completely around your machine. Make sure there is no one next to, under or on the machine. Warn any personnel nearby that you are starting up. IMPORTANT!

10.DO NOT take a chance with a defective machine. REPORT IT TO YOUR SUPERVISOR. 11.DO NOT LOOK inside the crusher when running.

1.5.6 Report a defective machine Inspect your machine daily, check for loose, worn or damaged parts. Report or correct any unsafe conditions immediately and do not operate the machine until they have been corrected. Even a minor defect can become serious report any machine defects to your supervisor.

1.5.7 Stopping safely Be sure crusher is stopped before cleaning, servicing, lubricating,. checking belt tension, removing housing covers, on the hydraulic system, making repairs, or attempting to clear a plugged cavity. DANGER Make no checks, adjustments or repairs of any kind while crushers in operation.

Report any defects to your supervisor..

1.5.5 Start up safely 1. CHECK equipment for warning tags. 2. FOLLOW the recommended starting procedures as outlined in section «Operation». 3. AFTER Crusher has been started, check all gauges and instruments to be sure that everything is operating properly. 4. SHUT DOWN immediately if any improper readings are observed. 5. TEST all controls for proper functioning. 6. LISTEN for and report any unusual noises. 7. RECHECK alarms or other warning and safety devices. 8. DO NOT STAND ON THE CRUSHER WHILE THE CRUSHER IS RUNNING. 9. DO NOT LEAN OR PLACE YOUR HANDS ON OR AGAINST THE TENSION SPRING OR ADJUSTMENT ROD ASSEMBLIES WHILE THE CRUSHER IS IN OPERATION.

1-4


1.6 Tips for safe maintenance Perform maintenance with care.

1.6.1 Read and understand 1. Instruction manual furnished with the crusher and specifically the USE section. 2. Instructions for inspection and maintenance in the USE section. 3. Warning and caution plates provided on the machine. 4. Warning and caution notes in the instruction manual. 5. The greasing guide for routine maintenance in the LUBRICATION section.

SECTION 1 - SAFETY

1.6.2 Warning tags Before working inside a crusher, be sure to tag and lockout the electrical controls so no one else will start it. Attach warning tags to prevent accidents: 1. If crusher is unsafe for operation. 2. If controls are being serviced. 3. If machine is being repaired.

1.6.3 Lockout electrical service 1. Always lockout electrical controls before performing any type of maintenance work on the crusher. 2. Provide each maintenance man with his own personal padlock and ONE key.

1.6.4 Clothing - Safe practice 1. Keep hands and clothing away from moving parts. Do not take chances by wearing loose sleeves, floppy ties, watches and rings. 2. Wear eye protection when handling fuel, cleaning fluid, oil or brake fluid. these materials can damage your eyes. 3. Wear a respirator when required. 4. Wear safety glasses when drilling, grinding or hammering metal. 5. Keep your pockets free of objects which can fall out and into machinery. 6. Wear hard hat and safety shoes, when required. 7. Wear gloves to protect your hands when changing cables. 8. Wear safety glasses and protective clothing when using high pressure air. 9. Wear goggles and protective clothing when handling molten metals; zinc, babbit, lead, etc... 10.Wear ear protective devices when required or reduce exposure time as required.

1.6.5 Alcoholic medication

beverages

and

1. DO NOT use alcoholic beverages before coming to work or while on the job.

2. BEWARE of medicines, tranquilizers or other drugs which can make you sleepy or less alert.

1.6.6 Work area 1. PROMOTE GOOD HOUSEKEEPING, keep the floor clean and dry, free of debris and tools. Oily and wet floors, steps and hand rails are slippery. In winter, watch out for ice and snow. Wet spots, especially near electrical equipment, are dangerous. 2. DO NOT let material lay and build up on or around the crusher. 3. STORE dangerous fluids in a suitable place - away from unauthorized personnel. ALLOW NO SMOKING IN THE AREA! 4. NEVER start a diesel or gasoline engine within an enclosed area unless there is adequate ventilation. Exhaust fumes can kill!

1.6.7 Equipment 1. Use the proper tools; handle tools and heavy parts sensibly. 2. Keep all tools and equipment free of dirt, oil and grease. Do not drop or toss them. 3. Use hoisting equipment for heavy lifting. Save your back. 4. Lower parts, do not drop them. 5. To prevent slipping, wipe hand levers and knobs clean of oil or grease. 6. Do not use pulleys with cracked rims or spokes. 7. Check for missing, cracked or frayed V-belts. 8. Check for broken, defective or missing parts and replace them. Keep equipment clean and free of dirt and oil so you can spot loose or defective parts. 9. When using cables to move a load, be sure cables are of adequate size and replace any worn, badly frayed, broken or kinked ones. Check end connections for wear.


1-5

SECTION 1 - SAFETY

1.6.8 Fire hazards 1. DO NOT smoke while refueling - or when handling fuel containers. 2. SHUT OFF engine when refueling - and use extra caution if engine is hot. 3. WHEN pouring fuel into the tank, ground the funnel or spout against the filter neck to avoid static electric spark. 4. DO NOT use gasoline or diesel fuel for cleaning parts. Good commercial, non-flammable solvents are preferred. 5. DO NOT smoke while using cleaning solvents. 6. DO NOT let greasy, oily rags accumulate in a poorly ventilated area. Store oily rags and other combustible material in a safe place. 7. 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! 8. KNOW where fire extinguishers are kept - and how they operate - and for what type of fire. Check regularly - at least monthly - to be sure it is in the working area.

1.6.9 Pressurized hydraulic or air

systems

-

1. Relieve ALL pressure before opening or removing any hydraulic or air pressure lines, valves, fittings etc... 2. Check for worn hoses and damaged lines. 3. High pressure oil can be dangerous.

1.6.10 Use quality parts A replacement part for any item should always be of comparable SIZE, TYPE AND QUALITY as the part being discarded.

1.6.11 Report necessary repairs If your daily check uncovers any item that needs attention, repair, replacement or adjustment - REPORT IT NOW!

1-6


The most minor defect could result in more serious trouble IF THE MACHINE IS OPERATED. Only perform the work you’re authorized to do. Do not attempt repairs you do not understand. Only work on equipment you thoroughly understand a pressure-loaded part, if carelessly released, could injure anyone in its path. Remember that you are responsible for the operation and maintenance of a very aluable machine. TREAT IT LIKE IT MERITS.

1.7 Plant safety 1.7.1 General The safety procedures mentioned here do not eliminate all safety hazards found in the area of crushing plants. However, they do highlight some of the procedures which have been found through long experience to improve safety conditions around crushers and crushing plants. Metso Minerals will welcome inquiries regarding other suggested safety procedures to use around their crushers and related equipment.

1.7.2 Drive guards Proper safety precautions start with the initial installation of the crusher. crushers are driven either by V-belts or by direct couplings to motors. DANGER The belt drive or coupling must have a protective guard around it.

Crusher pulleys in particular are designed for maximum rim speeds. If these speeds are exceeded, it is possible that the pulley could explode and cause severe injury or even death. Since the speed of the crusher is quite important for proper operation, most V-belt drive guards usually have a small opening immediately opposite the center of the crusher drive shaft so that a tachometer can be inserted to occasionally check the speed of the countershaft. This opening should be covered with an access door or hatch.

SECTION 1 - SAFETY

1.7.3 Operator’s platform DANGER Since periodic inspection and maintenance must be performed on each crusher, It Is Important That Some Type Of Platform Be Erected At A Level Convenient For The Maintenance Men Who Must Inspect And Work On The Crusher. A good operator’s platform constructed of «solid» floor plate should have hand railings,toe plates and wire mesh or expanded metal between the platform and the top of the hand railing to prevent tools from dropping off the platform and hitting someone working below. Do not fasten the operator’s platform to the adjustment rod assembly or tension rod beam as it can move backwards very quickly when trap iron passes through the crusher.

1.7.4 Electrical lockout DANGER The electrical power source for the crushing equipment must be locked out whenever anyone is working on it.

Each maintenance man who normally works on a crusher should be provided with his own personal padlock with only one key. When he works on any assembly of the crusher, he should use this padlock to lock out the electrical controls for the crusher. It is most important that only one key be provided for the lock and that key must be in the pocket of the person who is working on the crusher. If more than one person works on the crusher, each should have his own lock and key at separate lockout stations for the controls of the crusher. Accidental start-up of crushing equipment with men in the immediate area can be responsible for many accidents on what was supposedly a «clear» machine.

1.7.5 Hoist gear Macghine parts must be handled with hoist gear enabling slow and regular movements. DANGER ALWAYS RESPECT HOIST GEAR MAXIMUM LOAD LIMITS. Remember to include the weight of hoisting accessories (chain, hooks, swing bars...) in the maximum weight calculation.

1.7.6 Mobile cranes DANGER When you use a mobile crane, always work inside machine capacity to ensure the crane does not topple.

WHEN USING A MOBILE CRANE, ALWAYS OPERATE WITHIN THE RATED CAPACITY OF THE MACHINE TO AVOID BUCKLING THE BOOM OR TIPPING. Safe ratings are based on operating the crane on firm, level ground; outriggers should be properly extended and/or lowered whenever possible. 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 weight of the machine. Check clearances under bridges, for overhead electrical lines or any overhead obstruction. Check your hitcher, be sure he’s clear before starting lift. Make certain he securely attaches the load.


1-7

SECTION 1 - SAFETY

1.7.7 Welding equipment One of the most frequently used tools around the crusher is the cutting torch. Crushers which are equipped with hydraulic components should have these components depressurized and adequately covered with flame-proof material so that sparks, weld spatter, etc., cannot reach these 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. DANGER All maintenance personnel who normally use torch cutting equipment should be advised if there are hydraulic components in the immediate area in which they are working.

Then adequate precautions should be made to avoid contact with these components. Rubber lined hoses are not immune to the torch cutting equipment which is used in normal plant maintenance procedures.

1.7.8 Conveyor belts IMPORTANT! Do not use conveyor belts as walkways..

Conveyor belts leading to and from the crusher should be provided with walkways alongside the conveyor. Always provide hand rails along the conveyor belt walkway as an added safety precaution.

1.7.9 Backing All crushers require some type of backing when replacing the crushing members. Resins such as Epoxy Backing Material have all but eliminated the possibility of workmen being accidentally burned due to molten zinc either spilling or exploding when it comes in contact with wet surfaces. 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 CRUSHER LINER BACKING OBSOLETE !

When epoxy backings are used, care should be taken when removing the liners with a cutting torch. THE AREA SHOULD BE WELL VENTILATED BECAUSE EPOXY FUMES CAN CAUSE NAUSEA OR POSSIBLE EYE OR SKIN IRRITATION.

1.7.10 Sound level The various machines making up a finished product treatment installation have operating principles (breaking, screening, etc... ) which generate noise. Moreover, this is intensified by the noise caused by the materials being poured into the chutes, hoppers, etc... Furthermore, the sound levels vary according to the rock treated, the product discharge rate, the machine adjustments, the regularity with which it is fed, etc... It is thus impossible to accurately determine the noise generated by a machine in a precise operating and application context. However, after taking measurements in real life situations, we can indicate an acoustic power level between 110 and 125 dB (A). DANGER In accordance with these values, the directives of the work inspection department must be complied with as regards personnel protection (ear muffs, duration of exposure, booth,...).

1.7.11 Open frame crushers and access doors A system must be installed on open-frame crushers to prevent the frame from being opened when the crushing components are moving and to prevent crusher components from being started up when the frame is open. For machines fitted with access doors, chute the doors must require the use of a tool. doors must only be opened by personnel qualified to service this type of machine.


1-8

SECTION 1 - SAFETY

1.7.12 Clearing the crusher if it stalls when loaded DANGER The unexpected always happens - like power cuts, sudden crusher overloads, etc... which can jam the crusher and make it stall. CLEARING THE CRUSHER CAN BECOME EXTREMELY DANGEROUS IN THESE CONDITIONS. In many cases the only way to restart the crusher is to remove the material obstructing the crushing cavity by hand.

1.7.13 Crushing plant dust By their nature, crushing equipent and auxiliary equipent such as chutes, transfer stations, screens, etc... can create dust. Breathing dust may be hazardous to the health of anyone working at, on, or around the equipent. In general, high levels of dust create a hazard of lung disease, depending upon the concentrations of dust, the length of exposure, and the type of material being crushed. Metso minerals highly recommends that dust-protective devices such as a respirator be worn by anyone exposed to airborne dust to prevent its inhilation. Dust protective devices and dust warnings may be required by osha, msha or local laws. It is the responsability of the operator to determine the necessity and adequacy of such protective devices and warnings, to provide them, and to ensure that they are used and followed. It is possible to reduce the amount of airborne dust by making alterations to the crushing circuit, such as the addition of a dust collection system, or the use of water spray bars at the feed and/or discharge conveyor crushing with a choke level may also reduce the amount of dust issuing from the crusher iself. ATTENTION Optionally, machines can also be equipped with guards (vibrating or not) wich seal dust inside. Ask Metso Minerals for details.

1-9


1.7.14 General maintenance work A certain amount of work must be done in the immediate area of the crusher during the normal course of operations on a day-to-day basis. The following are some of the do’s and don’ts to be followed as part of normal crusher operating procedures. 1. DO NOT perform maintenance on moving machinery. This includes such items as adding lubricating oil or greasing parts of the crusher while it is in operation. 2. DO NOT put hands or feet on the adjustment rod assembly or tension spring system which protect the crusher from tramp iron overloads while the crusher is in operation. 3. 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 avoid harm to the operator as well. 4. DO avoid spillage around the crusher. Crushers seem to attract odd size pieces of rock, gravel, etc. Plant operators should make it a habit to keep the area immediately adjacent to the crusher free from this type of spillage which could cause unsuspecting personnel to trip and fall. 5. NEVER look into the crushing cavity while the crusher is in operation without protection from possible flying material.

REMEMBER - SAFETY IS UP TO YOU !

Section 2 GENERAL INFORMATION

2.1 - Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.2 - NP "M" impact crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.3 - How the crusher works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.4 - Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.5 - Main dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.6 - Technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2.7 - Crusher output estimation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 2.8 - Initial inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 2.9 - Spare parts book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 2.10 - Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

General information

SECTION

2.1 Terminology In this manual some terms are used to describe the crusher and crusher operation. To prevent confusion and improve understanding, these terms are defined as follows: Feed Raw materials to be crushed. Product size The size of the product after crushing. Output or capacity The output of the crusher in metric tons per hour (MTPH) or in short tons per hour (STPH). Feed opening (FO) Opening through which the materials are fed into the crusher. Generally speaking, maximum feed size is 80% of the feed opening but this also depends on the raw materials being crushed. Opening gape (G) Effective gape of the crusher feed opening which enables feed materials to enter the crusher.

2

Feed gape dimension or size (D) Raw material block size is assessed visually by its three main dimensions : length, thickness (D) and width. Feed size is defined by the size of the largest feed block. Crushing cavity (C) Crusher volume inside the cavity formed by the breaker plates, frame liners and the cylinder described by the ends of the hammers as they rotate. Crusher settings (S) The shortest distance between the breaker plates and the end of the hammer when it is facing the last breaker plate liner. Hammers (H) Wear parts fitted on the rotor (R). Hammers strike the materials in the crushing cavity. Breaker plate liners (BPL) Wear parts fitted on the breaker plates (BP) on which the materials are crushed by the hammers.

Figure 2-1 Terminology


2-1

SECTION 2 - GENERAL INFORMATION

2.2 NP "M" impact crushers

2.3 How the crusher works

There are 2 different crusher sizes : – NP1110M – NP1213M – NP1315M – NP1415M The first two figures indicate the diameter of the rotor (in dm). The last two figures indicate the feed opening width(in dm).

The way the crusher works is shown in Figure 2-2. Feed enters the crusher via the feed opening and is expelled through the bottom end of the crusher. The crusher rotor (R) is driven by an electric motor (M) or a diesel engine via drive belts (B) and pulleys. Materials are crushed by hammers (H), breaker plates (BP1, BP2) and side liners (SL). The Tension Spring System (TSS) withdraws the second breaker plate (BP2) in case of crushing overload or uncrushable material; then the breaker plate returns automatically to its initial position.

Figure 2-2 The way it works


2-2


2.4 Main components

Item 1 2 3 4 5 6 7 8 9

Designation Front frame Rear frame Frame hinge Frame cross beam Rotor shaft Rotor Hammer Hammer locking system Breaker plate

Item 11 12 13 14 15 16 17

Designation Breaker plate liner Breaker plate rods Breaker plate return springs Breaker plate adjustment Side liners Feed plate Access door

Figure 2-3 Main components

2-3



2.5 Main dimensions

Figure 2-4 Main dimensions NP1110M


2-4


Figure 2-5 Main dimensions NP1213M

2-5



2.6 Technical features NP1110M

NP1213M

1040 X 933 mm (40.9 x 36.7 in) 800 mm (31.5 in)

1320 X 987 mm (52 x 39.4 in) 843 mm (33.2 in)

Maximum feed size

600 mm (23.6 in)

650 mm (25.6 in)

Rotor diameter

1100 mm (43.3 in)

1200 mm (47.2 in)

4

4

Power

110 kW (170 HP) 132 kW (200 HP) 160 kW (250 HP)

132 kW (200 HP) 160 kW (250 HP) 200 kW (300 HP)

Standard crusher pulley diameter V-belt number and section (*)

1000 mm (39.4 in) 8-SPC

900 mm (35.4 in) 10-SPC

600 / 675 675 / 840 450 / 600

585 / 615 615 / 780 435 / 585

300 kg m² 7105 Lbs /ft²

570 kg m² 13500 Lbs/ft²

9200 kg (20240 Lbs)

12270 kg (27000 Lbs)

Feed opening: Width x height Throat

Number of hammers

Rotation speed (rpm) according to application Primary Secondary Recycling

Rotor assembly inertia Σ mr² (kg m²)

Weight of crusher (without option)

Table 2-1 Technical features

(*) Standard crusher pulley is in some cases replaced by a pulley having different diameter and different V-belt section.

Power rating and rotor speed are choosen according to the application.


2-6


2.7 Crusher output estimation Crusher output primarily depends on feed specifications (size, crushability, hardness, moisture content, etc...) and the way the crusher settings are controlled. To estimate output, refer to Figure 2-6, Figure 2-7 and Figure 2-8. For specific application, consult the manufacturer. The output charts have been developed for use as an application tool to correctly use the capabilities of the impact crusher.The crusher is one component of the circuit. As such, its performances is in part dependant on the proper selection and operation of feeders, conveyors, screens, supporting structures, electric motors, drive components and surge bins. The following factors will enhance crusher performances: 1. Correct selection of wear parts material. 2. Correct rotation speed. 3. Correct breaker plate adjustment. 4. Correct feed distribution : feed materials flow must have a width of at least 75% of the crushing chamber width and it must be regular. 5. In recycling application of concrete with rebars, the feed blocks must be reduced hydraulically or in any other way to a maximum length of 1 metre. The following factors reduce crusher performances: 1. Sticky materials in the crusher feed. 2. Fines in the crusher feed. 3. Excessive feed moisture. 4. Incorrect feed distribution; excessive crusher feed rate. 5. Extremely hard and tough material. 6. In recycling application, rebar that is too long.

2-7



Output (stph)

Production obtained in closed circuit

(mtph)

900

880

800 NP1520

770

700

660

600 NP1315

550 500

440 400 NP1213 - NP1213M 330 300 NP1110 - NP1110M 220 200

110

NP1007

100

0 0

20 0.75

40

60

1.5

2.5

80 3.15

100

120

140

160

4

5

5.5

6.3

180

200 (in)

DISCHARGE PRODUCT SIZE

The values shoun should only be used for reference purposes and are valid for dry crushing of rock having an average gradation for the considered crusher opening and density of 1.6 t/cu.m (100 Lbs/cu.ft) Figure 2-6 Outputs for NP crushers in quarry


2-8


Output (stph)

Production obtained in closed circuit Production obtained in closed circuit

(mtph 550 500 Output (stph) 495 450 440 440

NP1520

400

385 385

350 NP1315

330 330

300

275 275

250

220 220

200

165 165

150

110

100

NP1213 - NP1213M

NP1110 - NP1110M

NP1007

110 55

50

55

0 0

20

0.75

40

1.5

60

80

100

120

140

160

2.5

3.15

4

5

5.5

6.3

180

200

DISCHARGE PRODUCT SIZE The values shoun should only be used for reference purposes and are valid for recycling of concrete and demolition materials having an average gradation for the considered crusher opening and density of 1.6 t/cu.m (100 Lbs/cu.ft) Figure 2-7 Outputs for NP crushers in recycling application of concrete and demolition materials

2-9



(mtph

400

NP1520

350

300

NP1315

250 NP1213 - NP1213M

200 NP1110 - NP1110M

150

NP1007

100

50

0 0

10 0.5

20

30

40

50

60

70

0.75

1.25

1.5

2

2.5

2.75

80

(mm

3

(in)

DISCHARGE PRODUCT SIZE The values shoun should only be used for reference purposes and are valid for dry crushing of asphalt having an average gradation for the considered crusher opening and density of 1.6 t/cu.m (100 Lbs/cu.ft) Figure 2-8 Outputs for NP crushers in recycling application of asphalt


2-10


2.8 Initial inspection It is recommended that as soon as possible after receipt of the Crusher, a careful check be made for any possible damage which might have been incurred during transit. A careful check should also be made to be sure that nothing has been lost and that all items on the bill of lading, freight bill or manifest can be accounted for. If any shortages or damages are discovered, these should immediately be brought to the attention of the respective carrier so that necessary claims can be processed without any undue delay.

2.9 Spare parts book A parts manual containing the various assembly drawings pertaining to your crusher will be sent under separate cover at a later date; usually immediately after the crusher has been shipped. This manual illustrates and identifies each and every part used in the assembly of the crusher.

2.10 Spare parts Metso minerals endeavours to carry an ample supply of parts in stock to provide prompt and efficient service on all orders for repairs and replacements.

2-11 NP1110M - NP1213M IMPACT CRUSHERS

To avoid delay, and the possibility of incorrect parts being furnished, the following information must be given: – Crusher size. – The serial number of the crusher which is stamped on the crusher name plate as well as on the cover of the parts manual. – Exact quantity of each part ordered. – Complete name and part code number as shown in the parts manual. – Complete shipping instructions. Advise whether shipment is desired by water, train, road or air freight. If your crusher parts manuals have been lost or, destroyed, ask Metso minerals for another set. For correct operation, only genuine Metso minerals parts must be installed. These are guaranteed as to accuracy, workmanship and material.

Section 3 INSTALLATION

3.1 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 - Lifting the crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3.3 - Safety device for frame opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.4 - Crusher feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.5 - Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.5.1 - Type of drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.5.2 - Tensioning the V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.5.3 - Tension-deflexion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.5.4 - Elongation method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3.5.5 - Drive safety guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3.6 - General assembly and disassembly information. . . . . . . . . . . . . . . . . . . . 3-9 3.7 - General maintenance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 3.8 - Minimum recommended spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 3.9 - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 3.10 - Protecting the crusher against rust corrosion . . . . . . . . . . . . . . . . . . . . 3-10

Installation

SECTION

3

3.1 Installation See chapter 2.5 "Main dimensions" for general dimensions of the crusher. Weight of main components Weight

NP1110M

NP1213M

Complete crusher (without option))

9200 kg 20240 Lbs

12270 kg 27000 Lbs

Rotor assembly with hammers and pulley

3125 kg 6875 Lbs

4850 kg 10700 Lbs

Hammer

215 kg 475 Lbs

335 kg 740 Lbs

Hammer lifting tool

30 kg 66 Lbs

60 kg 132 Lbs

Standard crusher pulley (*)

250 kg 550 Lbs

485 kg 1070 Lbs

Lifting beam and hoist (option)

280 kg 616 Lbs

285 kg 627 Lbs

Hoist capacity (option)

500 kg 1100 Lbs

500 kg 1100 Lbs

(*) Standard crusher pulley is in some cases replaced by a pulley having a different diameter. Table 3-1 Weights information

Load by sealing bolt NP1110M

NP1213M

Vertical static load

18 KN 4000 Lbs

25 KN 5500 Lbs

Horizontal and vertical dynamic load

2.2 KN 485 Lbs

3.3 KN 720 Lbs

Table 3-2 Load by sealing bolt


3-1

SECTION 3 - INSTALLATION

3.2 Lifting the crusher Crusher component weights must be considered when preparing the study for the foundations and the hoisting equipment. A gantry crane, a tyre-mounted or track-mounted mobile crane, a chain hoist or any other suitable equipment must be used to lift and handle the heavy components of the crusher when installing the machine or replacing wear parts. Refer to Table 3-1 for the weights of the main crusher components.

Only use suitable approved equipment and braided metal cables of the correct weight-bearing capacity. When raising the complete crusher unit, attach the braided metal cables as shown in Figure 3-1. ATTENTION Never stand or work under a suspended load.

Figure 3-1 Lifting the crusher


3-2


3.3 Safety device for frame opening

3.5 Drive

One proximity sensor is fitted to the split of the frame near the pivoting bolts. When activated, they detect if the frame is open or closed. For safe crusher operation, the crusher motor and the hydraulic power pack motor must both be slaved to them.

3.5.1 Type of drive

ATTENTION When the sensor show that the frame is closed, crusher motor and hydraulic power pack operation are authorised to enable the first screen to be tramped. If an attempt is made to open the frame while the crusher is working, the slave system instantaneously shuts down the power pack and stops the crusher motor. The rotation sensor will only authorise power pack re-start once the rotation rate is zero.

3.4 Crusher feeder The crusher will only work at maximum efficiency if a sufficient quantity of feed is supplied in a constant way and at the correct width for the crushing cavity. Normally, material is fed to an impact crusher by means of a vibrating feeder or an apron feeder. Feeder equipment must be installed in such a way as to ensure that the materials are fed directly towards the crushing cavity and not onto the side liners of the frame. ATTENTION Never feed metallic or uncrushable parts into the crusher as they could damage it by jam or overload.

The feed system must always be shut down before the crusher. Interlocking the feeder to the crusher is the ideal way to shut down the crushing station.

3-3


The V-belts could be 8V or SPC typ and they could be single or banded typ.

SINGLE BELT

BANDED BELTS

Figure 3-2 Belt cross sections

The narrower belts are designed for compactness of drive, drive economy and reduced overhung load. Banded belts are single belts unitized with a common cover to prevent belt whip or turnover. Banded belts fit all standard pulleys, however, banded belts should be limited to only 2 or 4 individual belts banded together. Initial installation of V-belt drive 1. Clean all oil, grease or rust from the pulley grooves. 2. Make certain that the pulleys are correctly aligned and that the shafts are parallel. 3. Never force belts onto pulleys. Always shorten the center distance until belts can be slipped on easily. To determine the minimum allowances for shortening or lengthening the center distance between pulleys, see Table 3-3. After calculating a center distance from a standard pitch length make provision that the centers can be moved closer together by the amount shown in the following table to facilitate installing the belts without deterioration. Also, the centers should be adjustable over the calculated distance by an amount as shown in last column of the table because of manufacturing tolerance and possible stretch and wear of be.


1 2

3

5 4 Figure 3-3 Initial installation of V-belt drive

Item Item 1 2 3

Designation Crusher pulley Shorter center distance for V-belt installation Motor pulley

4 5

Designation Longer center distance for V-belt take-up Center distance

Minimum allowance mm (Inches) below center distance for installation of belts V-belt section 8V

8V (banded)

SPC

Minimum allowance above centers distance for stretch and wear

2000 (79) thru 2749 (108)

40 (1 1/2)

85 (3 3/8)

35 (1 3/8)

40 (1 1/2)

2750 (108) thru 3499 (138)

40 (1 1/2)

85 (3 3/8)

35 (1 3/8)

45 (1 3/4)

3500 (138) thru 4499 (177)

40 (1 1/2)

85 (3 3/8)

35 (1 3/8)

55 (2 1/8)

4500 (177) thru 5499 (216)

45 (1 3/4)

90 (3 1/2)

35 (1 3/8)

65 (2 1/2)

5500 (216) thru 6499 (256)

45 (1 3/4)

90 (3 1/2)

40 (1 1/2)

85 (3 3/8)

6500 (256) thru 7999 (315)

45 (1 3/4)

90 (3 1/2)

40 (1 1/2)

95 (3 1/2)

8000 (315) thru 9999 (394)

50

100

45 (1 3/4)

110 (4 3/8)

over 10000 (394)

50

100

45 (1 3/4)

145 (5 1/2)

Belt length * mm (inches)

from:

(*) In each group the range is to, but not including the second length. NP1110M - NP1213M IMPACT CRUSHERS

3-4


Table 3-3 V-belt installation and take-up allowances

1. Always use a matched set of belts and use new belts of the same manufacture. Never mix worn and new belts. 2. Place belts on pulleys and run the drive for a few minutes.

Then tension the drive until only a slight bow or sag appears on the slack side of the belts when the drive is running. An example of tight side and slack side is shown in Figure 3-4. The slack side depends on motor position and rotation direction..

2 1

3 4

3

1 2

Item 1 2 3 4

Designation Crusher pulley Tight side Motor pulley Slack side note bow or sag in belts Figure 3-4 Determining slack side

3.5.2 Tensioning the V-belt drive Tensioning the drive is a term used when force is applied to the V-belt by some method to provide the wedging action between the V-belt and the pulley. This wedging action provides the ability for a V-belt to transmit power from the motor pulley to the crusher pulley. Various methods of tensioning V-belts have been established. Two simplified methods will be described in the following paragraphs: Tension-deflection and percent (%) of elongation. Either of these two methods will

3-5


provide satisfactory belt tension. Each has certain advantages for a given type of belt.

3.5.3 Tension-deflexion 1. Place a straight edge across the top of both pulleys. See Figure 3-5. 2. Measure the span length. 3. Using a spring scale at right angles to the center of the span length, apply a force to the scale great enough to deflect one of the belts the equivalent of 0.016


times millimeters of span length (0.016 times inches of span length).

4. The force should approximate the forces shown in Table 3-4.

4

3

1

2 5

6

10 7 8 9 Figure 3-5 Tension deflection method

Item 1 2 3 4 5 6 7 8 9 10

Designation Straight edge 1/2 Span length Span length Deflection 0.4 mm (1/64") for each 25 mm (1") of span length Pull Motor pulley Belt Spring scale Force (per table) Crusher pulley

Example V-belt section = Standard 8V belt Span length (center distance) = 1575mm (62") Deflection force (from table) = 15-22 Kg (34-50 Lbs.) Deflection = 1575mm (62") x 0.016 = 25mm (1") Therefore, on a NEW installation with a standard 8V section belt and a span length of 1575mm (62"), the belt should deflect 25mm (1") with a spring force of 15-22 Kg. (34-50 Lbs.) for a properly tensioned drive.

5. At the end of 2-4 hours of operation, the drive should be retensioned to approximately the maximum force. 6. After 24-48 hours, it is well to check the drive to see if the force on the belts is between the minimum and maximum force shown in table. Retension if necessary. Either excessively low or high tension will affect the life and operation of a V-belt.. IMPORTANT! When properly tensioned a narrow v-belt may not feel as tight as one might expect from the tension they carry. Therefore, it is advisable to use a spring scale to check belt tension on these belts.


3-6


Standart belt

Banded belt*

Belt section

Minimum tension Kg (in Lbs.)

Maximum tension Kg (in Lbs.)

Minimum tension Kg (in Lbs.)

Maximum tension Kg (in Lbs.)

8V

15,4 (34)

22,7 (50)

18,1 (40)

27,2 (60)

SPC

10,4 (23)

15,4 (34)

11,8 (26)

18,1 (40)

(*) Multiply these values by number of belts in band. Table 3-4 Flexion forces

3.5.4 Elongation method For tensioning the drive using the PERCENT (%) OF ELONGATION method, proceed as follows. This particular method of tensioning V-belt drives was developed primarily for tensioning banded belts. 1. Remove the slack from the belts. 2. Next, wrap a 15 meter (50 foot) steel tape around the outside circumference

of the belt and measure to the nearest millimeter (1/16"). Record this length. See Figure 3-6. 3. Multiply this recorded length by a percent of elongation factor which is shown in Table 3-5 «Elongation factors» and add this amount to the initial measurement. 4. Elongate the belt to this new reading.

1

2

3

5

6

4

Figure 3-6 Percent of elongation method

Item 1 2 3 4 5 6

3-7

Designation Tape reading Steel tape Pull Motor pulley Belt Crusher pulley


Example V-belt section = Standard 8V belt Initial tape reading = 3048mm (120") Elongation factor (from table) = 0.009 (multiplier) which is 0.9% (percent) New length reading = 3048mm (120") initial reading x 0.009 elongation factor = 3048mm (120") + 27mm (1-1/16") or 3075mm (121-1/16").


Belt Section*

Multiply

Percent (%)

8V

0,009

0,9

(*) Standard or banded belts Table 3-5 Elongation factors

Therefore, on an installation with an 8V belt and an outside circumference measurement of 3048mm (120"), the motor pulley should be moved away from the crusher pulley until the steel tape reads 3075mm (121-1/16") for a properly tensioned drive. 5. Periodic belt tension checks must be made and if retensioning becomes necessary, the tensioning process just described should be repeated. It must be pointed out that the TENSION-DEFLECTION METHOD is the preferred method of tensioning V-belts. Usually the first sign that indicates retensioning is necessary is belt slippage. This slippage will show up in loss of power and speed at the crusher pulley and in a high rate of belt and pulley groove wear. These conditions are usually accompanied by belt «squeal» and also a heating up of belts and pulleys. These conditions are readily apparent and can be detected by simply looking, listening and feeling. V-belt precaution Some of the do’s and don’ts in connection with proper V-belt drive operation are as follows: 1. Do. Check belt tension frequently during the first few days of run-in operation. When the belts have had time to become seated in the pulley groove, retension the belts. New belts have a certain amount of initial stretch and will require additional tensioning.

for adequate circulation of air. Either perforated plate or expanded metal is ideal for this type of application. 4. Don’t. Allow any oil or grease to come in contact with the belts as excessive oil causes the rubber to swell and the belts to fail prematurely. 5. Do. Make V-belt drive general inspections on a periodic basis. The following points must be checked at each inspection. a. Loss of crusher speed - check tension. b. Unequal stretch - check each belt. c. Excessive elongation - check for overload. d. Belt softening or swelling-check for oil or grease. e. Belt hardening and cracking - check for excessive heat.

3.5.5 Drive safety guard The drive guard protects the operator and the drive from accidental rock falls. As the motor position is specific to each crusher installation, the guard is often designed and produced specifically for each crushing station. . DANGER For the safety of the personnel the drive guard must be built in compliance with current safety regulations for the site on which the crusher is used. The guard must be in position when the crusher is operating.

2. Don’t. Overtighten belts as too much tension shortens both belt and bearing life. Maintain uniform tension. Idle belts should appear tight; in motion, they have a slight sag on the slack side. 3. Do. Keep drives well ventilated as heat buildup over 60°C (140°F) causes belt life to become shortened. The sides of the belt guard must be designed to allow


3-8


3.6 General assembly disassembly information

and

coating of oil. This will act as a lubricant and prevent rusting in place..

See section 8 for the installation of the drive shaft line. Before installing any of these crusher parts, check that the protective coating applied to all machined surfaces for shipment has been removed and that all parts are clean and free from grit and dirt, especially oil passages and pipes. All machined surfaces and threads that may have possibly been damaged in shipment must be restored to the proper condition before assembly. After cleaning, lightly oil all bearing surfaces..

ATTENTION During a welding operation on the crusher, the welding current must never pass through the rotor bearings which might then be dammaged.

3.7 General information

maintenance

When performing any maintenance work on the crusher, the following general precautions should be observed: 1. When removing parts with machined or bearing surfaces which may rust, they should be well oiled or covered with a rust preventive, if they are to be kept out of the crusher for any length of time. 2. Use additional caution when handling any parts which have bearing surfaces or a machined surface that has close tolerances. 3. When disassembling any parts with bearing or machined surfaces, protect these surfaces from coming in contact with the ground by using wooden blocking. 4. Bearings should be handled with extreme care. Excessive ramming or pounding on this soft material may cause warping or springing of such parts. 5. Clean thoroughly and oil all machined parts before installing them in the crusher. Do not replace a bearing surface without coating it with oil. 6. When assembling two mating parts that require either a press or sliding fit, coat the contacting surfaces with a light

3-9


3.8 Minimum recommended spare parts list The following is a list of the minimum spare parts which should be on hand at all times to insure a minimum of down time: – hammers. – breaker plate liners and bolts. – lateral frame liners and bolts. – lateral hammer stops and bolts. – drive belts. It is to be understood that this list contains only the minimum compliment of spare parts and if the crusher installation is either in a remote location or consists of several crushers, this list should be expanded. Therefore, consult the factory for a suggested list of spare parts for your particular operation. Before storing any spare parts, check that the protective coating applied before shipment is still intact.

3.9 Special tools The only tools supplied with the crusher are those which is not easy to find commercially. These include: – flat spanners. – hex wrenches for hammer locking wedges. – hammer lifting system. – rotor locking pin.


3.10 Protecting the crusher against rust corrosion Corrosion is a natural phenomenon and all equipment must be protected. Corrosion can: – cause shut-downs. – increase maintenance costs. – reduce equipment service life. – generate risks. Factors accelerating corrosion are: – ambient humidity. – dirt. – temperature, rain and wind. To protect your crusher from rust corrosion during seasonal shutdown, or for foreign shipment or for outdoor storage (winter or summer), the following protective measures are recommended: 1. At least once each month while the crusher is in storage or during the seasonal shutdown the crusher should be operated for approximately 5 minutes to make sure the bearings remain properly greased. If the crusher is in storage and cannot be operated, the crusher pulley must be rotated 3 or 4 times by hand to make sure the bearings are properly greased. Add grease to the bearing at this time, if necessary. The above procedure is necessary as moisture condensation will cause corrosion where the bearing rollers contact the inner and outer rings. This corrosion will destroy the highly finished surfaces of the rollers and rings at this point.

2. The crusher hydraulic mechanism used for opening the upper rear frame is to be filled with a lubricating oil which has a rust-preventive blend designed for the protection of internal parts of enclosed assemblies such as engines, compressors, pumps, gear sets and hydraulic assemblies. Make sure the oil is compatible with neoprene, polyurethane, bronze, nickel, chrome, steel and iron. The hydraulic system must be operated to assure that the pump and hydraulic cylinders have been thoroughly coated with the rust preventive. After the hydraulic assembly has been completely filled with the special rust preventive oil drain system before placing it in storage. The remaining film is all that is required for adequate rust protection. In most applications, the residual rust-preventive film left by these products need not be flushed away or otherwise removed when the crusher is put into normal service. DANGER Do not use this oil to operate the crusher, it is designed only for rust prevention. If the above recommendations are followed, a crusher stored outdoors should have 6 to 12 months of rust protection.

When the crusher is started and operating under load, bearings not properly cared for will soon become rough, causing premature bearing fealure.


3-10

Section 4 OPERATION

4.1 - Rotation direction and speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.2 - Safety device for frame opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.3 - Crusher adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.3.1 - Unjamming the breaker plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.3.2 - Adjusting the breaker plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.4 - Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.5 - Unjamming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.6 - Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 4.7 - Starting the crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 4.8 - Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.8.1 - Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.8.2 - Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.8.3 - Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.8.4 - Reduction of dust emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.9 - Shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Operation

SECTION

4

4.1 Rotation direction and speed The crusher motor must rotate in the direction shown in Figure 4-1.

Figure 4-1 Rotor rotation direction

A correct rotation speed will give an efficient crushing. Keep running with the speed determined for crusher installation and in case of speed change please consult Metso minerals technical department. Never exceed the maximum rotation speed indicated on Table 2-1.

4.2 Safety device for frame opening ATTENTION Before starting the Crusher, check that the safety system is fitted and operating; see chapter 3.3 "Safety device for frame opening" for installation and operation. Protect sensor and electrical cables from accidental stone falls when the crusher is operating.


4-1

SECTION 4 - OPERATION

4.3 Crusher adjustment The space between the breaker plates and the hammers only permits calibrated products to exit from the crusher. Materials with higher dimension remain in the crushing cavity until the correct size is obtained and then they are discharged. The crushing cavity is limited by two adjustable breaker plates which control crushed product size. The closer the breaker plates to the hammers, the smaller the product size. The further the breaker plates from the hammers, the higher the output of the crusher and the bigger the product size. The setting is the distance between the top of the hammer and the breaker plate when the hammer is facing the laot liner. The

measurement of the setting is obtained through the side access doors with the frame closed. DANGER Check that the crusher rotor has fully stopped before adjusting the setting or before opening the inspection doors and measuring the setting. Always lockout controls of the power supply to the crusher motor before entering the crushing cavity or checking settings. supply operators with personal padlocks and one key. Be absolutely certain that the electric motor or engine cannot be started under any circumstances.

NP1110M

NP1213M

453 mm 17.8 ins

445 mm 17.5 in

Return spring length

Table 4-1 Return spring length

4.3.1 Unjamming the breaker plate 1. Raise the beam by action of the jacks. 2. Release the pressure of the jacks to return the piston and to place the beam and the breaker plate in initial location.

4.3.2 Adjusting the breaker plate 1. Untightthe blocking nuts of the beam of approximately 50mm (1,97in.) to release the setting nuts, or more to descend the breaker plate. 2. Raise the beam by action of the jacks. 3. Place the safety wedges between the frame and the beam. 4. Adjust the setting by action of the setting nuts. 5. Check the required setting through the access doors. 6. After the settings, take off the safety wedges and release the pressure of the jacks in order to place the beam in its location.


4-2


Figure 4-2 Breaker plate setting assembly for NP1110M and NP1213M

Item 1 2 3 4 5

4-3

Designation Setting rod Frame Setting nut Grease nipple Locking fork

NP 1110M - NP1213M IMPACT CRUSHERS

Item 6 7 8 9 10

Designation Return spring beam Jack Blocking nut Return spring + sheath See Table 4-1


During operation, a small movement of approximately 1 to 2 mm (0.04 to 0.1 in.)of the return spring beam is acceptable. Excessively frequent or large movements are generated by a setting too tight or an output too high; this kind of movements means the crusher is working over the limits for the considered application. Nevertheless return springs can be compressed by an additional 40 mm (1.6 in.).

The minimum operation setting depends on the size, the nature of the feed material and the capacity through the machine. Table 4-2 indicates minimum second breaker plate settings for each size of machine. The minimum setting is related to the application and should be defined on site. This value is always obtained before excessive movement of the second breaker plate return springs beam occurs.

Minimum breaker plate setting

NP1110M

NP1213M

Primary application

40 mm 1.6 in.

50 mm 2 in.

Secondary application

25 mm 1 in.

30 mm 1.2 in.

Table 4-2 Indicative minimum breaker plate setting

4.4 Running in

4.5 Unjamming

Although the crusher was test run at the factory, it is advisable after initial start-up or starting after installation of new bearings, to permit the crusher to run without a load or at reduced load for several hours.This will permit a general running-in of the crusher and an assurance that all parts are functioning properly.For crusher adjustment during the first working hours, see chapter 4.3 "Crusher adjustment". Before starting a new crusher, pump 60 to 90 g (two or three ounces) of fresh grease into each bearing. Then let the machine idle for 30 to 60 minutes, adding grease at 10 minute intervals, until signs of grease appear at the bearing grease seals. It is also advisable to check the bearing temperature more closely during this time. The crusher should be given special attention during its first two weeks of operation. Before the crusher is started each day during this period, check all bolts for tightness. Give special attention to the hammer wedge locking device bolts, liner bolts, bearing housing bolts and the capscrews on the pulley locking ring.

The return spring system is designed to protect the machine from overloads and uncrushable parts. The breaker plates open and return to their initial work position automatically. DANGER If the crusher stops under load, never attempt to restart it before emptying the crushing cavity completely. Any attempt to restart the crusher with the cavity full could cause serious damage.

The main reasons for a crusher to stop under load are: – the crusher motor or engine has stopped because of a power cut or a lack of fuel. – the feed capacity to the crusher is too high. – drive belts are slipping. – the extraction conveyor has stopped and product is building up under the crusher and blocking the rotor.


4-4


4.6 Before starting DANGER Start the crusher only when all safety and protection systems are fitted and in operation.

Before starting the crusher: – The frame opening safety device must be fitted and in operation. See chapter 3.3 "Safety device for frame opening". – The drive guard and the shaft guard must be fitted. – Inspect the crusher to check that the crushing cavity is empty, that no tools or mechanical obstructions remain on the crusher, that all fixations are fully tightened, that there are no visible leaks from the hydraulic circuits and that there are no other reasons why the crusher should not be started. – Check that the rotor locking pin has been removed. – If it is the first start-up or the first start-up after major reconditioning, follow the instructions in the chapter 4.4 "Running in" above. – Check that the crusher has been fully lubricated; refer to section "Lubrication". – Check that the breaker plates have been set to obtain the product size required. Refer to the chapter 4.3 "Crusher adjustment". – Turn the rotor by hand to check that it rotates freely and that it is not touching the breaker plate liners. – Check that with the frame open, the inspection and access doors are closed and locked or bolted.

4.7 Starting the crusher For the crusher station, the following start up sequence must be respected: start the product discharge conveyor, start the crusher and, once at nominal speed, start the feed system. The start-up of the crusher corresponds to the start-up of the electric motor or the engine done according to the manufacturer instructions. To start the crusher, proceed as follows:

4-5


1. Confirm that all the checks and inspections detailed in chapter 4.6 "Before starting" have been made and that any necessary corrective action has been taken. 2. Start the electric motor or diesel engine. 3. Check the rotor rotation direction. 4. Check the crusher rotor speed. The nominal speed must be within the range indicated in Table 2-1. 5. After start-up, listen to the crusher to make sure that there are no abnormal noises. The crusher must operate smoothly with very few vibrations. When all components are operating correctly, feed a small quantity of material into the crusher and gradually increase the feeding rate until the crusher is operating at full load. 6. Check bearing shaft temperature frequently and grease immediately if any unusual temperature rise is observed. During operation, bearings will feel warm to the touch but it should always be possible to support this heat for a few seconds. The normal operating temperature of the bearings is 60°-65°C (140°-149°F). If the operating temperature reaches 75°-85°C (170°-185°F), it is essential to determine the reason why the bearing is over-heating. Make sure that the bearing is lubricated as specified in section "Lubrication". 7. During operation, continue to listen for unusual noises and check for signs of trouble. Keep accurate operating and maintenance records. Record any unusual operating conditions and all maintenance performed. Make sure that the next operator is aware of any abnormal operating conditions. 8. Stop the crusher anytime operating conditions are dangerous to personnel or damage to the crusher is possible. 9. Prevent metal uncrushable parts and explosive material from entering the crushing cavity. Make sure that the feed conveyor to the crusher has a metal detector and it is working properly.


4.8 Operation 4.8.1 Feed Provide to the crusher a feed as regular as possible with no blocks larger than the crusher opening and a capacity corresponding to the rated power of the motor or engine. Feeding larger blocks than the crusher opening can lead to jams at the crusher opening or in the crusher cavity; crushing station efficiency will be then reduced due to production stoppages. REFERENCE It is also important to set the feed system to feed products into the crushing cavity little by little. This ensures that products are better fragmented and increases crusher capacity. If too much material is fed into the crusher cavity, blocks tend to be scraped and not hammered; this type of operation increases wear on the hammers and reduces output.

As far as possible, feed material should be dry and free of clay or earth. To prevent breaker plate clogging, alternate the feed of clean materials with materials containing earth or clay. REFERENCE Distribute the feed across the whole width of the crusher. This will improve crushing and distribute wear of hammers and liners evenly across the whole width of the crushing cavity.

When crushing demolition materials, concretes or asphalts it is essential to prepare them correctly before feeding them into the crusher: ATTENTION - Sort to remove rubble and uncrushable parts. - Use a hydraulic hammer or hydraulic shears to break up big blocks. - Cut rebars to limit length to 1 metre. Too long rebars can wind around the rotor and cause serious damage.

Never stand in front of the crusher feed opening when it is operating. Even though the feed chute is equipped with chain and rubber curtains, large blocks entering the feed box push the curtains to the side and occasionally small flying rock can be thrown out of the crushing cavity at high speed.

DANGER The speed of materials occasionally ejected from the crushing cavity is high enough to seriously injure anyone located in the immediate vicinity of the feed opening.

4.8.2 Settings Settings may have to be changed to match the material processed on site. During operation, a small movement of approximately 1 to 2 mm (0.04 to 0.1 in.) of the return spring beam is acceptable. Excessively freguent or large movements are generated by a setting too tight or an output too high; this kind of movements means the crusher is working over the limits for the considered application. Refer to chapter 4.3 "Crusher adjustment". REFERENCE Tight settings increase power consumption and wear on hammers and liners.

4.8.3 Inspection Inspect the crushing cavity regularly. The more abrasive the material, the more frequent inspection must be. In the case of non-abrasive material, one inspection per week is a minimum. Cover the following points:: ATTENTION - Check the wear on the hammers,

breaker plate and frame liners and change them if necessary; see section "Replacing wear parts". - Check the fixation of the hammer, breaker plate and frame liner locking systems and re-tighten if necessary. - Check the condition of the rotor, particularly the rotor protection build-up zones in front of the hammers and the condition of the setting rods behind the breaker plates. See section "Servicing". These inspections are done when the frame is open. For details about opening the frame and the use of the hydraulic pump, refer to section "Replacing wear parts". Once terminated, check the settings again with the frame closed via the lateral access doors; see chapter 4.3 "Crusher adjustment". For maintenance intervals, refer to section "Schedulde maintenance". NP1110M - NP1213M IMPACT CRUSHERS

4-6


4.8.4 Reduction of dust emission Some crushing applications cause sometimes high dust emission. Spraying water onto the feeder or into the crushing cavity can significantly reduce dust. Dust from product can be reduced by placing a 5 metre (200 in.) long housing over the exit conveyor. The crusher front frame beam is fitted with a hole open on the crusher cavity and a connector for a water hose located on the side of the frame. Use 5 to 10 litres (1.3 to 2.6 US gal) of water per minute depending on the size of the crusher,application conditions and material characteristics.

4.9 Shut down Shut the crusher down in the reverse order to the sequence used at start up. This means : shut down the feed system, shut down the crusher and finally, shut down the product discharge conveyor. Before shutting down the crusher, wait until all materials inside the crushing cavity have been discharged. DANGER Because of the inertia of the rotor assembly, the rotor continues to turn after the crusher motor has been switched off.

4-7


Section 5 LUBRICATION

5.1 - Rotor assembly bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.1.1 - Greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.1.2 - Grease specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.1.3 - Bearing temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.2 - Hydraulic circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.2.1 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.2.2 - Oil specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.3 - Other lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Lubrication

SECTION

LUBRICANTS MEETING THE SPECIFICATIONS OF THIS SECTION ARE ESSENTIAL FOR THE PROTECTION AND CORRECT OPERATION OF CRUSHER COMPONENTS. THEY ARE AVAILABLE FROM ALL MAJOR OIL COMPANIES. UNSUITABLE LUBRICANTS CAN DAMAGE CRUSHER COMPONENTS AND THEIR USE WILL VOID CRUSHER WARRANTY.

5

5.1 Rotor assembly bearings 5.1.1 Greasing Lubrication of spherical roller bearings is accomplished by a manual type grease gun through the grease nipples. A nipple is fitted on each bearing. See Figure 5-1.

1

2

Figure 5-1 Bearing lubrication

Item 1 2

Designation Grease nipple Bearing

Add grease immediately after the crusher has been shut down and when the bearings are still warm. Before greasing the bearings, thoroughly clean around each nipple before removing the nipple cap.

Quantity

IN NORMAL OPERATING CONDITIONS, GREASE BEARINGS EVERY 100 HOURS OR EVERY TWO WEEKS OF OPERATION. PUMP INTO THE BEARING THE QUANTITY OF GREASE SHOWN IN Table 5-1.

NP1110M

NP1213M

70 g 2.5 oz

90 g 3 oz

Table 5-1 Grease quantity per bearing


5-1

SECTION 5 - LUBRICATION

During operation, there is always a very slight working of the grease out through the bearings and the grease seals. Movement of grease out of the bearing and the adhering of grease outside the seal protect the bearing and seal from foreign particules. DO NOT REMOVE THIS GREASE FROM THE SEALS AS IT HELPS TO PROTECT THE BEARINGS FROM FOREIGN BODIES PARTICULES.

5.2 Hydraulic circuits

5.1.2 Grease specifications

5.2.2 Oil specifications

Use a class 2 NGLI multi-purpose lithium base grease having extreme pressure (E.P.) characteristics with oxidation, rust and corrosion inhibitors. ALL GREASES EQUIVALENT TO A TYPE XM2 GREASE (ISO STANDARD 3498) ARE SUITABLE. Never use a molybdenum base grease.

Use a paraffin base industrial oil of a viscosity as defined below. It must have a high film strength with high adhesiveness to metal surfaces and stable physical and chemical properties. Moreover, the oil used must have a high viscosity index, good water separation resist foaming, provide high protection from corrosion, resist oxidation and contain anti-wear additives. THE LUBRICANT MUST HAVE A VISCOSITY OF: 20 TO 40 CST AT 40°C (104°F) 6 CST OR HIGHER AT 100°C (212°F) THE OIL MUST HAVE A VISCOSITY INDEX OF 140 OR HIGHER. ALL OILS EQUIVALENT TO A TYPE HM32 (ISO STANDARD 3498) ARE SUITABLE.

5.1.3 Bearing temperature Check bearing shaft temperature frequently and grease immediately if any unusual temperature rise is observed. During operation, bearings will feel warm to the touch but it should always be possible to support this heat for a few seconds. The normal operating temperature of the bearings is 60°-65°C (140°-149°F). If the operating temperature reaches 75°-85°C (170°-185°F), it is essential to determine the reason why the bearing is over-heating.

5.2.1 Description The hydraulic assembly comprises a hydraulic power unit, two single-acting cylinders fitted on the crusher frame and hoses with push-pull connections. The hydraulic assembly is used to open the frame and then to replace wear parts.


5-2

SECTION 5 - LUBRICATION

5.3 Other lubrication points To ease breaker plate adjustments grease the setting rods periodically, for example when greasing the bearings. See Figure 5-2.

1

Figure 5-2 Setting rods lubrication

Item 1

5-3

Designation Grease nipple


Section 6 REPLACING WEAR PARTS

6.1 - Hydraulic frame opening assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.2 - Opening and closing the frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.2.1 - Opening the frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.2.2 - Closing the frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.3 - Hammer changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6.3.1 - Replacing hammers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6.3.2 - Vertical dismantling or fitting of the hammers . . . . . . . . . . . . . . . . . . . . . . . 6-4 6.3.3 - Lateral dismantling or fitting of the hammers . . . . . . . . . . . . . . . . . . . . . . . 6-6 6.3.4 - Reversing hammers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6.4 - Changing breaker plate liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 6.5 - Changing frame liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Replacing wear parts

SECTION

Open the frame to replace wear parts.

6.1 Hydraulic assembly

frame

opening

6

hydraulic power unit, hoses with push-pull and two cylinders fitted with safety valves mounted on the crusher frame. See Figure 6-1 «Crusher with hydraulic assembly».

The hydraulic assembly for frame opening is supplied with the crusher. It comprises a

Figure 6-1 Crusher with hydraulic assembly

Item 1 2 3 4 5 6

Designation locking fork pivoting bolt for frame locking safety arm stop frame opening cylinder hydraulic power unit Hose

Item 7 8 9 10 11 12

Designation Safety valves Cylinder rod spindle Safety arm Hole for safety pin Maintenance hoist boom Hoist


6-1

SECTION 6 - REPLACING WEAR PARTS

The single-acting cylinders are fitted with safety valves to prevent the frame from closing rapidly in case of hose or connection rupture. ATTENTION Safety valves are safety devices to protect operators. take care never to damage them and ensure that they are serviceable at any time.

6.2 Opening and closing the frame 6.2.1 Opening the frame

6.2.2 Closing the frame 1. Thoroughly clean the contact surfaces on both sections of the frame. 2. Run the pump until the slot of the safety arm is released from the cylinder rod spindle. 3. Raise the safety arms by pivoting them around their upper axis until they are in contact with the stop. 4. Gradually open the oil return knob to close the frame. Re-position the safety arms. 5. Correctly screw in the pivoting bolts and swing down the bolt head locking forks.

DANGER Make sure that the crusher rotor has stopped completely before opening the frame.

1. Raise the locking fork of the pivoting frame locking bolts. Unscrew the pivoting bolts and swing them to the open position. 2. Run the pump by pressing the ON button on the control panel until the cylinders are fully extended. 3. Check that the safety arms are correctly positioned on the cylinder rod spindles. Slowly open the oil return knob to enable the frame to bear on the safety arms. DANGER Once the frame opened, check that the safety arms are correctly engaged on the cylinder rod spindles.


6-2


6.3 Hammer changes Hammers are reversible. When one face is used, the hammer can be turned round to use the other face.

The wear limit is shown in Figure 6-2 and in Table 6-1.

3

2

4 1 5

Figure 6-2 Hammer wear limit

Item 1 2 3 4 5

6-3

Designation Safety pin hole Welding protections Worn out section Hammer Rotor



Dimension D in Figure 6-3

NP1110M

NP1213M

55 mm 2.2 in.

60 mm 2.4 in.

Table 6-1 Height limit for changing hammers

REFERENCE To protect the rotor from wear, do not exceed the maximum wear dimension shown for hammers in Table 6-1.

6.3.1 Replacing hammers 1. Open the frame and check that the safety arms are correctly locked. DANGER Always lockout controls of the power supply to the crusher motor before entering the crushing cavity or checking settings. supply operators with personal padlocks and one key. Be absolutely certain that the electric motor or engine cannot be started under any circumstances.

2. Install the safety pin supplied with the tooling through the holes of the frame and the rotor rib see Figure 6-1 and Figure 6-4. This safety pin immobilises the rotor with a hammer in top position. DANGER Never work on the rotor without locking it with the safety pin. rotor rotation might cause injury to the operator.

4. Clean under hammers and wedges if necessary. 5. Lower the lifting tool into position over the hammer and screw the four bolts of the lifting tool.

6.3.2 Vertical dismantling or fitting of the hammers 6. Put pins through the upper wedges to hold them in top position. Clean the threads on the lower wedge clamping bolts. Unscrew the bolts and remove the lower wedges by hammering them if necessary. 7. TO AVOID ANY SUDDEN MOVEMENT OF THE HAMMER, MAKE SURE THAT THE LIFTING CABLE IS KEPT TIGHT. Remove the wedge pins and lower the upper wedges down in their housing. 8. Move the hammer out of its rotor groove and lift it. 9. Clean thoroughly bearing surfaces on the rotor, the hammer and the wedges. ATTENTION If the wedge locking nuts are not locked any more because of nylon ring damage, replace the locking nuts imperatively.

3. Use the lifting tool. A beam and an electric hoist are supplied as an option on the machine. If you do not have this equipment, use a hoist of the right capacity for lifting the load (i.e.the weight of the hammer plus the lifting tool).


6-4


10.WHEN HAMMERS ARE REPLACED, IT IS IMPORTANT THAT BALANCE IS KEPT. FIT IN OPPOSITION AT 180 DEGRES THE HAMMERS WHICH WEIGHTS ARE CLOSEST. THE WEIGHT IS NORMALLY INDICATED ON THE HAMMERS. IN CASE OF DOUBT ON WEIGHTS OF THE TWO OPPOSITE HAMMERS, WEIGHT THEM TO ENSURE THEY

HAVE APPROXIMATELY THE SAME WEIGHT. Position the upper wedges in their housing. Put the new hammer in its groove. Put pins through the upper wedges to hold them in top position. Fit lower wedges and the locking bolts.

2

1

3 10 4

9

8 7

6

Figure 6-3 Hammer replacement

Item 1 2 3 4 5 6 7 8 9 10

6-5

Designation Lifting tool Hammer Upper wedge Stopping pin for the upper wedge Locking nut Lower Wedges Rotor Safety locking pin Locking bolt of the lower wedges Lifting tool bolts


5


11.Screw the locking bolts of the end wedge devices; the hammer must be locked on the backing beam of the rotor. For the NP1110M, lock the wedge bolts at a torque of 20 daNm (150 Lbs/ft). For the NP1213M, lock the wedge bolts at a torque of 30 daNm (220 Lbs/ft). 12.Proceed the same way for the three other hammers beginning by the one on the opposite side; the new hammer being heavier, it will take the botton position after the rotation of the rotor. 13.Remove rotor safety locking pin, turn by hand the rotor and make sure the hammers are correctly fitted in their housing. 14.Close the frame and adjust the breaker plate settings (i.e. distance between hammer and breaker plate liner checked through lateral visiting doors). Run the crusher under-load for at least one hour in order the parts settle down. . ATTENTION Tighten again the wedge locking bolts as per torque given here above. Check every 50 working hours the locking of the wedge bolts.

6.3.3 Lateral dismantling or fitting of the hammers This operation requires on the opposite side of the drive a clearance at least equal to the length of the hammer. Such operation can not be done on crushers equipped with two pulleys. Proceed the same way as for hammer vertical dismantling or fitting except for following operations : 6.Remove the lateral stop on the opposite side of the drive.

Create a clearance of about 3 mm (1/8") between the hammer and the upper wedge. 8.Slide the hammer out of its housing. 9.Slide in the new hammer and fit again the lateral stop.

6.3.4 Reversing hammers 1. ONCE THE HAMMER IS LIFTED OUT OF ITS HOUSING, PUT IT ON THE ROTOR OR ON THE GROUND TO PREVENT ANY ACCIDENTAL SWINGOVER DURING OPERATION. 2. Unscrew the 2 upper bolts from the lifting tool; the hammer is still in liaison with the lifting tool by the 2 lower bolts. 3. Lift the hammer slowly. It will pivot around the lower bolts and the worn face of the hammer will swing to the bottom position. 4. Turn the lifting tool and the hammer using the rotating shackle on the lifting tool to present the correct bearing face to be applied on the rotor backing beam.

6.4 Changing breaker plate liners 1. Open the frame and check that the safety arms are locked. DANGER Always lockout controls of the power supply to the crusher motor before entering the crushing cavity or checking settings. Supply operators with personal padlocks and one key. Be absolutely certain that the electric motor or engine cannot be started under any circumstances.

7.Unscrew the wedges bolts. Hammer the lower wedges to get the upper wedge down.


6-6


2. Put the rotor safety pin. DANGER Never work on the rotor without locking it with the safety pin. Rotor rotation might cause injury to the operator.

3. Open the access doors. Release the lock nuts of the liners to be changed. If breaker plates are fitted with manganese liners, a steel plate provided with a hole can be welded to the liners in order to be used as a lifting point. If breaker plates are equipped with chrome iron liners, replace one bolt by a longer one or by a threaded rod, then do the same operation for the other bolt. This will enable to get clearance between the breaker plate and the liner and then to use a sling or a rope to lift it. Reverse the procedure to fit a liner. Tighten the locking nuts until the spring washers are fully flattened. Tighten periodically if necessary.

6.5 Changing frame liners DANGER Adopt same safety precautions as when changing breaker plate liners chapter 6-4

Liners are easy to change as they are tapped and fitted to the frame by spring washers and locking bolts. Tighten the locking bolt until the spring washers are fully flattened.

6-7



1

3 11

12

9

2 6 4 7

10

8

5 Figure 6-4 Changing frame liners and breaker plate liner

Item Item 1 2 3 4 5 6 7

Designation Bolt Spring washer Frame liners Spring washers Locking nut Bolt Breaker plate liner

8 9 10 11 12

Designation Breaker plate liner (cast iron) Shim Washers Hexagonal screw Elastic washer


6-8

Section 7 SCHEDULDE MAINTENANCE

Scheduled maintenance Table 7-1 indicates the main maintenance operations and the recommended servicing frequency. The maintenance frequency depends essentially on crushing application conditions and on abrasivity of processed material.

SECTION

7

Maintenance will be scheduled according to application needs observed during first running months.

Every day

Maintenance operation

* Check locking of frame and access doors

Every 40 Every 80 to 50 H to 100 H

Every 160 to 200 H

X

* Remove accumulations of material from the frame

X

* Check belts tension

X

* Check condition of adjustement systems

X

* Check that frame opening sensor works correctly

X

* Lubricate the bearings

X

* Check condition of feed box curtains and dust protection (option)

X

* Lubricate the settings

X

* Check eventual bearing noise

X

* Check condition of hydraulic power unit

X

* Check condition of frame opening cylinders and setting adjustement hydraulic assistance jacks (option)

X

Wear parts X

* Check tightness of breaker plate liners

X

* Check tightness of frame liners

X

* Check locking of hammers

X

* Tighten hammer locking wedges X

* Check condition of wear parts for abrasive materials and recycling applications * Check condition of wear parts for average abrasive materials

X

* Check condition of wear parts for non-abrasive materials

X

Table 7-1 Periodical maintenance


7-1

Section 8 SERVICING

8.1 - Bearing replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.2 - Breaker plate replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 8.3 - Build-up on the rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Servicing

SECTION

8

8.1 Bearing replacement This operation, when needed, requires to be done in a work shop or in other clean and dust-free location. Dismantling – Dismantle the locking ring of the drive pulley. The locking ring will normally loose itself by unscrewing the opposite bolts. Proceed as follows:Desserrer progressivement les vis en opposition. a. Progressively unscrew the opposite bolts. b. Hit slightly on the bolt heads for loosening the rear conical ring of the locking ring. c. If the front conical ring is locked, screw bolts in the holes and pull on their heads for loosening the locking ring. – Remove the pulley. – On the other side, remove the shaft guard. – Unscrew the fixation bolts of the bearing housing on the frame. – Put shims under the shaft. – Remove the two screws of the labyrinth seal nut. – Remove the locking nut, the labyrinth seal nut and the bearing housing cover. – Remove the bearing adapter sleeve (by means of a standard or hydraulic nut). – Remove the bearing housing assembly. – Slide out the bearing, replace it.


8-1

SECTION 8 - SERVICING

.

3

2

1

5

4

11

6

9 7

10

8

Figure 8-1 Rotor assembly

Item 1 2 3 4 5 6 7 8 9 10

Designation Bearing housing cover Rotor safety pin Bearing adapter sleeve Bearing Pulley Locking ring Bearing housing Fixation bolts Locking nut Shaft guard

Assembling – Fit bearing housing, adapter sleeve and make sure to get the bearing clearance given here after.

– Distribute play equally between the bearing and dust guards on the mobile bearing block.


8-2

SECTION 8 - SERVICING

. Bearing clearances

NP1110M

NP1213M

0.16 to 0.2 mm

0,18 to 0.23 mm

0,006 to 0,008 in

0.007 to 0.009 in

0.065 to 0.09 mm

0.075 to 0.01 mm

0.0026 to 0.0035 in

0.0030 to 0.0040 in

Resutting clearance after assembly

0.08 mm 0.0032 in

0.09 mm 0.0035 in

Bearing block tightening torque (m daN)

94

100

Radial clearance before assembly

Radial clearance reduction

Table 8-1 Bearing clearance

– Fit the locking ring of the pulley: Apply a light coating of oil on the internal parts of the locking ring. Do not use oil with molybdenum disulfide additive or extreme pressure oil or grease. Do not put oil on the external surface which will be into contact with the pulley. Lightly tighten the bolts. Position the pulley hub. Progressively tighten the bolts by means of a torque wrench. Tightening torque must be as follows: – NP1110M: (Key) – NP1213M: 135 Nm (100 Lbs/ft) Check all bolts are tightened at the right torque. Tightening operation is accomplished when the correct torque is reached for all bolts. – Grease the bearings see section "Lubrication".

8-3


8.2 Breaker plate replacement If a breaker plate is damaged by excessive wear (i.e. liners changed too late) or deformed by uncrushable parts, it may be necessary to replace it. The easiest way is to disconnect the cylinders by removing the cylinder rod spindle pins on the rear frame, to remove the shaft connecting the 2 frames and then to remove the rear frame. The operation is simplified by turning the rear frame round after having removed the setting systems through the access doors.

8.3 Build-up on the rotor In front of the hammers, rotor ribs are protected by hard surface weldings. If necessary use a weld rod that will deposit a hardness layer of 550 to 650 BRINELL (TYPE SAFER R600 or AMSCO X53 or LINCOLN : ABRASOWELD or STOODY 21 or equivalent).

Section 9 TROUBLE SHOOTING

Trouble shooting

Problem Frame does not open

9

SECTION

Cause

Remedy

Check opening bolts are opened. Open the locking bolts. Check hydraulic connections, pump Repair or change faulty part and proximity sensor working condition.

Frame does not close down Safety valves on frame cylinders Use the pump to put pressure in the stopped the oil flow. cylinders, then open very slowly the oil return adjustement knob.

Crusher does jammed rotor.

not

Unusual vibrations.

start, Breakers plates are touching the rotor. Adjust and check breaker plates Rocks are jamming the rotor. setting. Clean up the chamber to run the rotor freely. Electrical connections.

Check electrical interlocking.

cabling

Failing motor. V-belt drive.

Motor to be controlled. Check V-belt condition and drive.

and

Check the speed. on Place hammers having similar weight into opposite housing.

Wrong rotation speed. Too much weight difference hammers.

Hammer wrongly positionned in the Check and rectify if necessary. housing. Noisy bearing.

Lubricate according to instruction manual recommandations.

Lack of grease.

Rotor does not rotate by Bearing seized up. hand

Check bearing condition.

Stalled motor, crusher under Power consumption too high. load

Decrease feed crusher setting.

Products get out of the feed Wrong rotation direction of the rotor. chute. Faulty chain and rubber curtains.

Check and reverse rotation direction.

Dust emission

Very dry products. Bad dust encapsulation discharge opening.

capacity

or

open

Repair the curtains. Place water sprays at the feed and at the discharge openings.

at

the Repair or improve it.


9-1

SECTION 9 - TROUBLE SHOOTING

Problem

Cause

Remedy

Improper movement of the Springs compression is not correct. breaker plates Too high capacity. Too tight setting regarding feed size.

Difficult breaker adjustement.

Check; see section "operation" Reduce feed capacity Increase machine settings; see section "operation" for setting calculation.

plates Threaded rod and protection tubes are Clean thoroughly rod and tubes, then dirty. Products have packed between put grease. breaker plate and frame side liners. Clean up the packed products, then adjust the breaker plate.

Uneven wear of hammers.

Feed segregation.

Check feed flow and spread it evenly on the widgh of feed opening.

Wear of rotor.

Hammers changed too late.

Hammers must be changed before their wear limit; see section "replacing wear parts"

Bolts of hammer stops are loosening.

lateral Bolts are not locked.

Use screwlock adhesive. Fit discs washers and tighten the bolts; check them periodically.

Damaging of hammer Clearance between hammer and Lock the wedges bolts. backing beam surface. housing hammers bear not on the backing beam.

Hammer breakage when Too violent shocks for chrome iron. Check metal detector. using chrome iron hammers. Metallic parts passing through the machine. Feed size too large. Feed machine with appropriate feed size.

Breaker plate wear.

The liners are too much worn.

Loose breaker plate / frame Locking bolts liners. tightened.

are

Frame wear. Excessive liner wear.

not

Replace liners and bolts in time. Clean thoroughly bearing surfaces of properly liners and breaker plate / frame, then tighten up the bolts. Check regularly the inside of the machine and replace liners in time.


9-2

Section 10 OPTIONAL EQUIPMENT

10.1 - Lifting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Optional equipment

SECTION

10.1 Lifting device The electric or manual hoist is used mainly when lifting the hammers. The lifting boom is slid in the tube mounted on the side of the frame. It can pivot freely.

10

The hoist trolley is fitted on the lifting boom. Then the stops of the trolley must be fixed on the boom. The electric motor of the hoist must be connected to the electrical supply by an electrician and taking care of the motor tension.

NP1110M

NP1213M

500 daN

500 daN

1100 Lbs

1100 Lbs

Capacity Table 10-1 Lifting device capacity

CAUTION The customer must perform the commissioning of the lifting machinery in accordance with the legislation of the country involved.


10-1

Metso Minerals P.O. Box 307 33101 Tampere Finland Phone: +358 20 484 140 Fax: +358 20 484 141 www.metsominerals.com

Metso Minerals (Mâcon) SA 41, rue de la République 71009 MACON France Phone:+33( 0) 3 85396200 Fax:+33( 0) 3 85396328

Instruction manual No. N23610-00 English

© 10/2003 Metso Minerals

Printed in France

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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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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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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Safety

6$)(7< 2.1 WARNING SYMBOLS

2.2 INTENDED USE

The following symbols for particularly important instructions are being used in the instruction manual:

Metso Minerals’ products are designed with safety as a major criteria and also manufactured according to the state of art principals in engineering and safety. Nevertheless, improper or careless operation can be dangerous. Operating personnel and others must be made aware of the inherent dangers in operating this type of equipment.

Reference

Refers to economical operation of the equipment.

Attention

Particular attention must be given to prevent possible incorrect or dangerous operating situations from occurring.

The equipment shall be used only when in proper mechanical condition, according to its "intended use", and careful consideration given to safe operation and possible danger. Strict attention must be paid to this instruction manual. Poor mechanical or site conditions that would prejudice safety must be corrected immediately. The equipment is intended to be used in ore, rock or rock-based materials handling exclusively. Any application different from above or exceeding the design limitations of the equipment will not be considered as intended. The manufacturer will not be liable for any consequential or inconsequential damages resulting from the product’s misuse. The user only, shall incur these risks. The "intended use" must also include: adherence to all instructions in this manual, proper and safe operation, and the observing of responsible inspection and maintenance procedures.

Danger

Particular attention must be given to prevent accidents or damage to personnel and/or property.

2.3 INSTRUCTION MANUAL Keep the instruction manual permanently accessible at the equipment’s location. In addition to the following advise provided in the instruction manual, observe and provide instruction regarding all general legal and mandatory regulations relating to safety, accidental prevention and environmental protection.

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Safety

Such responsibilities also include: handling and disposal of dangerous materials or consumables, wearing of personal protection apparel and other protective equipment, and observing of materials handling and transport regulations. Read the instruction manual completely. Initiate and institute proper training procedures for; operator instruction and education, reporting and control procedures, supervision guidelines and procedures, personnel supervision, etc. Before starting assembly or site preparation, personnel in charge must read the instruction manual and in particular the chapter on safety. This is imperative. Particular attention must be paid to the activities or safety of personnel not familiar with the equipment and its application, for example those involved in assembly, startup or maintenance. Control must be exerted over work performed on or near the equipment to ensure that strict adherence to this manual is maintained. The personnel must not wear long hair, loose clothing or jewelry, because of possible danger or injury. Use personal protection suits and other protective equipment where mandatory. Observe and follow any safety, danger or warning signs on the equipment. Keep all safety, danger and warning signs on the equipment in legible condition. If safety-related modifications to the equipment or its performance are required, stop the plant immediately and before beginning any work notify the person responsible. Do not make any modifications or repairs to the equipment which would prejudice safety, without the supplier’s written approval. This includes work on attached or remote safety devices, control valves, as well as the welding of supporting structures, brackets, etc. Spare and wear parts must meet the manufacturer’s technical specifications. Conformity

2-2

can only be fully guaranteed when original manufacturer’s parts are used. Replace hydraulic hoses and pipes at the indicated or appropriate time intervals, even if no safety-related defects are perceptible! Always replace them immediately when there is any indication of unsafe, worn, damaged or faulty parts. Always follow the time period guidelines specified in the instruction manual for inspection and maintenance. Always use tools and suitable for the work to be performed. Always know the location and proper use of fire extinguishers. Always observe the proper procedures for fire alarms and fire fighting.

2.4 PERSONNEL Any work on the equipment must be performed by skilled and trained personnel only. Observe the minimum legal age requirements. Clearly state and follow guidelines for personnel skills and requirements necessary for the safe operation, installation, service, maintenance and repair of the equipment. Ensure that only personnel with these skills and that meet these requirements work on the equipment. State clearly the responsibilities of the machine operator. Authorize him to refuse any unsafe instructions by third parties. Let personnel in training, in training on the job or in general education work with the equipment only under permanent supervision of an experienced person. Work on electrical controls and equipment must only be performed by a licenced electrician or under the guidance and supervision of an electrician, always according to applicable regulations.

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Safety

Only trained and experienced hydraulics technicians should perform work on any hydraulic system.

2.5 OPERATION Refrain from any work that would endanger safety. Before starting work, familiarize with the surroundings of the work place, e.g. any possible hindrances (barriers/obstructions/ obstacles) in the reach of work and traffic, soil bearing capacity and necessary site protection towards the public road traffic area.

tion or touch the moving parts. All the moving parts relating to power transmission ie. flywheels, shafts, couplings, Vbelt pulleys and V-belts must be covered guarded properly to eliminate danger to personnel. Make sure that all the persons operating or maintaining the equipment know the location of the emergency stop buttons or controls. Do not try to clear any blockings when the equipment is running. Rock or other objects may fall from the machine. Always wear a helmet in the dangerous area.

Take any necessary measures to ensure that the equipment is operated in a safe manner and when in good mechanical condition.

Be very careful near sharp corners, edges or rough surfaces.

If the equipment is used alone, it must be equipped with main switch and emergency switch.

2.6 MAINTENANCE AND REPAIR

Only operate when all safety devices and safety-related equipment, e.g. removable guards, emergency stops, sound insulation, dust collector are in proper position and operative.

Observe all guidelines outlined in the instruction manual regarding adjustment, maintenance and inspection schedules, as well as replacement of parts or equipment. Only trained technicians should perform this work.

Check the equipment at least once a shift for visible damage and defects. Notify the responsible person immediately of any problems including any deviations in normal operating performance. In every case stop equipment immediately and resolve the problem! In the case of any malfunction, stop and safeguard the equipment immediately. Have the problem immediately corrected. Observe starting and stopping procedures, control devices and signals as specified in the instruction manual. Before starting the equipment inspect the general area to ensure that there are no personnel that may be endangered from starting. Walk around the equipment and make sure that there is nobody on, by or below the equipment. Warn all persons in the area before starting. Do not climb on the equipment during opera-

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Inform the maintenance staff of any maintenance or service work required. Ensure proper supervision. In any work related to the operation, modification, conversion or adjustment of the equipment and its safety devices including inspection, maintenance and repair, observe all starting, stopping and maintenance procedures as outlined in the instruction manual. Ensure as extensively as possible that the immediate area is safe and secure. When installing or replacing parts, incorrect mounting may be hazardous. Always ensure that the parts are properly installed. When the equipment is switched off during maintenance and repair, the motor controls must be locked out/off. Secure the lock keys and attach a hazard notice at the main disconnect switch. Make sure that the equipment can

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2-3

Safety

not be started during maintenance and repair. During replacement of parts or heavy structural components careful handling and hoisting procedures must be followed to eliminate any possible danger. Only use appropriate, properly designed lifting and handling equipment with sufficient capacity. Place the parts on ground with sufficient bearing capacity. Never stand or work underneath a suspended load. Use only approved lifting equipment and slings when lifting components. Tighten any lifting eyebolts before lifting. Allow only skilled personnel to sling loads and direct the crane operators. The hoisting person in charge must keep in visual or voice contact with the crane operator. For any work above grade level, use appropriate stairs and working platforms. Do not use machine parts as platforms. For maintenance work involving any height other than grade level use appropriate safety equipment and procedures. Due to small size and mobility of the machine, the accesses may be different from the requirements of the standards. Always be very careful when walking on the machine. Keep all handles, steps, railings, platforms, stages and ladders free from dirt, snow, ice and other hazards.

Check all fuel, motor oil and hydraulic oil hoses for leaks, loose screws, fasteners, bolts, fittings, cuts, shearing or damage. Repair all of these immediately. After maintenance and/or repair work, tighten any loose fittings, bolts, fasteners, etc. If any maintenance and repair procedures require the dismantling of safety controls, they must be re-assembled and checked immediately upon completion of the work. Care must be taken for the safe and environmentally correct disposal of process materials, parts and other consumables. Always attach a hazard notice to the main electrical disconnect switch and lock it out, when starting the equipment may be hazardous or when maintaining or repairing the equipment. Always attach a hazard notice to the power supply of electrical components and lock them out, when starting the equipment/component may be hazardous or when maintaining or repairing the equipment/component.

2.7 OTHER SAFETY CONSIDERATIONS Electricity

When cleaning hoppers or other hazardous places be very careful to prevent falling and injuries.

Only use fuses of proper and recommended capacity. Never use fuses of higher capacity than indicated in the electrical drawings.

Prior to maintenance and repair work, clean the machine. In particularly clean all connections and leads to remove oil, fuel or other fluids. Do not use harsh cleansers. Use fibrefree cleaning rags.

In case of electrical problems, shut down the equipment immediately.

Before cleaning the machine with water, steam or high-pressure cleaning methods, cover and protect all openings where water, steam or cleanser must not penetrate, particularly electrical motors and controls. After cleaning remove any temporary covers or protection completely.

2-4

Any work on electrical equipment must only be performed by a licenced electrician or under the guidance and supervision of a licenced electrician, providing all codes and regulations are followed. Prior to any inspection, maintenance and repair being performed, the equipment must, if required, be secured electrically and switched voltage free. Follow all required safety procedures and regulations.

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Safety

The electrical equipment must be inspected at regular intervals. Defects such as loose connections, damaged wiring must be repaired immediately. The work must be performed by a licenced electrician or equivalent as specified by law. Should work be required on live electrical apparatus, a second person must be assigned to actuate the emergency stop or disconnect the main switch in case of emergency. Safeguard the working area with a red and white safety chain and "danger" sign. Use voltage isolated tools only.

Never search for leaks from the pressurized hoses with hand. High pressure fluid jet may penetrate the skin and cause injury. Search for leaks with paper, etc. Gas, dust, steam, smoke Perform welding, cutting and grinding work at the equipment only where allowed. Fire hazard may exist and explosion hazard may occur. Before welding, cutting and grinding clean the equipment and site to remove dust and com-

Where work is required on high voltage components, connect the supply cable after voltage clearance to mass, and short-circuit components, e.g. capacitors, by an ground rod. Use only proper parts in electrical appliances. Electric cables should be properly sized and protected, for example from falling rocks. Wiring should be long enough to provide for components requiring adjustment. Hydraulic, pneumatic Only persons with special knowledge and experience in hydraulics shall perform work on the hydraulic equipment. Check at specified intervals that all conduits, hoses, lines and fittings are free of leaks or visible defects. Repair any defects immediately. Spurting oil may cause injury and fire. Prior to any repair work, depressurize any air or hydraulic system, including hoses, lines and fittings to be opened. This must be done in a safe, approved manner. Assemble hydraulics and compressed-air piping carefully according to all proper procedures. Take precautions to not mix up any connections. Fittings, length and quality of the hoses and pipes must satisfy any requirements set. When replacing or repairing hydraulic parts, make sure that only parts designed for the operating pressures of the system are used. This also relates to any pressure hoses.

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bustible materials. Take the necessary precautions in providing for sufficient ventilation. Dust protection must be fitted to the machine where necessary to prevent injury to personnel or contamination of the environment. Airborne dust must be minimized while feeding, moving or discharging the product. Recommended methods for dust prevention are: 1. Dust covers and dust extraction 2. Dust enclosures 3. Water suppression Noise During operation, sound insulation, if available, must be in its proper and safe location. Wear ear protection. Oil, grease and other chemical materials When using oil, grease and other chemical materials, observe the product safety guidelines and warnings. Be careful when using any hot materials to protect personnel from burning or scalding.

Hot surfaces

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Safety

During operation some surfaces become very hot (for example exhaust pipes and turbo-chargers). The wear parts of the crusher and metallic object which go through the crusher can also become hot. Fire

advice provided herein. Fasten the lifting equipment only to the points meant for lifting. Use only proper means of transport with adequate transporting capacity!

In case of fire near the equipment:

Fasten the load carefully! For lifting, use only the fastenings showed in instructions!

— — — — —

Secure all component parts of the equipment immediately after loading to avoid any accidental shifting. Attach required warning signs to the load.

Warn all persons in the dangerous area. Stop the equipment. Turn off the main disconnect switch. Make sure that all persons are in safe area. Start fire fighting and give the alarm if necessary. — If possible move the equipment away from the dangerous area.

Remove all temporary supporting structures or brackets before re-starting the equipment. Carefully assemble all of the parts previously disassembled.

In case of fire in the equipment: — Warn all persons in the dangerous area. — Stop the equipment using emergency stop. — Turn off the main disconnect switch (if possible). — Make sure that all persons are in safe area. — Start fire fighting and give the alarm if necessary.

Disconnect all external power supply before moving any part of the equipment and reconnect it properly before re-starting. Perform any start-up in accordance with the instruction manual.

Blasting The use of the radio control device is strictly forbidden during blasting operations, as it may cause a premature explosion. The equipment must be moved far enough away from the dangerous area when blasting. Explosives must be prevented from entering the equipment.

2.8 TRANSPORTATION Only use appropriate transportation and lifting equipment with adequate capacity. Provide a supervisor to direct lifting operations. Transport or hoist components, and handle any parts in accordance with the instructions and

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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

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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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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.

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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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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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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

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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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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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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

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The tightening torques of the screws are explained in the previous point.

The grizzlies are described more in detail in the Specifiactions annex.

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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.

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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.


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.

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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.


The body clatters.

Vibrator becomes too hot.

Vibrators will not start.

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V150 Hydraulic drive

Instruction manual

Instruction manual, V150 hydraulic drive 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 930640 (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 930640, 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.

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B-1

Instruction manual


Checking the oil level and changing the oil The oil level is checked by opening the cap shown in figure 930461 (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 930461 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 winter use and for cold conditions (temperature below -10$C):

Manufacturer

Oil

BP ESSO FINA MOBIL NESTE SHELL TEBOIL TEXACO

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.

For summer use (temperature above -10 ºC): Manufacturer

Oil

BP ESSO FINA MOBIL NESTE SHELL TEBOIL TEXACO

Energol GR-XP 150 Spartan EP 150 Giran 150 Mobilgear 629 Vaihteisto 150 EP Omala Oil 150 Pressure Oil 150 Meropa Lubricant 150

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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.

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Instruction manual

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.

The breather must always be replaced in connection with changing the oil (see above).

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 930461) is always installed correctly.

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B-3

Instruction manual


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 angle of stroke

Flow speed of material

Accuracy of the grizzling operation

Raising

Faster

Worse

Lowering

Slower

Better

The angle of stroke is adjusted as indicated in figure 930722. 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.

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.

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.

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Instruction manual

B-5

Instruction manual


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):

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):

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).

B-6

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.

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Instruction manual

B-7

Instruction manual


Hydraulic motor 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.

B-8

Reassembling:

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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Instruction manual

B-9

Instruction manual


Additional weights Many additional weight options are available for the vibrator:

Identification N11897099 N11897100 N11897101 N11897103 N11897106 N11897111 N11897557

B-10

Mass torque 5.34 kgm 6.10 kgm 6.87 kgm 7.58 kgm 8.35 kgm 9.12 kgm 9.12 kgm

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.

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IC500 / IC600 INSTRUCTION MANUAL

IC500 / IC600 Instruction Manual

Introduction This Instruction Manual refers to the controller used in LT units, manufactured by Metso Minerals (Tampere) Oy. To obtain the best performance from this product, please read this manual carefully. It will guide you in operating the IC500 / IC600 system. This Instruction Manual is valid for IC500 / IC600 controller. Because of the continuous development of the product, the manufacturer reserves the right to alter the technical specifications written in this manual, without any advance information.

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IC500 / IC600 Instruction Manual TABLE OF CONTENTS 1

PRECAUTIONS .............................................................................................................................................5 1.1 HANDLING INFORMATION ............................................................................................................................. 5 1.1.1 Storage................................................................................................................................................ 5 1.1.2 Transport ............................................................................................................................................ 5 1.1.3 Function Keys..................................................................................................................................... 5 1.2 WELDING OF THE UNIT ................................................................................................................................. 5 1.3 BATTERY CHARGING .................................................................................................................................... 5 1.3.1 Quick Chargers .................................................................................................................................. 5 1.3.2 Jump Starting ..................................................................................................................................... 6 1.4 CLEANING THE DISPLAY ............................................................................................................................... 6

2

GENERAL.......................................................................................................................................................7 2.1 2.2 2.3 2.4

3

IC500 / IC600SYSTEM .................................................................................................................................. 7 RUN MODE ................................................................................................................................................... 8 ADMINISTRATION MODE ............................................................................................................................... 8 SERVICE MODE ............................................................................................................................................. 8

DISPLAY WINDOWS ...................................................................................................................................9 3.1 STRUCTURE AND ORDER OF THE DISPLAY WINDOWS ................................................................................... 9 3.2 GENERAL INFORMATION ............................................................................................................................. 11 3.3 DISPLAY SCREEN ........................................................................................................................................ 11 3.3.1 Choosing the Language.................................................................................................................... 12 3.3.2 Adjusting the Display Contrast and Brightness ............................................................................... 12

4

STARTING THE PROCESS.......................................................................................................................12

5

STOPPING THE PROCESS .......................................................................................................................13

6

MAIN WINDOW (RUN MODE WINDOW).............................................................................................14 6.1

HELP-WINDOW ............................................................................................................................................ 17

7

UNIT INFORMATION................................................................................................................................18

8

FEEDER ........................................................................................................................................................19

9

CRUSHER.....................................................................................................................................................20

10

ENGINE.........................................................................................................................................................22

11

HYDRAULICS .............................................................................................................................................23

12

TIME COUNTERS.......................................................................................................................................24

13

PROCESS OPTIONS ...................................................................................................................................25

14

MANUAL CONTROL .................................................................................................................................26 14.1 14.2

15

TRACK-DRIVING WINDOW (OPERATION IN SERVICE MODE ONLY)......................................30 15.1

16

STARTING THE PROCESS WITH MANUAL CONTROL (HYDRAULIC CRUSHER DRIVE) ................................. 27 STOPPING THE PROCESS WITH MANUAL CONTROL .................................................................................. 27

TRACK DRIVE SPEED............................................................................................................................... 31

PARAMETERS/SERVICE WINDOW ......................................................................................................32 16.1 EDITING CONTRAST, TIME, DATE OR UNITS ............................................................................................ 33 16.2 PARAMETERS ......................................................................................................................................... 33 16.2.1 Supervisor access parameters .......................................................................................................... 33 16.2.2 User editable parameters ................................................................................................................. 33 16.3 HUB JUNCTION MODULE........................................................................................................................ 41

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IC500 / IC600 Instruction Manual 16.4 17

DIAGNOSTICS ............................................................................................................................................44 17.1 17.2

18

HYDRAULIC OVERLOAD PARAMETERS (JAW CRUSHERS ONLY)............................................................... 41

TRACK DRIVE DIAGNOSTICS .................................................................................................................. 45 PUSH BUTTON TEST ............................................................................................................................... 46

LOG FILES ...................................................................................................................................................47 18.1 ALARM LOG ........................................................................................................................................... 48 18.1.1 Alarm list .......................................................................................................................................... 48 18.2 DIESEL DIAGNOSTIC TROUBLE CODES (ACTIVE AND STORED) .............................................................. 52 18.3 TEMPERATURE HISTORY LOG ................................................................................................................ 53 18.4 PARAMETER LOG ................................................................................................................................... 53 18.5 FACTORY PARAMETERS .......................................................................................................................... 54

19

MODULE PROGRAM VERSIONS ...........................................................................................................55

20

READING INPUT/OUTPUT MODULES DATA .....................................................................................56

21

TROUBLESHOOTING ...............................................................................................................................56

Appendices 1 2 3

Parameter explanations Engine diagnostics codes SAE J1939 Input/Output list

Version 2.5

47 50 58

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1

Precautions

1.1

Handling Information

1.1.1

Storage

Store the device control module (DCM), power supply unit and hub junction module (Hub), hydraulic control module (HCM) and engine control module (ECM) at a temperature between –50 oC and +85 oC (-58 oF and + 176 oF). Store the unit control display (UCD) at a temperature between –25 oC and +60 oC (-13 oF and +140 oF). (See Chapter 2.1 IC500 / IC600 system: Explanations of Abbreviations). 1.1.2

Transport

DCM, Hub, HCM and ECM: Dimensions: 147 x 136 x 46 mm. Weight: 0.7 kg (1.5 lbs) UCD: Dimensions: 182 x 120 x 53 mm Weight: 1.2 kg (2.6 lbs) 1.1.3

Function Keys

Always press the function keys with bare fingers. Do not press the keys with a screwdriver or any other sharp tool, as it will break the keys. Do not use gloves as you may by mistake press many buttons simultaneously. 1.2

Welding of the Unit

If any welding is to be done on the unit, care must be taken to protect the control system. Stop the engine. Disconnect the earth cable from the batteries. Disconnect engine wire harness sockets from engine control module (Ref. Engine instructions) Fasten the earth cable of the welding device as close to the part to be welded as possible. Make sure that no welding current is able to pass through any bearings or electrical equipment. 1.3 1.3.1

Battery Charging Quick Chargers Do not use quick chargers or start boosters. The rough voltage control and interference of the above-mentioned devices may damage the components of the control system. If unit batteries need to be charged, remove the + and – cables from the batteries during charging.

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IC500 / IC600 Instruction Manual 1.3.2

Jump Starting

Jump-starting can be used to help the engine start if the batteries of the unit are unable to start the engine. Make sure that the power source voltage level corresponds to the control system (24 VDC).

Make sure the polarity is correct.

1.4

Cleaning the Display

Wipe the display with a damp, soft cloth.

Do not use material that may scratch or otherwise damage the surface of the window. Do not direct a jet of water on to the IC500 / IC600display screen when washing the unit with a pressure washer.

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2 2.1

General IC500 / IC600 System

The IC500 / IC600 controller is used to control LT functions. IC500 / IC600 is a computer system designed for field operation, and it consists of five components: • • • • •

Device Control Module (DCM) Power Supply Unit and Hub Junction Module (Hub) Hydraulic Control Module (HCM) Engine Control Module (ECM) Unit Control Display (UCD)

Figure 2.1.1 Layout of IC500 / IC600 control system IC500 / IC600 controls the devices of the LT unit. The devices are: • • • • • • • • •

Feeder Crusher Main conveyor Side conveyor Magnetic separator Screen module Engine Hydraulic system Tracks

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IC500 / IC600 Instruction Manual IC500 / IC600 has three modes: a running mode, an administration mode and a service mode. The running mode is active when the machine is running normally. The administration mode is active when the user is making changes to the system. The service mode is active when an authorized person has entered a password to be able to change service parameters. 2.2

Run Mode

In run mode the system continuously monitors the machine functions and controls the operating devices. All functions are performed automatically and you do not need to interfere in the operation. You are only expected to give instructions if there is an emergency or malfunction when the system is run down. 2.3

Administration Mode

In administration mode you have access to certain system parameters. You can bring devices into use (magnetic separator, side conveyor, etc.) and change the values of the system parameters. You may change some parameters while the process is running, but some parameters require the process to be off. 2.4

Service Mode

In service mode the authorized user has access to all system parameters. Access is given with a password or with a hardware keylock.

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3 3.1

Display Windows Structure and Order of the Display Windows

Figure 3.1.1 Structure of display windows

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IC500 / IC600 Instruction Manual This structure will give you an idea of how the system is built. The figures refer to the number of windows. It will also show a path from one window to another. The explanations of the windows are given below: 0 1 1.1 1.2 1.3 1.4 2 3 3.1 3.1.1 4 5 5.1 5.2 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14

Main window Unit information Feeder information Crusher information Engine information Hydraulics information Help Process options Manual control Tracks movement Parameters: general, feeder, crusher, tracks, engine and hydraulics, update, Hub, language, supervisor access, contrast adjustment, time and units Diagnostics / Troubleshooting Track drive, control test Control keys and push button test Log files Alarm log Diesel diagnostic trouble codes Temperature history log Parameter log Factory settings Module versions Module input/output status Device control module, XM1 input/output status Device control module, XM2 input/output status Device control module, XM3 input/output status Engine control module XM1 input/output status Engine control module XM2 input/output status Engine control module XM3 input/output status Hydraulic control module XM1 input/output status Hydraulic control module XM2 input/output status Hydraulic control module XM3 input/output status

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IC500 / IC600 Instruction Manual 3.2

General Information

UCD is mounted on the control panel of the unit. The UCD has a 16 bit, 4 MHz crystal display and five control keys (F1 – F5) which are used for the actual control operations. User interface gives you all the information you need about the system and the required actions.

F1 = Unit information

F2 = Help

F3 = Process options

F4 = Settings

F5 = Diagnostics/ troubleshooting

Figure 3.2.1 Display The Help key function (F2) stays the same in every window. Thus you always obtain information on the window by pressing F2. 3.3

Display Screen

The system always opens to the main menu (window 0). The key symbols are displayed above the control keys. If the control key does not have any symbol above it, it does not have any function in that window. NOTE! The function of the control keys varies depending on the window you are in. In each display window you will find: • symbol of the window (excluding the main window) • running number of the window • time Use arrow keys F4 and F5 (not in the main window) to move to an action you want to. Choose or save the required information by pressing OK (F3).

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IC500 / IC600 Instruction Manual 3.3.1

Choosing the Language

Select the language in the display window 4 (see chapter 15). You do this by pressing the F4 function key in the main window. 3.3.2

Adjusting the Display Contrast and Brightness

Adjust the display contrast and brightness in display window 4 (see chapter 15). You do this by pressing the F4 function key in the main window.

4

Starting the Process

First, switch the power on with the unit key switch. The control system starts up when the power is switched on (see Fig. 5.1.1) Start the process by pressing the "Process start" –button in the control panel of the unit. (NOTE: The "Process start" –button is not in the UCD, see Fig. 5.1.1.) The system is provided with a certain “Process start” sequence, which starts the devices of the unit in a specific order. Thus it is easy to use the unit. It also ensures that the devices are started in the correct order. There is a delay of 1 - 15 seconds between the start of each device. The message of the starting device is visible in the message field in the main window. You can start the process if (Message "Process enabled" in the message field): • • • • • • •

Engine is running correctly Crusher is enabled Safety switches are not activated Hydraulic oil temperature is correct Hydraulic oil level is correct The maintenance safety switch of the conveyor is not activated. Cone crusher lubrication oil temperature must be above 20oC/68oF

If the hydraulic oil temperature is below –10 oC (14 oF), the system will ask you whether to use the process cold start or the normal process start sequence. For more information, please refer to chapter 5, "Starting and Stopping", in the Instruction Manual of the unit.

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5

Stopping the Process

Stop the process by pressing the "Process stop" –button on the control panel of the unit. (NOTE: The "Process stop" –button is not in the UCD, see Fig. 5.1.1.) The “Process stop” sequence stops the devices of the unit in a specific order. The order is opposite to the start process sequence. The automatic stopping sequence ensures that the devices are stopped in the correct order. The delay between the shut down of each device varies from 5 to 45 seconds. If the process is disabled, the “Process stop” sequence is activated. For more information, please refer to chapter 5, "Starting and stopping", in the Instruction Manual of the unit.

Figure 5.1.1 Control center of the unit 1 2 3 4 5

Emergency stop Lubrication unit Radio key Water pump Display

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6 7 8 9 10

Process ON Key switch Signal horn Process OFF Work light

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6

Main Window (Run Mode Window)

When you start up the system the main window (run mode window) is displayed. In the main window you will see the key values of the crushing process. To access unit information, process options, settings or diagnostics, press the function key below the symbol. If you need more information about the main window press the help function key.

Figure 6.1.1 Main window with unit type LT95, LT105, LT1110, LT1213: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Feeder control % and control mode (M = manual, A = automatic) Crusher speed (rpm) Crusher pressure bar/psi Engine running speed (rpm) Engine load % Material capacity according to the belt scale (optional) Radio control / Drive box symbol Material level detector symbol visible when beam is blocked Fuel amount Window number Time Unit information (=F1) Help (=F2) Process options (=F3) Settings (=F4) Diagnostics (=F5) Message field

Numbers 1 – 6 refer to the figures on the unit and on the window. Symbol field (7) shows whether the radio control or drive box is selected. If the crusher level sensor is blocked then that information is also shown in the symbol field. The message field (17) gives you information about the system status. Before the engine has started the message field informs you when the engine is ready for starting.

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IC500 / IC600 Instruction Manual Figure 6.1.2 Main window with unit type: LT200HP (and LTX00HP)

Explanations: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Lifting conveyor feeder control % and control mode (M = manual, A = automatic) Lifting conveyor speed % Feed rate (Requested by the crusher cavity level * crusher speed, * crusher pressure) Crusher load kW Crusher setting mm / ‘’. Device pump pressure Radio control / Drive box symbol Cavity level symbol when high level Fuel amount Window number Time Unit information (=F1) Help (=F2) Process options (=F3) Settings (=F4) Diagnostics (=F5) Message field

Numbers 1 – 6 refer to the figures on the unit and on the window. Symbol field (7) shows whether the radio control or drive box is selected. If the crusher level sensor is blocked then that information is also shown in the symbol field. The message field (17) gives you information about the system status. Before the engine has started the message field informs you when the engine is ready for starting. Display messages during “Process start” phase: • • •

Process enabled Process started Engine rpm increase to work rpm (10 sec ramp)

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IC500 / IC600 Instruction Manual • • • • • • • •

Starting screen module conveyors Starting screen Starting magnetic separator Starting main conveyor Starting crusher Starting discharge conveyor Feeder enabled Process running

If a cold start is selected, all of the above messages are shown except for "Feeder enabled" and "Process running". The system shows a message: •

Process cold start, waiting for the machine to warm up.

When the machine has warmed up the "Feeder enabled" and "Process running" messages are shown. Messages are visible for 3 seconds after the "|Process running" status is achieved. Messages to other systems: • • •

Process starting Process cold start Process running

Display messages during process stop phase: • • • • • • • • • • •

Process disabled Process stop activated Feeder stopped Discharge conveyor stopped Crusher stopped Main conveyor stopped Magnetic separator stopped Screen stopped Screen module conveyors stopped Engine to idle rpm Process stopped

Messages to other systems: • •

Process stopping Process stopped

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IC500 / IC600 Instruction Manual 6.1

Help-window

This is the Help-window of the main window. Press F2 in the main window and you obtain Help. To obtain more information, scroll the screen with arrow keys F4 (down) and F5 (up). All windows have their own help to assist and guide in unit operations.

Figure 6.1.3 Help-window

Press F1 to return to the main window.

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7

Unit Information

Press F1 in the main window to go to the unit information window.

Figure 7.1.1 Unit information (Jaw, Impactor, Cone) 1 2 3

4 5 6 7 8 9 10 11

Symbol of the window Feeder data (to the window 1.1) a) Jaw crusher data (to the window 1.2) b) Impact crusher data (to the window 1.2) c) Cone crusher data (to the window 1.2) Engine data (to the window 1.3) Hydraulic data (to the window 1.4) Time counters (to the window 1.5 ) Back (to the previous window) (F1) Help (F2) Enter (F3) Backwards (F4) Forwards (F5)

Press F4 or F5 to select the data you want to enter. After this, press F3 and the device you want is selected. Return to the main window with F1.

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8

Feeder

Highlight the symbol of the feeder in the unit information window and press F3. You will obtain the feeder information window.

Figure 8.1.1 Feeder information (Jaw, Impactor, Cone) 1

1c 2 3 4 5 5c 6 7 8

9 9c 10 11 12

Feeder speed ( LC-feeder) Symbol of the running status: = Stop = Running = Pause Lifting conveyor control voltage Manual/automatic operation Manual stop for feeder (start not enabled) Feeder speed decrease/increase Feeder valve control % -Lifting conveyor speed in % Control voltage Crusher speed a) Number of material level alarms in a selected period of time (Automatic operation) (Jaw crusher only) b) Feed funnel up (Impact crusher only) c) Cone crusher material level in crushing chamber % (If digital sensor selected: level count / count time visible) Crusher pressure Crusher power kW Hydraulic oil temperature Feed rate % (generated by the IC600 ) Feed hopper level

The values shown in this window are actual. NOTE: The parameters can not be adjusted in this window. Return to the previous window with F1.

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9

Crusher

Highlight the symbol of the crusher in the unit information window and press F3. You will obtain the crusher information window.

Figure 9.1.1a Crusher information (Jaw, Impactor, Cone)

1 2 3 4 5 6 7 8 9 10 11

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Crusher speed Number of material level alarms in a selected period of time Crusher operating hours Clamping pressure / Return rod cylinder pressure Setting sensor Crusher pressure Control current of the jaw crusher pump Status of the service platform control buttons + / - (setting) Status of the service platform control buttons 0 / 1 (setting direction) Control current of the impact crusher pump Control current of the impact crusher adjust motor

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Figure 9.1.1b Cone crusher information 1 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26

Crusher speed Clamping pressure ( 1 = ok , 0 = crusher start / feed prevented) Cooler symbol visible when cooler running Release pressure ( 1 = ok, 0 = crusher start / feed prevented) Lubrication pump running status: Pump speed with hydraulically driven lubrication pump 0 or 1 with electrically driven lubrication pump –Lubrication tank oil temperature C / F. Symbol is blinking when heater is on. Return oil temperature C/ F Feed state: Feed rate % Crusher power kW Material level in crushing chamber % Crusher setting Counter shaft pressure 0 ( off ) 1 ( on ) Main conveyor running state Crusher running state Message field ( same messages as in main view ) Note: Cooling fan symbol will appear only when the lubrication oil cooler is controlled on. Symbol of the running status: = Stop = Running = Pause

The crusher parameters shown in this window, are actual measured values. NOTE: The parameters can not be adjusted in this window. Return to the previous window with F1.

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10 Engine Highlight the symbol of the engine in the unit information window and press F3. You will obtain the engine information window.

1 2 3 4 5 6

7 8 9 10 11 12

Figure 10.1.1 Engine information 1 2 3 4 5 6 7 8 9 10 11 12

Engine coolant temperature Engine load Engine oil pressure Engine operating hours Fuel consumption System voltage Engine speed, required Engine speed, actual Engine coolant level % (0 = no coolant, 1 = coolant) Engine intake air temperature Engine intake air restricted (Filter condition indicator) Cooler fan control current

These are the actual engine values. NOTE: The parameters can not be adjusted in this window. Return to the previous window with F1.

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11 Hydraulics Highlight the hydraulics symbol in the unit information window and press F3. You will obtain the hydraulics information window.

1 2

7 8 9

3

10

4 5 6

Figure 11.1.1 Hydraulics information

1 2 3 4 5 6 7 8 9 10

Hydraulic oil temperature (circuit # 1) Hydraulic oil temperature (optional circuit # 2) Device pump pressure (pump # 1) Crusher pump pressure Hydraulic oil filter (0 = OK/ 1 = not OK) Hydraulic oil level (1 = OK/ 0 = not OK) Device pump pressure ( pump # 2) Lifting conveyor rpm Main conveyor rpm Screen discharge conveyor speed

Actual hydraulics information. NOTE: The parameters can not be adjusted in this window. Return to the previous window with F1.

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12 Time Counters Highlight the time counters symbol in the unit information window and press F3. You will obtain the time counters information window.

Figure 12.1.1 Time Counters (Jaw, Impactor, Cone) 1 2 3 4

Tracks driving active hours Process operating hours Feeder operating hours a) Impact crusher operating hours b) Jaw crusher operating hours c) Cone crusher operating hours

These are actual operating hours.

NOTE: The time counters can not be adjusted.

Return to the previous window with F1.

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13 Process Options Press F3 in the main window and you will obtain the process options window.

Figure 13.1.1 Process options selection page (Jaw, Impactor, Cone) 1 2 3 4 5 6(6a) 6b 7 7c1 7c2 8 8c 9

Magnetic separator off/on Side conveyor off/on Screen rotation (counter-clockwise / clockwise) Hydraulic output on continuously (1) Hydraulic output off continuously Hydraulic output on during the process Hydraulic output active when lubrication oil heating required Manual control of the devices Manual control of the devices Manual control of the cone crusher functions Selection of impact crusher target speed 1, 2 or 3 (2) Selection of cone crusher target speed 1,2 or 3 Selected target speed

Move in the window with F4 or F5. Confirm your selection with F3. For example, move with F4 or F5 to the magnetic separator off/on button and choose either one of them. Press F3 to save the information. In this way you are able to select whether the magnetic separator is on or not. NOTE: If you want to edit the process options during the process, their validation becomes active only on next “Process start” (e.g. if you want to run the process without the magnetic separator you are able to select the magnetic separator off (0), but the separator keeps running until the process is switched off.) (1)

Hydraulic driven generator for the cone crusher can be activated with this button. When oil temperature is above +20oC (+68oF), deactivate hydraulic output. (2) To edit target speed, please see crusher parameters C24, C25 and C26 in chapter 16.2 Press F1 to obtain the main window. Version 2.5

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14 Manual control of devices Highlight the manual control symbol in the process options window and confirm your selection with F3. You will obtain the manual control window. Manual control for cone crusher, see chp. 14.3. The safety devices of the unit will stop devices when activated from the hard wiring side. The activation of the safety device will not disengage the control, which has been set in the on position. Special care must be taken when the manual control is used.

Figure 14.1.1 Manual control

1 2 3 4 5 6 7 8 9 10

Main conveyor off/on Side conveyor off/on Magnetic separator off/on Feeder off/on a) Jaw crusher off/on b) Impact crusher off/on Engine speed adjustment Screen off/on Screen conveyors (2 pieces) off/on Tracks movement Scalper off/on (impact crushers only)

11 12 13

Lifting conveyor By pass conveyor Return conveyor

off/on off/on off/on

Use F4 and F5 to move in the window. Confirm your selection with F3. To obtain the track window (3.1.1) move with F4 or F5 onto the track symbol and press F3 to access the window. NOTE: This window allows you to set which of the devices is on or off. If you select 0, it means the device in question is OFF. Number 1 stands for ON.

NOTE: This control method should only be used if: the system is not able to run the process normally or the unit is being serviced

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IC500 / IC600 Instruction Manual NOTE: No interlocking is valid when the system is running under manual control. The material level indicator is unable to control the feeder. The function of the manual control sets the selected output on/off according to the window 3.1.

14.1 Starting the process with manual control (Jaw crusher / impact crusher) Start the engine as instructed in chapter 5.2, “ Starting the Diesel Engine”, in the Instruction Manual of the unit. 1

2 3 4 5 6 7 8 9

Increase the engine rpm to maximum (CAT C9 & C12 value 2100 rpm / Cummins 5,9 value 2300 rpm) by highlighting the + button on the left side of the engine symbol (see Fig. 14.1.1 number 6). Press F3 as long as the engine is running with the requested rpm. If the unit has a screen module, start the screen module conveyors (see Fig. 14.1.1, number 8). Highlight button 1 and activate it by pressing F3. Start the screen (see Figure 14.1.1, number 7). Highlight button 1 and activate it by pressing F3. Start the main conveyor (see Figure 14.1.1, number 1). ). Highlight button 1 and activate it by pressing F3. Start the crusher (see Fig. 14.1.1, number 5a/b). Highlight button 1 and activate it by pressing F3. Start the magnetic separator (see Fig. 14.1.1, number 3). Highlight button 1 and activate it by pressing F3. Start the side conveyor (see Fig. 14.1.1, number 2). Highlight button 1 and activate it by pressing F3. Start the feeder (see Fig. 14.1.1, number 4). Highlight button 1 and activate it by pressing F3. Start the scalper (see Fig. 14.1.1, number 10). Highlight button 1 and activate it by pressing F3. (Only when LT1110/LT1213 impact crusher is selected).

14.2 Stopping the process with manual control (Jaw crusher / impact crusher) 1 2 3 4 5 6 7 8 9

Stop the scalper (see Fig. 14.1.1, number 10). Highlight button 0 and activate it by pressing F3. (Only when LT1110/LT1213 impact crusher is selected). Stop the feeder (see Fig. 14.1.1, number 4). Highlight button 0 and activate it by pressing F3. Stop the side conveyor (see Fig. 14.1.1, number 2). Highlight button 0 and activate it by pressing F3. Stop the magnetic separator (see Fig. 14.1.1, number 3). Highlight button 0 and activate it by pressing F3. Stop the crusher (see Fig. 14.1.1, number 5). Highlight button 0 and activate it by pressing F3. Stop the main conveyor (Figure 14.1.1, number 1). ). Highlight button 0 and activate it by pressing F3. Start the screen (Figure 14.1.1, number 7). Highlight button 1 and activate it by pressing F3. Stop the screen module conveyors (see Fig. 14.1.1, number 8). Highlight button 0 and activate it by pressing F3. Decrease the engine rpm to minimum by highlighting the - button on the left side of the engine symbol (see Fig. 14.1.1 number 6) and stop the engine as instructed in chapter 5, “Starting and Stopping", in the Instruction Manual of the unit.

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14.3 Cone crusher manual controls Highlight the cone crusher manual control symbol in the process options window and confirm your selection with F3. You will obtain the manual control window.

1 2 3 4 5

Figure 14.1.2 Cone crusher functions 1 (Not in use // Reserved for additional lubrication oil heating. Use Hydraulic power takeoff to produce electricity for the immersion heaters) 2 Lubrication pump off / on 3 Lubrication cooler off / on 4 Cone crusher off / on 5 Engine rpm control off / on Return to the previous window (process options) with F1.

14.4 Starting the process with manual control with cone crusher Start the engine as instructed in chapter 5.2, “ Starting the Diesel Engine”, in the Instruction Manual of the unit. 1

2

3

4 4

Increase the engine rpm to by highlighting the + button on the left side of the engine symbol (see Fig. 14.1.2 number 5). Press F3 as long as the engine is running with the 2100 rpm Activate lubrication oil heating if oil temperature is below 20 °C/ 68 °F. Lubrication tank electrical heaters can operate internally with hydraulic driven generator or by external power source. Activate hydraulic driven generator separately. When lubrication oil temperature is above 20 °C/ 68 °F)/ 68 °F start the crusher lubrication pump. Highlight button 1 of the item #2 and activate it by pressing F3. Deactivate hydraulic driven generator. Start the main conveyor (see Figure 14.1.1, number 1). ). Highlight item #1 button 1 and activate it by pressing F3. Start the crusher (see Fig. 14.1.2, number 4). Highlight item # 4 button 1 and activate it by pressing F3 ( Note: the lubrication must be on going at least 2 min before starting the crusher )

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IC500 / IC600 Instruction Manual 5

6 7

Start screen module (see fig 14.1.1) highlight the item #7 button 1 and activate is by pressing F3 & screen module conveyors (see fig 14.1.1) highlight the item #8 button 1 and activate is by pressing F3. Start the LC feeder and / or lifting conveyor (see Fig. 14.1.1, number 4). Highlight items 1/11 button 1 and activate it by pressing F3. Start the cooling fan when lubrication oil temperature has exceeded 40 °C/ 104 °F

14.4 Stopping the process with manual control with cone crusher 1 2 3 4 5 6 7

8

Stop the material feed by disabling the feed lifting conveyor or LC feeder & lifting conveyor. Highlight items 1/11 button 0 and activate it by pressing F3. wait until crusher is free from crushed material Stop the crusher (Fig 14.1.2). Highlight the item #4 button 0 and activate by pressing F3 Keep lubrication on at least two minutes to cool down the bearing surfaces. Stop the crusher lubrication pump. (Fig 14.1.2). Highlight the item #2 button 0 and activate by pressing F3 Stop the cooling fan. Highlight the item #3 button 0 and activate by pressing F3 Stop screen module (see fig 14.1.1) highlight the item #7 button 0 and activate is by pressing F3 & screen module conveyors (see fig 14.1.1) highlight the item #8 button 0 and activate is by pressing F3. Stop main conveyor. (See Figure 14.1.1, number 1). ). Highlight item #1 button 0 and activate it by pressing F3

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15 Track-driving window (operation in service mode only) Highlight the track symbol in the manual control window and confirm your selection with F3. You will obtain the track-driving window. The purpose of the track-driving window is to make it possible to move the unit on a site by using the UCD.

Figure 15.1.1 Track driving

1 2 3 4

Left track backwards Left track forward Right track backwards Right track forward

Left and right are defined from the feeder end of the unit. The “forward” instruction moves the unit in the direction of the main conveyor (the same direction as the crushing material moves in the unit). If you press the button continuously, the LT unit will move in the direction you want. You cannot use the forwards and backward functions simultaneously. Drive speed is controlled by the engine rpm. Return to the previous window (process options) with F1.

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IC500 / IC600 Instruction Manual 15.1 Track drive speed Slow speed is active when the process is running and track driving is allowed. It is also active when the engine rpm is below the T6 parameter (CAT C9 & C12: 1200 rpm / Cummins 5,9: 1500 rpm). Normal speed is active when neither slow nor fast speed is active. Fast speed is active when the engine rpm value is over the T5 parameter and both tracks are driven straight forward/backwards (CAT C9 & C12 value 1900 rpm – 2100 rpm / Cummins 5,9 value 2100 rpm – 2300 rpm). In other words fast speed is not active when turning the unit. It is forbidden to drive the unit with the UCD if the drive control box (cable) or radio control is in operation due to a high risk of personal injury. Because of the unit weight and its dimensions, special attention should be paid to safety issues if you drive the unit with the UCD.

Return to the previous window (manual control) with F1

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16 Parameters / service window Press F4 in the main window and you will obtain the parameter adjustment window.

Figure 16.1.1 Parameters (Jaw, Impactor, Cone) 1 2 3

4 5 6 7 8 9

10 11 12 13 14 14c 15

General parameters Feeder parameters a) Jaw crusher parameters b) Impact crusher parameters c) Cone crusher parameters Tracks parameters Engine parameters Hub junction module UPD (Module update) Language Service code: -lock open: access to user and service parameters -lock closed: access to user parameters Contrast adjustment Time Date Units (metric/imperial) Hydraulic overload parameters Cone crusher setting calibration page Lubricating unit parameters

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IC500 / IC600 Instruction Manual 16.1 Editing contrast, time, date or units Highlight the required parameter with F4 or F5 arrow keys and select it by pressing F3 (OK). Adjust the parameter with F4 or F5 and confirm with F3 (OK).

16.2 Parameters There are two types of parameters: user editable parameters and supervisor access parameters.

NOTE: If a parameter has an "S" with it, it means that it is a service parameter and only an authorized person has access to it.

16.2.1 Supervisor access parameters These parameters are listed in Appendix 1 of this instruction manual.

16.2.2 User editable parameters You can access the system parameters from the Parameter/service window (4). First, use arrow keys F4 or F5 to move to the device symbol that you want to adjust. The symbol will be highlighted. After this, press F3 to obtain the parameter setting window of the device in question. When the parameter setting window has been opened, choose the parameter you want to adjust (or view) with the arrow keys (F4, F5). The parameter number box (on the left) is highlighted. The middle view shows the parameter description. The box on the right indicates the value of the parameter. The help view (press F2) provides more information on how the parameter can be modified as well as default values and range.

Figure 16.2.1 An example of a parameter setting window.

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Figure 16.2.2 An example of a parameter setting window To change the parameter value, do the following: Press F3 to highlight the value box. F4 becomes a – button and F5 becomes + button. With the - / + buttons you are able to change the parameter value. Press F3 and the data will be saved. F4 and F5 will turn back into arrow buttons. All the parameters are listed in Appendix 1 of this instruction manual. Below you will find explanations for the user editable parameters:

F1 FEEDER MINIMUM SPEED This parameter will affect the minimum speed of the feeder. The higher the value, the higher the actual feeder running speed. Default: 63 % Range: 55 - 70 % Used with: jaw and impact crushers. F2 FEEDER MAXIMUM SPEED This parameter will affect the maximum speed of the feeder. The higher the value, the higher the actual feeder running speed. Default: 80 % Range: 70 - 90 % Used with: jaw and impact crushers. Note: The allowed maximum running speed is adjusted separately. You can adjust this parameter without having to be afraid of damaging any components. F3 AUTOMATIC FEEDER SPEED CONTROL / SELF LEARNING TIMEBASE This parameter is part of the automatic feeder speed control. In the case of the jaw crusher the automatic feeder control can be understood as a self-learning material level detector. Automatic mode tries to keep the number of material level detector alarms constantly on a certain time base. The time base is adjusted with this parameter. Default: 0 min Range: 0 - 20 min Used with: jaw crushers. Note: If the parameter value is set to 0 (zero), the self-learning feeder speed control will not be used.

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F4 AUTOMATIC FEEDER SPEED CONTROL / CRUSHER MATERIAL LEVEL COUNTER When automatic mode is selected (Parameter F5), the control system tries to keep the material level detector alarms constant. If the number of alarms is below the set value the speed of the feeder is increased. If the number of alarms is above the set value the speed of the feeder is reduced. You can adjust the level in the parameter F3. Default: 1 Range: 0 - 5 Used with: jaw crushers. F5 AUTOMATIC FEEDER SPEED CONTROL / ON – OFF SELECTION Automatic feeder speed control = 0 Manual feeder speed control = 1 Default: 0 Used with: jaw and impact crushers. Note: If you want to use the automatic speed control, set the level detector as “on". Check that the material level detector is functioning. F6 CRUSHER MATERIAL LEVEL DETECTOR Level sensor ON = 1 Level sensor OFF = 0 Default: 1 Used with: jaw crushers. F7 FEEDER SPEED INCREASE / DECREASE STEP IN THE FEEDER AUTOMATIC CONTROL MODE The speed of the feeder varies in order to keep the material level detector alarm counter at a given amount in a selected time base. Default: 5 % Range: 0 - 100 % (Feeder min, max values = 100%) Used with: jaw crushers. F16 THE LENGTH OF TIME WHICH THE CRUSHER LEVEL MAY BE OVER THE HIGH LEVEL LIMIT BEFORE THE FEEDER IS PAUSED The crusher level sensor relay has a potentiometer type adjustment to tune the behavior of the level sensor. You can adjust an additional delay with this parameter. Default: 1 sec Range: 1 – 20 sec Used with: jaw crushers. F18 CRUSHER LEVEL HIGH ALARM TIME OF THE POSSIBLE SECONDARY LT The length of time, which the secondary unit level detector alarm can be on before the primary unit’s feeder is set to stand by. Default: 5 sec Range: 1 – 20 sec Used with: jaw and impact crushers F23 FEED HOPPER LOW CAVITY LEVEL Material feed to the forward can be interrupted if there is no material o the feed hopper in order to keep crusher in choke feed during crushing Default: 1500 Range: 500 – 3500 mm Used with cone crushers only.

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F24 FEED HOPPER HIGH CAVITY LEVEL RANGE Material feed to the forward can be interrupted if there is no material o the feed hopper in order to keep crusher in choke feed during crushing Default: 800 Range: 500 – 3500 mm Used with cone crushers only. F25 LIFTING CONVEYOR ACCELERATION AND DECELERATION RAMP TIME Time ramp from set minimum speed to maximum speed will effect how rapidly material level will increase or decrease above the cone crusher F26 LIFTING CONVEYOR MINIMUM SPEED Enables to set the conveyors feeding speed to the desired speed. Generally the speed should be so low that the crusher cavity level will lower rapidly. Default; 15% Range; 0 – 100% Used with cone crushers only F27 LIFTING CONVEYOR MAXIMUM SPEED Enables to set the conveyor feeding speed to desired. Generally the speed should be set to the point where feed material will enable choke feed of the crusher. Default; 50 % Range; 0 – 100% Used with cone crushers only F28 FEED HOPPER ANALOG LEVEL DETECTOR IN USE Default 0, range 0 – 1 Used with cone crushers only F30 METAL DETECTOR STOP TIME Used to set the material exactly to the collecting point. Default; 0,5sec Range; 0 – 5,0 sec 0 = not in use Used with cone crushers only F31 LIFTING CONVEYOR MINIMUM SPEED TIME When material high level detected lifting conveyor will continue to run with minimum speed the time set with this parameter. Default; 10 sec Range; 0 – 15 sec Used with cone crushers only F33 HYDRAULIC OIL SLOW DOWN LIMIT Feed rate is reduced if the hydraulic oil temperature exceed parameter value Default; 75 oC Range; 60 – 80 oC F34 LIFTING CONVEYOR SPEED ALARM Optional lifting conveyor speed detector can be activated & adjusted to detect belt slip Default; 0 rpm Range; 0 – 500 rpm 0 = not in use

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F35 LC FEEDER MINIMUM SPEED This parameter will affect the minimum speed of the LC feeder. The higher the value, the higher the actual feeder running speed. Default: 50 % Range: 0 - 100 % Used with: LT300HP

F36 LC FEEDER MAXIMUM SPEED This parameter will affect the maximum speed of the LC feeder. The higher the value, the higher the actual feeder running speed. Default: 80 % Range: 0 - 100 % Used with: LT300HP F37 LC STOP DELAY Once stopped restart enabled after the time set with parameter Default: 5 sec Range; 0 – 20 sec Used with: LT300HP F38 STOP DEALY BETWEEN LC FEEDER AND LIFTING CONVEYOR Default; 3 sec Range; 1 – 60 sec Used with: LT300HP F40 LC FEEDER CONTROL MODE 0 = Manual, 1 = Automatic F41 LC FEEDER MINIMUM SPEED START TIME Default; 3 sec Range; 0 – 10 sec Used with: LT300HP F42 SCREEN MODULE DISCHARGE CONVEYOR SPEED SENSOR Optional speed sensor can be activated and adjusted with this parameter. 0 = speed sensor not in use Speed sensor must be pulse type sensor what will pass the signals according the belt speed The alarm limit can be adjusted between 1 – 400 rpm Conveyor speed can be observed from the hydraulic information page (page 1.4) F43 CRUSHER CAVITY LEVEL SENSOR Sensor type is selected with this parameter 0 = not in use, 1 = Analog sensor, 2 = Digital sensor (on / off) F44 CAVITY LEVEL SENSOR CURRENT AT 0% Sensor polarity & range adjustments Default; 4 mA Range; 0 – 20 mA

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F45 CAVITY LEVEL SENSOR CURRENT AT 100% Sensor polarity & range adjustments Default; 20 mA Range; 0 – 20 mA F46 FEED POWER MODE Cone crusher power draw controls the material feed to the crusher 0 = Not in use, 1= in use F47 CRUSHER POWER OK LIMIT Cone crusher power limit when the material feed starts to derate. Default; HP 200 = 119 kW, HP300 = 178kW Range; 40 – 400 kW F48 CRUSHER POWER HIGH LIMIT Material feed is paused when power high limit is achieved Default; HP 200 = 149 kW, HP300 = 223kW Range; 100 – 400 kW F49 CRUSHER POWER HIGH FEED PAUSE DELAY To pause the material feed, cone crusher power draw must remain over the parameter F48 value longer than the time set with this parameter Default; 5 sec Range; 1 – 20 secs F50 CRUSHER LOW SPEED ALARM LIMIT If the crusher speed is too low the process is stopped. Default 650 rpm Range; 500 – 1500 rpm

C1 JAW CRUSHER RUNNING SPEED The crusher running speed can be adjusted with this parameter. The parameter is the mA value for the crusher drive pump control solenoid. Default: Depends on the unit type. Please refer to the parameters help file. Range: 200 – 650 mA Used with: jaw crushers Note: If you edit the parameter then notice that the crusher must, during the process start phase, accelerate to the speed set by the parameter FS11. C24 CRUSHER TARGET SPEED 1 (IMPACTOR AND CONE) The target speed 1 of the crusher can be adjusted with this parameter. Default: Depends on the unit type. Please refer to the parameters help file. Range: 400 – 900 rpm Used with: impact and cone crushers.

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C25 CRUSHER TARGET SPEED 2 The target speed 2 of the crusher can be adjusted with this parameter. Default: Depends on the unit type. Please refer to the parameters help file. Range: 400 – 900 rpm Used with: impact and cone crushers. C26 CRUSHER TARGET SPEED 3 The target speed 3 of the crusher can be adjusted with this parameter. Default: Depends on the unit type. Please refer to the parameters help file. Range: 400 – 900 rpm Used with: impact crushers. Note: The desired target speed (1, 2, 3) can be taken into use in the Process Options window (See Fig. 13.1.1, number 8) C36 CRUSHER AUTO SPEED Autospeed in use = 1 Autospeed not in use = 0 Default: 1 Used with: impact and cone crushers.

T1 MIN VALUE FOR RIGHT TRACK BACKWARD T2 MIN VALUE FOR RIGHT TRACK FORWARD T3 MIN VALUE FOR LEFT TRACK BACKWARD T4 MIN VALUE FOR LEFT TRACK FORWARD From T1 to T4: Adjust the value so that the track motion is 0,25m/sec. T5 FAST SPEED TRACKING RPM LIMIT The engine speed when fast tracking speed automatically shifts in. (CAT C9 & C12 value 1900 rpm – 2100 rpm / Cummins 5,9 value 2100 rpm – 2300 rpm). Fast speed is not active while turning the unit. T6 NORMAL SPEED TRACKING RPM LIMIT The engine speed when normal tracking speed automatically shifts in. Normal tracking speed is enabled when neither fast nor slow tracking speed is active (Max slow tracking speed CAT C9 & C12 value 1200 rpm / Cummins 5,9 value 1500 rpm). T7 TRACK STOP RAMP The stop time of the unit can be adjusted with this parameter. Default: 1000 msec Range: 1 – 1000 msec

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E1 ENGINE MIN SPEED Diesel minimum speed Default: 850 rpm Range: 700 – 1200 rpm E2 ENGINE MAX SPEED Diesel maximum speed Default: 2100 rpm (LT105, LT1110, LT1213, and LT200), 2300 rpm (LT95) Range: 1900 – 2100 rpm (CAT C9 & C12), 2100 – 2300 rpm (Cummins 5,9) E3 FUEL LEVEL ALARM LIMIT When the fuel level is below the alarm limit an alarm is displayed and material flow is immediately shut down. Default: 5 % Range: 0 – 20 % H1 DEVICE PUMP PRESSURE ALARM LIMIT Permission to run the feeder is based on the device pressure alarm limit. If the pressure is over the alarm limit there will be no permission to run the feeder. Default: 250 bar (LT105, LT1213, LT200), 300 bar (LT95, LT1110) Range: 0 - 350 bar H13 DEVISE PUMP #2 PRESSUE LIMIT Can be used to detect jammed lifting conveyor Default; 200 bar Range; 0 – 350 bar (0 = not in use) Used only in LT300HP H14 MAIN CONVEYOR SPEED ALARM Used to observe main conveyor running speed. Default; 200rpm Range; 0 –500 rpm (0 = not in use) Used only with cone crushers

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IC500 / IC600 Instruction Manual 16.3 HUB junction module In the HUB view window you can determine which alarm messages are shown or hidden in case of an alarm. To change the alarm status, service mode must be active. ON = 1, OFF = 0. These alarms are also saved in the system’s alarm log (18.1).

NOTE: If an alarm is turned off and that specific alarm has caused a malfunction, there will be no record of it and finding the cause of the malfunction will become very difficult. You can access the alarm parameters from the Parameter/service window (4) by selecting the HUB icon with the arrow keys (F4, F5) and pressing OK (F3). The middle view of the alarm parameter window shows the alarm description. The box on the right indicates the value of the alarm. The box on the left indicates the number of the alarm parameter. Use the arrow keys to move to the alarm that you want to adjust and press OK. Use the + / buttons (F4, F5) to enable (1) or disable (0) an alarm and press OK. Press F1 to return to the previous window.

NOTE: For more information on the alarm messages and the alarm log refer to chapter 18.1.

16.4 This chapter is reserved for future use

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IC500 / IC600 Instruction Manual 16.5 Cone crusher setting calibration window (Cone crushers only) Due to material wear the crusher actual setting will enlarge during the crushing process. Calibration of the setting is recommended at least in every 40 h of operation. Fast and correct setting changes are easily done when the actual setting is maintained in the setting calibration window.

2

1

3 4 5

Figure 16.5 Cone crusher calibration page 1 2 3 4 5

Setting value Operating hours after the last setting calibration Time & date of last setting calibration kWh consumed after the last setting calibration Calibration window

16.5.1 Setting calibration With the new liners (liner contact method) 1 Make sure that the process is switched off. 2 Install the crusher control panel on the service platform 3 Make sure that the crushing chamber is clean. 4 Activate the crusher lubrication as instructed in chap.14.3 4 Turn the bowl to setting decrease direction 5 When the crusher head turns stop turning the bowl. 0-mm setting is achieved. 6 Return to the control panel and open page 4.1 7 Activate calibration by pressing F3 button. 8 Adjust the new measured actual crusher setting value to the calibration window by adjusting the actual value with buttons F4 & F5. (See fig 16.5 item 5) 9 Confirm the new value to the control system by pressing button F3. 10. Set the desired setting from the crusher control panel. NOTE: Check the allowed minimum setting from the instruction manual Nordberg 100, 200, 300,400,500 cone crushers.

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(Used liners: No liner contact before the A-limit according to chapter 3.13 of the instruction manual Nordberg 100, 200, 300, 400, 500 cone crushers) 1 2 3 4 5 6 7

Check the setting according to instruction manual Nordberg 100, 200, 300, 400, 500 cone crushers / chapter 3.11. Compare the measured setting to the setting value #1 in window 4.1. If a difference is noticed in actual setting and display value, calibrate the setting. Activate calibration by pressing F3 button. Adjust the new measured actual crusher setting value to the calibration window by adjusting the actual value with buttons F4 & F5. Confirm the new value to the control system by pressing button F3. Set the desired setting from the crusher control panel.

NOTE: Check the allowed minimum setting from the instruction manual Nordberg 100, 200, 300, 400, 500 cone crushers.

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IC500 / IC600 Instruction Manual Diagnostics You obtain the diagnostics window by pressing F5 in the main window. This is the main window for diagnostics. In this window you can select whether you want to view basic diagnostics (tracks, buttons and log files) or detailed diagnostics (connectors of each module). For example, the tracks symbol (Fig. 17.1.1, number 1) opens the track drive diagnostics window.

Figure 17.1.1 Diagnostics

1 2 3 4 5 6 7 8

Tracks (window 5.1) Control keys window 5.2) Log files (window 5.3) Module program versions (window 5.4) Status of information by each connector of the device control module Status of information by each connector of Hub junction module Status of information by each connector of engine control module Status of information by each connector of hydraulics control module

Move with F4 and F5 to the box that you want to see and select it with F3. Return to the main window with F1.

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IC500 / IC600 Instruction Manual 16.6 Track Drive Diagnostics You can obtain the track drive diagnostics window by selecting the tracks symbol in the diagnostics main window.

Figure 17.1.2 Track drive diagnostics 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

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Drive box / radio control Left track "forward" control received (radio/drive box) Left track "backward" control received (radio/drive box) Right track "forward" control received (radio/drive box) Right track "backward" control received (radio/drive box) Left track control percentage Left track control voltage percentage Right track control percentage Right track control voltage percentage Left track forward output. When activated, the triangle is black. Left track backward output. When activated, the triangle is black. Right track forward output. When activated, the triangle is black. Right track backward output. When activated, the triangle is black. Engine rpm down or feeder off with radio control received Engine rpm up or feeder on with radio Engine rpm down output. When activated, the triangle is black. Engine rpm up output. When activated, the triangle is black. Tracking controls active in radio Crushing controls active in radio Feeder speed down control received from radio Feeder speed up control received from radio

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IC500 / IC600 Instruction Manual This window shows you the most important data for track driving. The window is also the diagnostics window for the drive box. The selected control (drive box or radio) is shown in this window (see Fig. 17.1.2, number 1). You will also see the control percentages for the proportional valves, as well as the control voltage area. Engine rpm and increasing/decreasing of the engine speed are also indicated. 16.7 Push Button Test You will obtain the push button test window by selecting the control button symbol in the diagnostics main window.

Figure 17.2.1 Push button test (depending on selected LT unit) 1 2 3 4 5 6 7 8 9

Feeder off/on / Feed on/off Feeder speed decrease / increase Feed decrease / increase Crusher off/on (jaw crusher only) Crusher swing clockwise / counter clockwise (jaw crusher only) Crusher setting increase / decrease (jaw crusher only) Engine key switch, start, running status Process key switch off/on Radio control off/on Feed funnel up (impact only)

This window allows you to check whether the buttons in the remote control function normally. For instance, if you press feeder on/off button of the service platform, the function is indicated by a highlighted feeder on (number 1) symbol at this window. To carry out the service platform test you need an assistant to activate the button in the service platform, as the button needs to be pressed and its status read simultaneously. Return to the previous window by pressing F1.

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17 Log Files In window 5 selecting symbol "log files" (figure 17.1.1, number 3) you will obtain the log files window (5.3).

Figure 18.1.1 Log files 1 2 3 4 5

Alarm history Diesel diagnostics trouble codes Temperature history log Factory settings Parameter log

From window 5.3 you have access to windows: 5.3.1 (Alarm log) 5.3.2 (Diesel diagnostics trouble codes) 5.3.3 (Temperature history log) 5.3.4 (Parameter log) 5.3.5 (Factory settings). Return to the previous window by pressing F1.

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IC500 / IC600 Instruction Manual 17.1 Alarm log In the log files window select number 1 to obtain the alarm log window.

Figure 18.1.2 Alarm log When a malfunction occurs, the system shows an alarm message window and saves the information about the alarm in the alarm log database. The database consists of the date, time, alarm code and number of alarms. If the same alarm occurs sequentially, only the first and last alarms and the number of alarms are saved. The maximum number of alarms in the database is 100. The date of the last reset is saved. How to use the alarm messages and the alarm log: When the system gives out an alarm message, read it and try to understand it. If you do not understand the meaning of the alarm or do not know how to fix the problem, you can get additional information by pressing F2 (help) to access the alarm message’s help view window while the alarm message is active. You can find a list of alarms (the number of alarms depends on the selected unit type) by going to the Parameters/service window (4) and choosing the HUB icon (Fig 16.1.1, number 6) by highlighting it and pressing OK. Here the alarm help view can be accessed by pressing the F2 button. Example on how to use the alarm log: Problem: A malfunction occurs that stops the process. You know the approximate time when the malfunction occurred but you do not know what alarms occurred before and after the malfunction. Solution: From the alarm log you can find out the dates, times, alarm codes and the number of times the alarms have occurred. Use the alarm log to look up all the alarms that occurred near the time the malfunction occurred, this way you can narrow down the cause. If you need further information on how to deal with the problem, refer to chapter 16.3. The complete list of alarms and their corresponding alarm codes can be found in chapter 17.1.1. Return to the previous window by pressing F1. 17.1.1 Alarm list HUB JUNCTION MODULE ( ALARM LIST ) Version 2.5

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IC500 / IC600 Instruction Manual Code

Message

HB1 HB2 HB3 HB4 HB5 HB6 HB7 HB8 HB9 HB10 HB11 HB12 HB13 HB14 HB15 HB16 HB17 HB18 HB19 HB20 HB21 HB22 HB23 HB24 HB25 HB26 HB27 HB28 HB29 HB30 HB31 HB32 HB33 HB34 HB35 HB36

Process disabled alarm1. On (1), Off (0) Crusher over pressure alarm 2. On (1), Off (0). Crusher pressure rising too fast on start alarm 3. On (1), Off (0) Clamping pressure alarm 4. On (1), Off (0). Toggle plate condition alarm 5. On (1), Off (0). Crusher pressure rising too slowly on start alarm 6. On (1), Off (0) Crusher speed rising too slowly on start alarm 7. On (1), Off (0). Crusher speed low alarm 8. On (1), Off (0). Hydraulic oil temperature high, feeder stopped alarm 9. On (1), Off (0). Fuel level low alarm 10. On (1), Off (0). No connection to diesel engine alarm 11. On (1), Off (0). Engine red stop alarm 12. On (1), Off (0). Engine amber warning alarm 13. On (1), Off (0). Hydraulic oil level low alarm 14. On (1), Off (0). Hydraulic oil filter clogged alarm 15. On (1), Off (0). Hydraulic oil main valve closed alarm 16. On (1), Off (0). Hydraulic oil temperature high alarm 17. On (1), Off (0). Main conveyor safety switch left alarm 18. On (1), Off (0). Main conveyor safety switch right alarm 19. On (1), Off (0). Crusher critical overload alarm 20. On (1), Off (0). Conveyor maintenance safety switch alarm 21. On (1), Off (0). Screen over size conveyor safety switch alarm 22. On (1), Off (0). Screen under size conveyor safety switch alarm 23. On (1), Off (0). Side conveyor safety switch left side alarm 24. On (1), Off (0). Side conveyor safety switch right side alarm 25. On (1), Off (0). Drive box remote stop alarm 26. On (1), Off (0). Radio remote stop alarm 27. On (1), Off (0). Emergency stop pressed from control panel alarm 28. On (1), Off (0). Emergency stop pressed from service platform alarm 29. On (1), Off (0). Emergency stop pressed from engine module alarm 30. On (1), Off (0). Emergency stop pressed from hydraulic center alarm 31. On (1), Off (0). Wrong program in one of the control modules alarm 32. On (1), Off (0). Ultrasonic sensor not in range alarm 33. On (1), Off (0). Clamping pressure sensor not in range alarm 34. On (1), Off (0). Device pump pressure sensor not in range alarm 35. On (1), Off (0). Toggle plate pressure sensor not in range alarm 36. (Setting pressure) Not in use, On (1), Off (0). ECM module missing alarm 37. On (1), Off (0) HCM module missing alarm 38. On (1), Off (0). DCM module missing alarm 39. On (1), Off (0). Device pump pressure high alarm 40. On (1), Off (0). Crusher pressure sensor not in range alarm 41. On (1), Off (0). Hydraulic overload device / setting sensor detected overload alarm 42. On (1), Off (0). Toggle plate failure alarm 43. On (1), Off (0).

HB37 HB38 HB39 HB40 HB41 HB42 HB43 Version 2.5

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IC500 / IC600 Instruction Manual HB44 HB45 HB46 HB47 HB48 HB49 HB50 HB51 HB52 HB53 HB54 HB55 HB56 HB57 HB58 HB59 HB60 HB61 HB62 HB63 HB64 HB65 HB66 HB67 HB68 HB69 HB70 HB71 HB72 HB73 HB74 HB75 HB76 HB77 HB78 HB79 HB80 HB81 HB82 HB83 HB84 HB85 HB86 HB87 HB88 Version 2.5

Bypass conveyor safety alarm 44 On(1), Off(0) Bypass conveyor motor overload alarm 45.On (1), Off (0). Return conveyor safety alarm 46. On (1), Off (0). Return conveyor motor overload alarm 47. On (1), Off (0). Generator voltage alarm 48. On (1), Off (0). Generator thermistor alarm 49. On (1), Off (0). Generator frequency alarm 50. On (1), Off (0). Cone crusher feedback alarm 51. On (1), Off (0). Vibration chute motor overload alarm 52. On (1), Off (0). Feeder hopper level sensor not in range alarm 53. On (1), Off (0). Feed stop, metal detected alarm 54. On (1), Off (0). Lifting conveyor rotating sensor alarm 55. On (1), Off (0). Lifting conveyor safety alarm 56. On (1), Off (0). Lifting conveyor oil pressure high alarm 57. On (1), Off (0). Lifting conveyor oil temperature high alarm 58. On (1), Off (0). LC-feeder motor overload alarm 59. On (1), Off (0). Side conveyor motor overload alarm 60. On (1), Off (0). Crusher stop without ramp alarm 61. On (1), Off (0). Feed authorization lost alarm 62. On (1), Off (0). Lifting conveyor speed low alarm 63. On (1), Off (0). Lifting conveyor oil pressure out of range alarm 64. On (1), Off (0). Impactor speed low alarm 65. On (1), Off (0). Impactor cover open alarm 66. On (1), Off (0). Impactor speed sensor faulty or jammed alarm 67. On (1), Off (0). Impactor feedback fault alarm 68. On (1), Off (0). Cone crusher in service mode On (1), Off (0). Process disabled cone crusher alarm On (1), Off (0). Connection between IC600 and IC70 is lost On (1), Off (0). Winter mode with internal power supply in activated alarm On (1), Off (0). Main conveyor low speed alarm On (1), Off (0). Engine cooler current feed back fault alarm On (1), Off (0). System voltage low alarm On (1), Off (0). Screen discharge conveyor jammed or low speed alarm On (1), Off (0). Lubrication oil tank temperature sensor not in range On (1), Off (0). Process disabled: Lubrication tank oil too cold On (1), Off (0). Lubrication return oil temperature sensor not in range On (1), Off (0). Lubrication oil too hot On (1), Off (0). Crusher speed sensor fault or crusher jammed alarm On (1), Off (0). HP crusher slow speed On (1), Off (0). HP Crusher hydraulic pump feedback fault alarm HP crusher excessive power limit alarm On (1), Off (0). Clamping pressure fault alarm On (1), Off (0). Release pressure fault alarm On (1), Off (0). Counter shaft pressure fault On (1), Off (0). Cone lubrication oil level low On (1), Off (0). 50/75

IC500 / IC600 Instruction Manual HB89 HB90 HB91 HB92 HB93 HB94 HB95 HB96 HB 130

Lubrication pump low speed alarm On (1), Off (0). Analog cavity level sensor not in range On (1), Off (0). Lubrication pump safety device tripped On (1), Off (0). Setting sensor A fault On (1), Off (0). Setting sensor B fault On (1), Off (0). Gearbox Clutch pressure alarm On (1), Off (0). Lubricationb oil cooler safety device tripped On (1), Off (0). Oil heating alarm due to lifting conveyor safety or conveyor maintenance switch On (1), Off (0). Vibration chute motor overload

The list of alarms can also be found in the Parameters/service window (4) by highlighting and choosing the HUB icon.

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IC500 / IC600 Instruction Manual 17.2 Diesel Diagnostic Trouble Codes (Active and Stored) In the log files window select number 2 to obtain the engine trouble code log window.

Figure 18.2.1 Diesel diagnostic trouble codes This window shows you the engine trouble codes. By pressing the function key F3 you will be able to select whether to see the active trouble codes (DM1) or previously active (stored) trouble codes (DM2). By default the window always shows the DM1 page first. With F4 and F5 you will be able to scroll the screen. Return to the previous window by pressing F1. Example on how to use the Diesel diagnostic trouble codes: In the DM1 window you can see all active trouble codes concerning the diesel engine. By crossreferencing the SPN and FMI to the list in Appendix 2 you can determine what the problem is. The count tells you how many times a specific trouble code has been active. SPN 111 Translation: SPN FMI Cnt

FMI 1

Cnt 1

= Coolant level = Data valid but below normal operational range - most severe level = Trouble code has been active one (1) time

Engine diagnostic codes according to SAE J1939 are shown in Appendix 2. SPN: Suspect parameter number FMI: Failure mode identifier Refer to Engine Instruction manual.

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IC500 / IC600 Instruction Manual 17.3 Temperature History Log In the log files window select number 3 to obtain the temperature log window.

Figure 18.3.1 Temperature history log The number of module temperatures that are below –40 oC (-40 oF) or above +70 oC (158 oF) is registered in this window by each module. Also, the number of hydraulic oil temperatures that exceed –25 oC (-13oF) and +85 oC (185 oF) is registered. Return to the previous window by pressing F1. 17.4 Parameter Log In the log files window select number 4 to obtain the parameter log window.

Figure 18.4.1 Parameter log In the parameter log window you can see the changed parameters and the date and time when they were changed. You can also see the old and new values. Using the arrow keys you will be able to scroll the screen. Return to the previous window by pressing F1.

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IC500 / IC600 Instruction Manual 17.5 Factory parameters In the log files window select number 5 to obtain the factory parameter window.

Figure 18.5.1 Factory parameters

Select load/save with arrow keys F4 or F5. Confirm your selection by pressing F3 (OK). The Load function will reset the factory parameters.

Saving and loading are only allowed in service mode.

Return to the previous window by pressing F1.

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18 Module Program Versions In the diagnostics main window select number 4 (Module program versions) to obtain this window.

Figure 19.1.1 Module program versions

This window shows you the module program versions and the date of the program. In this window you cannot enter any information. 1 2 3 4 5

Device control module Engine control module hydraulic control module Hub junction module Display control unit


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19 Reading Input/Output Modules Data Select the Hub XH4 connector of the modules shown in window 5 and this window will be opened.

Figure 20.1.1 Input/output data by connectors 1 2 3

Module Number of the terminal / pin Input/output value

The window shows all pins in the selected connector. A detailed list can be found in the Help file. Value is either 0 (no voltage in the input/output), 1 (input/output active, voltage sent or received), mA-value or V-value.

Help file will contain information on all terminals. You can also use unit electrical diagrams to locate terminals.


20 Troubleshooting Generally troubleshooting with the IC500 / IC600control system is based on checking the controller INPUT and OUTPUT values. However, this is to help you if the IC500 / IC600control system will not start up at all. Check the following: If the reason is not shown in the message field of the main window: Reset the control system. Stop the engine by turning the control voltage off for 15 seconds. Restart the engine. Check the battery voltage.

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IC500 / IC600 Instruction Manual Appendix 1 / 1 (4) If the parameter is marked with --- the parameter is not used and not displayed PARAMETERS G = General, F = Feeder, C = Crusher, T = Tracks, E = Engine, H = Hydraulics Note: The letter S with one of these letters stands for a service parameter. Only an authorized person has access to them. Parameter Code General GS1 Delay between device start, range 1 - 15 sec. GS2 Delay after feeder stopped with "Process stop" sequence, range 10 - 45 sec. GS3 Delay between the shut down of the devices, range 5 - 45 sec. G4 Vibrating chute in use (1), not in use (0). G5 Generator in use (1), not in use (0). G6 Bypass conveyor in use (1), not in use (0). G7 Dust removal in use (1), not in use (0). G8 Dust removal fan time, range 1 - 180 min. G9 Dust removal vibrating time, range 5 - 200 sec. G10 Return conveyor in use (1), not in use (0). GS11 Unit type (Select from the parameter list). GS12 Radio controller type: 0 = I/O-radio, 1 = CAN-radio GS13 Lifting conveyor feeder in use (0=not in use, 1=in use ) GS14 Feed hopper in use (0=not in use, 1=in use ) GS15 Scalper in use (1), not in use (0). G16 Magnetic separator in use on (1), not in use (0).

95 5 20

Default values by LT type 105 1110 1213 5 5 5 20 20 20

10 --------------1 1

10 --------------1 0

10 --------------2 1

10 --------------2 1

---

---

0

0

G17 Side conveyor in use on (1), not in use (0). GS18 Separate crusher automation (IC70) in use on (1), not in use (0). Code FEEDER F1 Feeder MIN speed, range 55 - 70 %. F2 Feeder MAX speed, range 70 - 90%, MAX speed must be higher than MIN speed. F3 Crusher level high alarms time period, range 0 - 20 min. If 0 adaptive control will not be used. F4 Crusher level high count before feeder speed reduction, range 0 –5 F5 Automatic (0) /manual (1) feeder speed setting mode selection. F6 Level sensor ON (1) / OFF (0). F7 Feeder speed increase/decrease step, range 0 - 100 % (% between min and max speed setting) FS8 Crusher pressure OK limit, range 100 - 300 bar. FS9 Crusher pressure HIGH limit, range 200 - 400 bar. FS10 Crusher pressure high limit time delay, range 1 - 20 sec. FS11 Crusher speed OK limit, range 260 - 370 rpm. FS12 Crusher speed LOW limit, range 210 - 320 rpm. FS13 Crusher speed low limit time delay, range 1 - 10 sec. FS14 Hydraulic oil temp OK limit, range 65 - 85oC.

200 5 20 10 0 0 0 0 120 10 ------0 0 --0 0 0

63 80

63 80

66 84

66 84

-----

0

0

---

---

0

1

1

---

---

0

1 1 5

1 1 5

0 -----

0 -----

0 --0

200 250 3 310 295 1 75

200 250 3 310 295 1 75

180 300 1 ------75

180 300 1 ------75

----------2 ---

FS15 Hydraulic oil temp HIGH limit, range 70 - 90oC.

85

85

85

85

85

F16

1

1

---

---

20

Crusher level high alarm delay, range 1 - 20 sec.

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IC500 / IC600 Instruction Manual Appendix 1 / 2 (4) F17 F18

Feeder start minimum time Crusher level high alarm time of the possible second LT, range 1 - 20 sec. FS19 The length of the feeder acceleration and deceleration ramp in seconds, range 5 - 25 sec. FS20 Feeder-hopper analog level detector 0% mA value, range 4- 19 mA.. FS21 Feeder-hopper analog level detector 100 % mA value range, 4 – 19 mA F22 Feed-hopper analog level detector, “0” not in use, “1” in use F23 Feeder-hopper low cavity level, , range 0 –100 % F24 Feeder-hopper high cavity level, range 0 – 100 % F25 Lifting conveyor acceleration and deceleration ramp time time from min to max), range 0 - 30 sec F26 Lifting conveyor min speed, range 0 - 100 % F27 Lifting conveyor max speed, range 0 - 100 % F28 Feed hopper analog sensor in use (0=not in use, 1=in use ) F30 Metal detector stop time, range 0 - 5.0 sec. (If set to 0, metal detector not in use) F31 Lifting conveyor min speed time, range 0 - 15 sec. F33 Hydraulic oil slow down limit, range 60 - 80oC. F34 F35 F36 F38 F40 F41 F42 F43 F44 F45 F46 F47 F48 F49 F50

Lifting conveyor speed alarm, range 0 - 500 rpm. (If set to 0, sensor not in use) LC feeder min speed, range 0 - 100 %. LC feeder max speed, range 0 - 100 %. Stop delay between LC feeder and lifting conveyor,range1-60 Lifting Conveyor / LC feeder control manual (0), automatic (1) LC feeder min speed start time, range 0 - 10 sec. Screen discharge conveyor low speed limit, range 0 – 400rpm Cavity level sensor type (0=not in use, 1=analog, 2=digital ) Cavity level sensor current at 0%. Range 4 – 20 mA Cavity level sensor current at 100%. Range 4-20 mA Feed power mode in use (0=not in use, 1=in use ) Crusher power OK limit, range 40 – 400 kW Crusher power high limit, range 100 – 400kW Power high feed pause delay, range 1 – 20 sec. Crusher low speed alarm limit, range 500 - 1500

Code CRUSHER C1 Crusher speed control current maximum value in milliampers, range 200 - 650 mA. CS2 Crusher speed control current minimum value in milliamperes, range 100 - 400 mA. CS3 Toggle plate (0) / hydraulic cylinder protection (1) / mechanical setting adjustment (2) !! Select !! CS4 Minimum clamping pressure range 80 - 300 bars. Note! CS10: Minimum pressure value 10 bar. CS5 Max. clamping press. , Range 100-300 bar. Note! Max. value must be higher than min CS6 Crusher starting low pressure alarm limit, range 0 - 200 bar. CS7 Crusher starting low pressure alarm delay, range 0 - 60 sec. CS8 Crusher starting high pressure alarm limit, range 100 - 300 bar. CS9 Crusher starting high pressure alarm delay, range 0 - 30 sec.

Version 2.5

5 5

5 5

1 5

1 5

1 5

10

10

15

15

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---

---

18

---

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---

---

6

-------

-------

-------

-------

0 25 90 3

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-----

-----

-----

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16 46 0 0

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-----

-----

-----

0 75

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0

-----

-----

-----

-----

50 80

---------

---------

---------

---------

1 0 0 2 18 5 1 130 150 5 700

600

580

---

---

---

250

250

---

---

---

0

0

---

---

---

95

120

---

---

---

125

170

---

---

---

50 10 200 5

50 10 200 5

---------

---------

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IC500 / IC600 Instruction Manual Appendix 1 / 3 (4) CS10 Low clamping pressure limit, range 80 - 150 bar. Note! Minimum press. value 10 bar CS11 Crusher over pressure alarm delay, range 1 - 20 sec. CS12 Crusher over pressure alarm limit, range 100 - 400 bar. CS13 Crusher start ramp time, range 8 - 25 sec. CS14 Crusher stop ramp time, range 10 - 30 sec. CS15 Setting sensor 4 mA reading (Ultrasonic) in mm. CS16 Setting sensor signal range (Ultrasonic) in mm. CS17 Crusher overload when setting is n % of fully open. CS18 Normal setting movement during crushing. C19 Crusher speed sensor in use (1), not in use (0). C24 Crusher target speed 1, default 500, range 400-900rpm C25 Crusher target speed 2, default 650, range 400-900rpm C26 Crusher target speed 3, default 850, range 400-900rpm CS27 Crusher speed sensor, detected pulses per one round, range 1 - 50 CS28 Pump zero speed for impact crusher target speed 1, range 200 - 750 mA CS29 Adjust motor zero speed for impact crusher target speed 1, range 200 - 750 mA CS30 Pump zero speed for impact crusher target speed 2, range 200 - 750 mA CS31 Adjust motor zero speed for impact crusher target speed 2, range 200 - 750 mA CS32 Pump zero speed for impact crusher target speed 3, range 200 - 750 mA CS33 Adjust motor zero speed for impact crusher target speed 3, range 200 - 750 mA CS34 Crusher target speed change hysteresis, range 5-100 CS35 Crusher target speed ramp fastness mA/s, range 0.2 - 3.0 mA/s C36 Crusher auto speed. 0 = not in use, 1 = in use CS37 Crusher idling power limit, default 30 kW, Range 10-100kW CS38 Hydraulic motor size default 180 cm3 range: 50-500cm3 CS39 Hydraulic motor v-belt pulley diameter default 250 mm CS40 Clamping fault delay, default 20 sec range:0-60 sec CS41 Release fault delay , default 20 sec range:0-60 sec CS42 Excessive power alarm limit : range:100-400kW CS43 Excessive power alarm delay default 10 sec range:0-20 sec CS44 Crusher soft start time default 20 sec range 0- 60 sec CS45 Crusher prelubrication time default 120 sec range:1- 300sec CS46 HP crusher setting change per tooth default 0,18mm range0,10 - 0,39 mm CS47 Crusher drive type 0=hydraulic 1=Katsa gear box CS48 Diesel engine size default 317 kW range 200 –600kW CS49 Power draw without Crusher default 90kW range: 0-400kW CS50 Hydraulic pump size default 250cm3 range:50-500cm3 Code T1 T2 T3

TRACKS MIN value for right track backward, range 50.0 - 95.0 %. MIN value for right track forward, range 5.0 - 50.0 %. MIN value for left track backward, range 50.0 - 95.0%.

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80

110

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---

10 300 15 20 0 0 5 15 1 ---------

10 300 15 20 0 0 5 15 1 ---------

10 380 25 30 --------1 500 570 650 6

10 380 25 30 --------1 480 550 630 1

----20 30 --------1 830 940 1050 4

---

---

560

560

540

---

---

0

0

---

---

---

590

590

580

---

---

225

0

---

---

---

638

638

630

---

---

320

0

---

-----

-----

20 2.0

20 2.0

20 2,0

---

---

1

1

1 25 180 224 1 1 160 5 35 120 0,18 0 317 90 250

65 35 65

65 35 65

65 35 65

65 35 65

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IC500 / IC600 Instruction Manual Appendix 1 / 4 (4) T4 T5 T6 T7

MIN value for left track forward, range 5.0 - 50.0%. Fast speed rpm, range 1500 - 2300 rpm. Normal speed rpm, range 1000 - 2000 rpm. Stop ramp, range 1 - 300 ms.

35 2000 1200 20

35 2000 1200 20

35 2000 1200 20

35 2000 1200 20

35 2000 1200 20

Code E1 E2 E3 ES4 ES5 ES8 ES9 ES10 ES11 ES12 ES13 ES14 ES15 ES16

ENGINE AND HYDRAULICS Diesel MIN speed, range 700 - 1200 rpm. Diesel MAX speed, range 1900 - 2500 rpm. Fuel level alarm limit, range 0 - 20 %. Fuel level sensor min output voltage, range 0 - 5 V. Fuel level sensor max output voltage, range 0 - 5 V. Engine cooler control in use 0 = not in use, 1 = in use Cooler max mA value Range 400 – 750 mA Cooler min mA value Range 0 – 400 mA Coolant temperature OK limit, Range 60 – 85 oC Coolant temperature high limit, range86 – 100 oC Charge air temperature ok limit, Range 35 – 45 oC o Charge air temperature high limit, Range 46 – 70 C Cooler speed ramp fastness range 1 – 5 sec Diesel engine type “0” = CAT, “1” = Cummins

1000 2300 5 1,20 0,01

850 2100 5 1,20 0,01

850 2100 5 1,20 0,01

850 2100 5 1,20 0,01

1

0

0

0

850 2100 5 1,20 0,01 0 600 200 70 98 43 50 0,5 ---

H1 HS2

Device pump pressure alarm limit, range 0 - 350 bar. Hydraulic oil temperature sensor gain (mV/100oC).

250 905

250 905

290 905

290 905

0 905

HS3

Hydraulic oil temperature sensor 0oC voltage reading.

2.13

2.13

2.13

2.13

2.13

HS4 HS5 HS6 HS7 HS8 HS9 HS10 HS11 HS12 H13 H14

Hydraulic oil temperature limit for monitoring oil filter. Crusher pressure sensor 4 mA value. Crusher pressure sensor range. Clamping pressure sensor 4 mA value. Clamping pressure sensor range. Device pump and lifting conveyor pressure sensor 4 mA value. Device pump and lifting conveyor pressure sensor range. Toggle plate pressure sensor 4 mA value. Toggle plate pressure sensor range. Lifting conveyor pump pressure limit, range 0 - 350 bar. Main conveyor speed alarm, range 0 – 500 rpm. “0” =not in use

20 0 600 0 600 0 600 0 0 -----

20 0 600 0 600 0 600 0 0 -----

20 0 600 0 600 0 600 0 0 0 ---

20 0 600 0 600 0 600 0 0 0 ---

20 0 600 0 600 0 600 0 0 0 200

Code LS1 LS2 LS3 LS4 LS5 LS6 LS7 LS8 LS9 LS10 LS11 LS12 LS13 LS14 LS15 LS16 LS17

LUBRICATION UNIT Tank oil temperature sensor 4 mA-value; range –30 - 100 oC Tank oil temperature sensor range; 0 - 1000 oC Return oil temperature sensor 4 mA-value; range –30 - 100 oC Return oil temperature sensor range; 0 - 1000 oC Tank oil heaters off limit range; 0 – 100 oC Return oil hot, feed stop limit temperature range 0 – 100 oC Return oil too hot, crusher alarm limit temperature 0 - 100 oC Counter shaft pressure alarm delay range; 0 – 10 sec. Lubrication pump low speed limit range; 1000 – 1400 rpm Oil cooler on temperature limit range 30 – 50 oC Oil cooler off temperature limit range;20 – 40 oC Lubrication pump motor type; 0 = Hydraulic , 1 = Electric Tank oil temperature process enable limit range; 0 – 30 oC Lub.pump running time after crusher stop range; 1 –300 sec. Lub.pump speed sensor pulses per one round range; 1 -50 Lube oil cooler motor type; 0 = hydraulic, 1 = electric Oil heating hydraulic pump time range; 0 – 300 sec.

Version 2.5

0 100 0 100 30 55 60 5 1250 45 35 0 20 120 38 0 0

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IC500 / IC600 Instruction Manual Engine diagnostic codes

Appendix 2 / 1 (8)

ENGINE DIAGNOSTIC CODES SPN ( Suspected Parameter Number ) PID 0 1(1) 2(1) 3(1) 4 5(1) 6(1) 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 Version 2.5

Parameter Single data character length parameters Request parameter Invalid data parameter (see appendix A) Transmitter system status (see appendix A) Transmitter system Diagnostic (see appendix A) Reserved - to be assigned Underrange warning condition (see appendix A) Overrange warning condition (see appendix A) Axle # 2 lift air pressure Brake system air pressure low warning switch status Axle lift status Axle slider status Cargo securement Brake stroke status Entry assist position/deployment Entry assist motor current Fuel supply pump inlet pressure Suction side fuel filter differential pressure Engine oil level remote reservoir Extended range fuel pressure Extended range engine oil pressure Extended range engine coolant pressure Engine ECU temperature Extended engine crankcase blow-by pressure Generator oil pressure Generator coolant temperature Air conditioner system status # 2 Estimated percent fan speed Percent Exhaust gas recirculation valve # 1 position Percent accelerator position # 3 Percent accelerator position # 2 Crankcase blow-by pressure Transmission range position Transmission splitter position Clutch cylinder position Clutch cylinder actuator status Shift finger actuator status # 2 Clutch plates wear condition Transmission tank air pressure Second fuel level (right side) Tire pressure check interval Engine retarder switches status Cruise control switches status Pressure switch status Ignition switch status Attention/warning indicator lamps status 61/75

IC500 / IC600 Instruction Manual Engine diagnostic codes 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95

Version 2.5

Appendix 2 / 2 (8)

Inlet air heater status Vehicle wet tank pressure Retarder status Extended range barometric pressure ABS control status Air conditioner system clutch status/command # 1 Throttle position Engine intercooler temperature Transmission synchronizer clutch value Transmission synchronizer brake value Shift finger actuator status # 2 Transmission range switch status Transmission actuator status # 2 Shift finger actuator status Shift finger gear position Shift finger rail position Parking brake actuator status Retarder inhibit status Transmission actuator status # 1 Direction switch status Service brake switch status Vehicle enabling component status Shift request switch status Torque limiting factor Two speed axle switch status Parking brake switch status Idle shutdown timer status Blower bypass value position Auxiliary water pump pressure Maximum road speed limit Steering axle temperature Axle # 1 lift air pressure Forward rear drive axle temperature Rear rear-drive axle temperature Road surface temperature Washer fluid level Particulate trap inlet pressure Air start pressure Road speed limit status Road speed Cruise control status Cruise control set speed Cruise control high-set limit speed Cruise control low-set limit speed Power takeoff status PTO oil temperature Percent accelerator pedal position Percent engine load Output torque Fuel delivery pressure Fuel filter differential pressure

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IC500 / IC600 Instruction Manual Engine diagnostic codes 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145

Version 2.5

Appendix 2 / 3 (8)

Fuel level Water in fuel indicator Engine oil level Engine oil filter differential pressure Engine oil pressure Crankcase pressure Boost pressure Turbo speed Turbo oil pressure Intake manifold temperature Air inlet pressure Air filter differential pressure Barometric pressure Coolant pressure Engine coolant temperature Coolant level Coolant filter differential pressure Governor droop New battery current Alternator current Brake application pressure Brake primary pressure Brake secundary pressure Hydraulic retarder pressure Hydraulic retarder oil temperature Engine retarder status Engine retarder percent Clutch pressure Transmission oil level Transmission oil level high/low Transmission filter differential pressure Transmission oil pressure Double data character length parameters Component-specific request Injector metering rail # 2 pressure Power specific fuel economy Exhaust back pressure Mass air flow Average fuel rate Wheel speed sensor status Extended range fuel delivery pressure (absolute) Auxiliary vacuum pressure reading Auxiliary gage pressure reading # 1 Auxiliary absolute pressure reading Tire pressure control system channel functional mode Tire pressure control system solenoid status Trailer # 1, tag # 1, or push channel # 1 tire pressure target Drive channel tire pressure target Steer channel tire pressure target Trailer # 1, tag # 1, or push channel # 1 tire pressure Drive channel tire pressure

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IC500 / IC600 Instruction Manual Engine diagnostic codes 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193(1) 194

Version 2.5

Appendix 2 / 4 (8)

Steer channel tire pressure Average fuel economy (natural gas) Instantaneous fuel economy (natural gas) Fuel mass flow rate (natural gas) PTO engagement control status ATC control status Number of ECU resets Crankcase pressure Auxiliary input and output status # 2 Auxiliary input and output status # 1 Injector timing rail pressure Injector metering rail pressure Battery potential (voltage) - switched Gas supply pressure Main shaft speed Input shaft speed Transmission range selected Transmission range Attained Injection control pressure Compass bearing Rated engine power Alternator potential (voltage) Battery potential (voltage) Cargo ambient temperature Cab interior temperature Ambient air temperature Air inlet temperature Exhaust gas temperature Fuel temperature Engine oil temperature Turbo oil temperature Transmission # 1 oil temperature Front axle weight Rear axle weight Trailer weight Cargo weight Trip fuel Fuel rate (instantaneous) Instantaneous fuel economy Average fuel economy Power takeoff speed Power takeoff set speed Idle engine speed Rated engine speed Engine speed Transmission output shaft speed Variable and long data character length parameters Multisection parameter Transmitter system diagnostic table (see appendix A) Transmitter system diagnostic code and occurrence count table

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IC500 / IC600 Instruction Manual Engine diagnostic codes 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245

Version 2.5

Appendix 2 / 5 (8)

Diagnostic data request/clear count Diagnostic data/count clear response Connection management Connection mode data transfer Traction control disable state Reserved - to be assigned Reserved - to be assigned Reserved - to be assigned Reserved - to be assigned Reserved - to be assigned Reserved - to be assigned Reserved - to be assigned Reserved - to be assigned Reserved - to be assigned ABS control status, trailer Tire temperature (by sequence number) Tire pressure (by sequence number) Tire pressure target (by sequence number) Wheel end assembly vibration level Vehicle wheel speeds Brake temperature Wheel bearing temperature Fuel tank/nozzle identification State line crossing Current state and country Engine torque history Anti-theft request Anti-theft status Auxiliary A/D counts Immobilizer security Reserved for text message acknowledged Reserved for text message to display Reserved for text message display type Speed sensor calibration Total fuel used (natural gas) Total idle fuel used (natural gas) Trip fuel (natural gas) DGPS differential correction Unit number (power unit) Software identification Total idle hours Total idle fuel used Vehicle identification number Velocity vector Vehicle position Change reference number Tire pressure by position Tire temperature by position Component identification Trip distance Total vehicle distance

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IC500 / IC600 Instruction Manual Engine diagnostic codes 246 247 248 249 250 251 252 253 254 255

256 (0) 257(1) 258(2) 259(3) 260-361 362(106) 363(107) 364(108) 365(109) 366(110) 367(111) 368(112) 369(113) 370(114) 371(115) 372(116) 373(117) 374(118) 375(119) 376(120) 377(121) 378(122) 379(123) 380(124) 381(125) 382(126) 383(127) 384(128) 385-405 406(150) 407(151) 408(152) 409(153) 410(154) 411(155) 412(156) 413(157)

Version 2.5

Appendix 2 / 6 (8)

Total vehicle hours Total engine hours Total PTO hours Total engine revolutions Total fuel used Clock Date Elapsed time Special parameters Data link escape Extension Single data character length parameters (modulo 256 value identified in parentheses) Request parameter Cold restart of specific component Warm restart of specific component Component restart response Reserved (page 2) to be assigned Percent exhaust gas recirculation valve # 2 position Hydraulic retarder control air pressure HVAC unit discharge temperature Weighing system status command Engine oil level high/low Lane tracking system status Lane departure indication Distance to rear object (reverse) Trailer pneumatic brake control line pressure Trailer pneumatic supply line pressure Remote accelerator Center rear drive axle temperature Alternator AC voltage Fuel return pressure Fuel pump inlet vacuum Compression unbalanced Fare collection unit status Door status Articulation angle Vehicle use status Transit silent alarm status Vehicle acceleration Double data character length parameters Component-specific request Reserved (page 2 ) -to be assigned HVAC blower motor speed Axle group full weight calibration Axle group empty weight calibration Axle group weight Extended range road surface temperature Recirculated engine exhaust gas differential pressure Recirculated engine exhaust gas temperature Net vehicle weight change

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IC500 / IC600 Instruction Manual Engine diagnostic codes 414(158) 415(159) 416(160) 417(161) 418(162) 419(163) 420(164) 421(165) 422(166) 423(167) 424(168) 425(169) 426(170) 427(171) 428(172) 429(173) 430(174) 431(175) 432(176) 433(177) 434(178) 435(179) 436(180) 437(181) 438(182) 439(183) 440(184) 441(185) 442(186) 443(187) 444(188) 445(189) 446(190) 447(191) 448(192) 449(193) 450(194) 451-497 498(242) 499(243) 500(244) 501(245) 502(246) 503(247) 504(248) 505(249) 506(250) 507(251) 508(252) 509(253)

Version 2.5

Appendix 2 / 7 (8)

Air conditioner Refrigerant low side pressure Air conditioner refrigerant high side pressure Evaporator temperature Gross vehicle weight Transmission # 2 oil temperature Starter circuit resistance Starter current (average) Alternator/generator negative cable voltage Auxiliary current Extended range net battery current DC voltage Auxiliary frequency Alternator/generator field voltage Battery resistance change Battery internal resistance Starter current peak Starter solenoid voltage Starter negative cable voltage Starter motor voltage Fuel shutoff solenoid voltage AC voltage Cargo ambient temperature (by location) Trip sudden decelerations Trailer # 2, tag # 2, or push channel # 2 tire pressure target Trailer # 2, tag # 2, or push channel # 2 tire pressure Extended range boost pressure # 1 Extended range boost pressure # 2 Auxiliary temperature # 1 Auxiliary temperature # 2 Auxiliary gage pressure reading # 2 Battery # 2 potential (voltage) Cylinder head temperature bank B (right bank) Cylinder head temperature bank A (left bank) Passenger counter Variable and long data character length parameters Page 2 multisection parameter Reporting interval request Bridge filter control Reserved (page 2) -to be assigned Send keypress command Driver interface unit (DIU) object/form command Intersection preemption status and configuration Signage message Fare collection unit - point of sale Fare collection unit - service detail Annunciator voice message Vehicle control head keyboard message Vehicle control head display message Driver identification Transit route identification Mile post identification

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IC500 / IC600 Instruction Manual Engine diagnostic codes

Appendix 2 / 8 (8)

Special parameters 510(254) Page 2 data link escape 511(255) Page 2 extension (1) = these PIDs are superseded by PIDs 194, 195 and 196

FMI (Failure Mode Identifier) 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 – 30 31

Version 2.5

Data valid but above normal operational range - most severe level Data valid but below normal operational range - most severe level Data erratic, intermittent or incorrect Voltage above normal or shorted to high source Voltage below normal or shorted to low source Current below normal or open circuit Current above normal or grounded circuit Mechanical system not responding or out of adjustment Abnormal frequency or pulse width or period Abnormal update rate Abnormal rate of change Root cause not known Bad intelligent device or component Out of calibration Special instructions Data valid but above normal operating range - least severe level Data valid but above normal operating range - moderately severe level Data valid but below normal operating range - least severe level Data valid but below normal operating range - moderately severe level Received network data in error Reserved for SAE assignment Not available or condition exists

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IC500 / IC600 Instruction Manual I/O List

Appendix 3 / 1 (7)

Input/Output List

HUB Input/Output data

Terminal/no = explanation XH4/1 = +24V (System supply) XH4/2 = +24V (System supply) XH4/3 = Not in use XH4/4 = Not in use XH4/5 = Not in use XH4/6 = Not in use XH4/7 = Not in use XH4/8 = Not in use XH4/9 = Ground XH4/10 = Ground XH4/11 = Emergency stop, service platform XH4/12 = Emergency stop, control panel XH4/13 = Emergency stop, engine module XH4/14 = Emergency stop, hydraulic module XH4/15 = BSL XH4/16 = CAN2 H XH4/17 = CAN2 L XH4/18 = RS485 H XH4/19 = RS485 L XH4/20 = Not in use XH4/21 = Not in use XH4/22 = Ref + XH4/23 = Ref -

Terminology: AI = Analog input AO = Analog output PI = Pulse input FB = Feedback O/ = Output O-PWM = Pulse Width Modulation output BSL = Boot sequence line

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Appendix 3 / 2 (7)

DCM Input/Output data

Terminal/no = explanation XM1/1 = O/Primary feeder authorization pause XM1/2 = O/ Dust removal unit vibrator XM1/3 = O/ Dust removal unit fan XM1/4 = Key switch on start position XM1/5 = Not in use XM1/6 = Not in use XM1/7 = Process start button XM1/8 = Process stop button XM1/9 = Ground XM1/10 = Ground XM1/11 = Ground XM1/12 = Fuel level sensor /AI XM1/13 = (+24 V) XM1/14 = Metal detector alarm XM1/15 = O/ screen support legs up XM1/16 = O/Crusher running XM1/17 = Not in use XM1/18 = Sound alarm horn XM1/19 = Not in use XM1/20 = Radio operation selected XM1/21 = Feeder support legs are down XM1/22 = O/Primary feeder authorization XM1/23 = Lifting conveyor safety switch

XM2/1 = Hydraulic hammer operating switch XM2/2 = Not in use XM2/3 = Not in use XM2/4 = Not in use XM2/5 = Secondary LT level, feeder paused XM2/6 = Secondary LT level, feeder stopped XM2/7 = Fuse indicator 1 XM2/8 = Fuse indicator 2 XM2/9 = Secondary LT connected XM2/10 = Feeder speed + (service platform) XM2/11 = (+24 V) XM2/12 = Feeder speed – (service platform) XM2/13 = Ground XM2/14 = Ground XM2/15 = Ground XM2/16 = Feeder start (service platform)

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Appendix 3 / 3 (7)

XM2/17 = Feeder stop (service platform) XM2/18 = Setting increase (service platform) Feed funnel down (service platform) XM2/19 = Setting decrease (service platform) Feed funnel up (service platform) XM2/20 = Crusher off (service platform) XM2/21 = Crusher on (service platform) XM2/22 = Crusher swing normal direction (service platform) XM2/23 = Crusher swing reverse direction (service platform

XM3/1 = +12 V XM3/2 = +5 V XM3/3 = Ground XM3/4 = Ground XM3/5 = Drive box right track forward XM3/6 = Drive box left track forward XM3/7 = Drive box right track backward XM3/8 = Module identification /AI XM3/9 = +12 V XM3/10 = +5 V XM3/11 = Ground XM3/12 = Ground XM3/13 = Drive box left track backward XM3/14 = Crusher setting sensor /AI XM3/15 = BSL XM3/16 = Crusher speed /PI XM3/17 = Crusher level high XM3/18 = Lifting conveyor rotation detector XM3/19 = Drive box engine rpm + XM3/20 = Drive box engine rpm – XM3/21 = Drive box connected XM3/22 = Drive box remote stop XM3/23 = Not in use


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Appendix 3 / 4 (7)

ECM Input/Output data

Terminal/no = explanation XM1/1 = O/ Flash alarm XM1/2 = O/ Vibration chute XM1/3 = O/ Distribution gearbox “choke” XM1/4 = By pass conveyor electric motor protective switch ok XM1/5 = FB/ Engine cooler control XM1/6 = Not in use XM1/7 = Generator voltage protection circuit alarm XM1/8 = Air filter condition XM1/9 = Ground XM1/10 = Ground XM1/11 = Ground XM1/12 = AI / Cone crusher analog / digital cavity level XM1/13 = (+24 V) XM1/14 = O/ Lubrication tank oil temperature ok. / Return conveyor XM1/15 = O/ HP crusher XM1/16 = O/ HP crusher soft start XM1/17 = Not in use XM1/18 = Counter shaft pressure XM1/19 = Lubrication oil level XM1/20 = Not in use (RADIO) XM1/21 = Electric driven lubrication pump protective switch ok XM1/22 = Side conveyor electric motor protective switch ok XM1/23 = Return conveyor electric motor protective switch ok

XM2/1 = O/ Crusher speed normal direction (current in mA) O/ Impact crusher hydraulic pump valve ………….O/ distribution gearbox clutch valve XM2/2 = O/Crusher speed reverse direction (current in mA) O/Impact crusher hydraulic adjust motor valve XM2/3 = FB/Crusher speed both directions (current in mA) FB/Impact crusher hydraulic pump valve XM2/4 = FB/Impact crusher hydraulic adjust motor valve XM2/5 = O/Engine start XM2/6 = O/Engine stop solenoid XM2/7 = O/Horn XM2/8 = Generator frequency alarm XM2/9 = Generator thermistor alarm XM2/10 = O/ hydraulic cooler fan / lubrication oil cooler fan XM2/11 = (+24 V) XM2/12 = Hydraulic oil temperature /AI XM2/13 = Ground XM2/14 = Ground XM2/15 = Ground XM2/16 = Hydraulic oil filters

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Appendix 3 / 5 (7)

XM2/17 = Hydraulic oil level XM2/18 = Hydraulic oil main valve XM2/19 = Clamping pressure switch XM2/20 = Release pressure switch XM2/21 = Distribution gearbox clutch pressure switch XM2/22 = PWM / Engine cooler control XM2/23 = O/ cone crusher lubrication pump

XM3/1 = +12 V XM3/2 = +5 V XM3/3 = Ground XM3/4 = Ground XM3/5 = Cone crusher lubrication tank oil temperature XM3/6 = Crusher pressure /AI XM3/7 = Cone crusher lubrication oil return oil temperature XM3/8 = Module identification /AI XM3/9 = +12 V XM3/10 = +5 V XM3/11 = Ground XM3/12 = Ground XM3/13 = AI/ Distribution gearbox clutch pressure XM3/14 = Not in use XM3/15 = BSL XM3/16 = PI/ crusher speed XM3/17 = PI/ Cone crusher setting sensor A XM3/18 = PI/ Cone crusher setting sensor B XM3/19 = PI/ Crusher drive shaft speed XM3/20 = PI/ Speed of hydraulic driven lubrication pump XM3/21 = Vibrating chute motor protective switch ok XM3/22 = Hydraulic pump safety device XM3/23 = Electric driven lubrication oil cooler fan motor protective switch ok


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Appendix 3 / 6 (7)

HCM Input/Output data

Terminal/no = explanation XM1/1 XM1/2 XM1/3 XM1/4 XM1/5 XM1/6 XM1/7

= O/Screen hydraulic valve CW (clockwise) = O/Screen hydraulic valve CCW (counter-clockwise) = O/Screen conveyors hydraulic valve = Side conveyor safety switch, right side = Not in use = Not in use = O/LS pressure discharge valve O/Impact magnetic separator or side conveyor on XM1/8 = O/Hydraulic power take off (PTO) valve XM1/9 = Ground XM1/10 = Ground XM1/11 = Ground XM1/12 = Not in use XM1/13 = (+24 V) XM1/14 = O/Hand valves hydraulic valve XM1/15 = O/Main conveyor hydraulic valve XM1/16 = O/Magnetic separator hydraulic valve XM1/17 = O/Side conveyor hydraulic valve XM1/18 = Screen module connected XM1/19 = Screen module safety switch, oversize conveyor XM1/20 = Screen module safety switch, undersize conveyor XM1/21 = Side conveyor safety switch, left side XM1/22 = Main conveyor safety switch, right side XM1/23 = Main conveyor safety switch, left side

XM2/1 XM2/2 XM2/3 XM2/4 XM2/5

= O/Fast track drive hydraulic valve = O/Scalper / Lifting conveyor = Not in use = Not in use = O/Feeder valve power-line O/Impact funnel up with scalper valve power-line XM2/6 = O/Left track valve power-line XM2/7 = O/Right track valve power-line XM2/8 = O-PWM/Feeder control value O-PWM/Impact funnel up with scalper control value ………….O/ PWM LC feeder XM2/9 = O-PWM/Left track control value XM2/10 = O-PWM/Right track control value XM2/11 = (+24 V) XM2/12 = AI/ Hydraulic oil temperature circuit #2 XM2/13 = Ground XM2/14 = Ground XM2/15 = Ground

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XM2/16 = O/ Setting increase hydraulic valve O/ Impact funnel up if not scalper ………….O/ return conveyor XM2/17 = O/Setting decrease hydraulic valve …………..O/ by pass conveyor XM2/18 = Conveyors maintenance switch XM2/19 = Not in use XM2/20 = Not in use XM2/21 = Hand valves XM2/22 = O/Clamping cylinder – pressurize, hydraulic valve XM2/23 = O/Clamping cylinder – unpressurize, hydraulic valve …………..PWM / Lifting conveyor

XM3/1 = +12 V XM3/2 = +5 V XM3/3 = Ground XM3/4 = Ground XM3/5 = Belt scale /AI (FUTURE PLAN) XM3/6 = Toggle pressure /AI (FUTURE PLAN) …………..AI / Feed hopper level sensor XM3/7 = AI/ Component pump pressure XM3/8 = Module identification XM3/9 = +12 V XM3/10 = +5 V XM3/11 = Ground XM3/12 = Ground XM3/13 = Not in use XM3/14 = Clamping pressure /AI XM3/15 = BSL XM3/16 = Feeder speed /PI XM3/17 = Main conveyor speed /PI XM3/18 = Toggle plate condition XM3/19 = PI/ Screen discharge conveyor speed XM3/20 = Return conveyor safety switch XM3/21 = Impact crusher cover open limit switch / by pass conveyor safety switch XM3/22 = Lifting conveyor feeder motor protective switch ok XM3/23 = Not in use


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Instruction Manual LT1213 With IC Contol

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