Manual R900 With Mondial & CAT 7.0

Impact Crusher R900 - Manual
Serial number:
Page 0
CONTENT:
I Preface I. P f II. Intended use III Safety Safety hazard symbols p g instructions Operating Maintenance work IV.Technical data Overview Building groups V. Start up V Operation devices Transport System set up Gap adjustment VI. Operation VI O ti Special operating information Procedure crusher operation VII. Maintenance Hydraulic system Di Diesel l motor t Vibration feeder Caterpillar crawler Crawler gear Conveyor belts V belts V-belts Impact crusher Welding preparations Oil level monitor Service plan Recommended oil qualities VIII. Standard forms Rockster warranty registration CAT warranty registration Warranty claim Terms and conditions Sid 2 Side Side 4 Side 6 Side 7 Side 13 Side 24 Side 26 Side 27 Side 28 Side 34 Side 35 Side 41 Side 43 Side 46 Sid 48 Side Side 49 Side 51 Side 53 Side 54 Sid 56 Side Side 56 Side 57 Side 57 Side 58 Side 59 Side 59 Side 60 Side 63 Side 65 Side 67 Side 68 Side 69 Side 70 Side 71 Side 72
CONTENT
R900 IMPACT CRUSHER
Page 1
CONTENT:
I Preface I. P f II. Intended use III Safety Safety hazard symbols p g instructions Operating Maintenance work IV.Technical data Overview Building groups V. Start up V Operation devices Transport System set up Gap adjustment VI. Operation VI O ti Special operating information Procedure crusher operation VII. Maintenance Hydraulic system Di Diesel l motor t Vibration feeder Caterpillar crawler Crawler gear Conveyor belts V belts V-belts Impact crusher Welding preparations Oil level monitor Service plan Recommended oil qualities VIII. Standard forms Rockster warranty registration CAT warranty registration Warranty claim Terms and conditions Sid 2 Side Side 4 Side 6 Side 7 Side 13 Side 24 Side 26 Side 27 Side 28 Side 34 Side 35 Side 41 Side 43 Side 46 Sid 48 Side Side 49 Side 51 Side 53 Side 54 Sid 56 Side Side 56 Side 57 Side 57 Side 58 Side 59 Side 59 Side 60 Side 63 Side 65 Side 67 Side 68 Side 69 Side 70 Side 71 Side 72
I PREFACE I.
R900 IMPACT CRUSHER
I. PREFACE
Page 2
PREFACE:
This Operator's Manual applies for the track-mounted crushing plants R900 manufactured by Kormann Rockster Recycler GmbH. The crushers are designed for the processing of virgin stone and recycling material. The technical specifications, p , drawings, g ,p photos, , and other information contained in this manual are non-binding g and may be changed, revised or updated due to further technical developments at any time without obligation. The machine owner/operator is responsible to supplement the information contained in this manual with any and all applicable local guidelines and regulations for safety prevention and environmental protection. This Operator's Manual must be available and accessible at the operation site at all times. All persons who operate, maintain, repair or transport the crusher plant must first read and understand this Operator's Manual and must conscientiously observe and follow the guidelines and regulations herein.
Manufacturer: Kormann Rockster Recycler GmbH Wirtschaftszeile West 2, 4284 Ennsdorf / Austria Phone: +43 (0) 7223 81000 Fax: +43 (0) 7223 81000-329 e-Mail: office@rockster.at Homepage: www.rockster.at
I. PREFACE
Page 3
CONTENT: INHALTSVERZEICHNIS:
I Preface I. P f II. Intended use
Sid 2 Side Side 4
I. Vorwort III Safety

Safety hazard symbols
Seite 2 Side 6
Side 7
II. Verwendungszweck p g instructions Operating III. Sicherheit IV.Technical data Sicherheits/Gefahrensymbole Overview Betriebsanleitung Building groups Wartungsarbeiten
V Start up V. Operation devices IV. Technische Daten Transport berblick Baugruppen System set up Gap adjustment Maintenance work
Seite 4 Side 13 Seite 6 Side 26 Seite 7 Side 27 Seite 13 Side Seite 28 24

Side 34 Side 35 Seite 26 Side 41 Seite 27 Seite 28 Side 43 Side 46 Side 24
V. Inbetriebnahme VI Operation VI. O ti Bedienelemente Special operating information Transport Procedure crusher operation Aufstellen der Anlage VII. Maintenance Spaltverstellung
Hydraulic system
Seite 34 Sid 48 Side Seite 35 Side 49 Seite 41 Side 51 Seite 43 Side 53 Seite 46
Side 54
VI. VI B lt motor i b Seite S it 56 48 Di Betrieb Diesel t Sid Side Besondere Betriebshinweise Seite 49 Vibration feeder Side 56 Vorgangsweise Brecherbetrieb Seite 51 Caterpillar crawler Side 57
Crawler gear Side 57
II INTENDED USE II.

R900 IMPACT CRUSHER
II. INTENDED USE
Page 4
VII. Wartung Conveyor belts Hydraulikanlage V belts V-belts Diesel Impact Motor crusher Vibrationsrinne Welding preparations Laufwerk Oil level monitor Laufwerksgetriebe Service plan Frdergurte Recommended oil qualities Keilriemen VIII. Standard forms Prallbrecher Rockster warranty registration lstandskontrolle CAT warranty registration Wartungsplan Warranty claim Schmiermittelbersicht
Terms and conditions
Seite 53 Side 58 Seite 54 Side 59 Seite 56 Side 59 Seite 55 Side 60 Seite 56 Side 63 Seite 56 Side 65 Seite 58 Side 67 Seite 59 Side 68 Seite 59 Side 69 Seite 60 Side 70 Seite 62 Side 71 Seite 64
Side 72
INTENDED USE:
The machine is constructed in compliance with prevailing technical standards and safety regulations. Nonetheless, the operation or use of the machine may be connected with hazards which may endanger personal safety or lead to material damage to the machine and/or other objects objects. Operate the machine only in good order and condition and only in the intended manner of use. Observe all safety regulations and accident-prevention guidelines according to this Operator's Manual and applicable local regulations. Circumstances or technical defects which may pose a threat to operational safety must be immediately remedied or repaired. The machine is intended solely for the purpose of crushing, screening, or sorting recycling material. Use of the machine for any other purpose is contrary to the manufacturer's intended purpose. The manufacturer/dealer is not liable for damages arising from such contrary use. The customer/operator assumes sole risk and responsibility for costs and damages which may result from such contrary use. Use of the machine according to the manufacturer's intended purpose explicitly includes the observation of and compliance with all parts of the Operator's Manual and the adherence to inspection and maintenance regulations.
II. INTENDED USE
Page 5
Sid 2 Side Side 4

Seite 2 Side 6
Side 7

Hydraulic system
Side 54
III SAFETY III.

R900 IMPACT CRUSHER
III. SAFETY
Page 6
Side 72
SAFETY HAZARD SYMBOLS:
Many of the following symbols appear frequently in these operating instructions; they call special attention to hazardous situations which may arise when operating the machine.
Danger of entrapment. Do not reach into open machinery. Entrapment may cause serious or fatal injuries. Body parts can be drawn in and crushed or torn. Be sure that all machinery has come to a complete standstill before opening or removing protective covers. covers Keep in mind the necessary run-down time for rotating/sliding/reciprocating machinery (rotor, jaws, belt pulleys, V-belts, flywheel, vibro plate, pre-screener, centrifugal weights, etc.).
Danger of entrapment. Do not reach into open machinery. Entrapment in rotating parts may cause serious or fatal injuries. Body parts can be drawn in and crushed or torn. Be sure that all machinery has come to a complete standstill before opening or removing protective covers. Ignition key and battery switch have to be pulled off, the machine has to be protected against start-up by external persons.
III. SAFETY
Page 7
SAFETY HAZARD SYMBOLS (continued):
Crush hazard. Caution is required at points where hands and/or feet can be crushed. Never use feet, hands, fingers, or other body parts to support or hold machine parts. Always use the provided anchors and/or mechanical supports.
Danger of falling/flying material. Do not enter loading/discharging zones. Doing so may cause serious or fatal injuries. A hard hat must be worn in the immediate vicinity of the machine.
Personal hearing protection must be worn.
III. SAFETY
Page 8

Wide or loose clothing may be drawn into or caught in moving machinery. Wear EN/ANSI tested, correctly fitting protective clothing. Personal protective gear includes hard hat, goggles, hearing protection, close-fitting overalls, steel-toed boots, flourescent safety vest and protective gloves. Do not wear jewellery.
The operator's manual must be read and understood before operating the machine. Read and observe the various warning symbols on the machine. Only specially schooled and trained personnel may operate or work with the machine.
Turn off the motor and remove the key from the ignition before beginning maintenance or adjustment work. Ignition key and battery switch have to be pulled off, the machine has to be protected against start-up by external persons. The key and battery switch must be kept on your person during maintenance or repair work. We recommend, to never work alone.
III. SAFETY
Page 9

Danger of falling: do not climb onto or stand on the machine when it is moving or in operation. Only use the intended upward mobility ladder ladder on the catwalk. catwalk . An appropriate work platform with fall protection must be used when working at heights exceeding 2 m.
Danger of burning or scalding: beware of hot machinery or exhaust parts.
Beware of escaping hydraulic oil. Pressurized hydraulic oil can penetrate the skin and lead to poisoning. The system must be depressurized before beginning maintenance or adjustment work. If hydraulic oil has penetrated the skin it must be surgically removed removed. Seek professional medical care immediately immediately.
III. SAFETY
Page 10
Personal safety hazard: acids acids, chemicals chemicals, und caustic fluids fluids.
Personal safety safet ha hazard: ard magnetic field field. Do not allow persons with pacemakers or other electronic medical devices to enter the danger zone.
Personal safety hazard: electrical current. Danger of serious or fatal injuries. Never perform work on the electrical system if you are not thoroughly familiar with all technical details and specifications. Only qualified electricians may perform work on the electrical system.
III. SAFETY
Page 11
These symbols call attention to various regulations and prohibitions to prevent damage and avoid hazardous situations, as well as highlight special manufacturer's instructions for correct machine operation.
III. SAFETY
Page 12
OPERATING INSTRUCTIONS:
The operating instructions must always be within easy access at the site of operation of the machine. Universally applicable statutory and other binding regulations/laws concerning accident prevention and environmental protection (supplementary to the operating instructions) must be observed/complied with. These obligations can also concern handling hazardous materials; or providing and wearing protective equipment as well as road transport regulations. The operating instructions must be supplemented by instructions including supervisory and reporting obligations with regard to special operational circumstances, for example with reference to workflows, work organisation, staff employed etc. All persons authorised for work on the machine must have read and understood the operating instructions before commencing work. This applies in particular for individuals who only occasionally work with the machine, for example during maintenance or assembly work on the machine. Regularly check that the personnel are working with an awareness of the safety and hazard aspects in compliance with the operating instructions. instructions All safety and hazard indications must be easily visible and legible and must be observed. Damaged safety and hazard indications have to be replaced immediately. Removal of the safety and hazard instructions from the system is strictly prohibited. Personnel must tie back long hair and may not wear loose clothing or jewellery (also rings). There is risk of injury, for example, if the hair or clothing becomes caught or pulled into the machine. Personnel authorised for work on the machine are personally responsible for compliance with the regulations.
III. SAFETY
Page 13
OPERATING INSTRUCTIONS (continued):
Personal protective equipment must be worn in compliance with the regulations to the extent necessary. In the event of changes to the operating state of the machine (insofar as these are safety-relevant), safety-relevant) the system must be stopped and brought to a standstill and the fault reported to the person responsible; the latter must immediately rectify the fault or have it rectified, and return the system to its correct operating state. No changes and assembly or conversion work may be carried out on the machine without authorisation by the manufacturer. This applies in particular for mechanical, electrical and hydraulic safety devices as well as for welding work on load-bearing components.
Replacement and wearing parts must correspond to the technical requirements specified by the manufacturer. This is always guaranteed for original and wearing parts. Specified schedules and/or those cited in the operating instructions for recurrent tests must be adhered to.
III. SAFETY
Page 14
OPERATING PERSONNEL:
Operating personnel must be instructed in correct and safe operation of the system and its accompanying accessories. Work on/with the machine may only be carried out by reliable, trained and instructed personnel who have experience in working with machines. Observe the statutory minimum age. Clearly specify areas of responsibility for personnel in regard to operation, assembly, maintenance, commissioning etc. Ensure that only authorized personnel work on the machine. Also specify responsibilities for machine transportation drivers in respect to road-transport road transport regulations, and ensure that drivers do not receive instructions contrary to safety by third parties. Personnel who are to be trained or instructed or who are currently receiving general training may only work on the machine under continuous supervision by an experienced person. Work on the electrical system of the machine may only be carried out by qualified electricians or by instructed personnel under the guidance and supervision of a qualified electrician in accordance with the regulations concerning electrical engineering. Work on the hydraulics of the machine may only be carried out by personnel with specialist knowledge of hydraulic systems.
III. SAFETY
Page 15
BEFORE COMMENCING WORK OPERATING PERSONNEL MUST: ...be instructed in the work to be performed by means of a specialist training. be be advised of the dangers dangers. ...check all safety relevant covers and casings on their correct position ...be informed about safety functions, like f.i. the EMERGENCY OFF switch, in order to be able to use th them in i any case of f emergency. be familiar with all moving parts of the system, in order to beware of these. ...have read and understood the operating instructions together with all warning/safety instructions in the operating instructions as well as all other safety-relevant warning/safety instructions for the product. ...take sufficient time to examine in detail and become familiar with the warning instructions, th i significance their i ifi and d consequence.
III. SAFETY
Page 16
HYDRAULIC SYSTEMS AND THEIR COMPONENTS:
Only persons with special knowledge and experience may work on the hydraulic units. Return all control valves to the neutral position (discharge system pressure). Switch off the motor before disconnecting or removing hydraulic pipes, tank covers, hydraulic filters or couplings. Disconnect the power supply. Replaced hydraulic components must correspond to the same standard and quality. Ensure that the parts are correctly mounted.
Beware of leaking hydraulic pipes. Pressurized hydraulic oil can penetrate through the skin or cause injury to the eyes. Leaks in pressure pipes may not be visible to the naked eye. Never check leaks with your hands or fingers. Use an aid, such as cardboard for example.
Always y wear g goggles. gg If hydraulic y oil comes into contact with the eyes, y seek medical advice immediately. y Immediately replace defective hydraulic pipes. Fires can result from leakages. Ensure that the replaced hydraulic pipes correspond to the specifications of the original. Ensure that the hydraulic pipes are correctly mounted and laid. Never exceed safety y limits. Never set overpressure p valves higher g than the default settings. g
III. SAFETY
Page 17
ELECTRICAL SYSTEMS AND MOTORS:

In case of electric incidents of safety relevant components, immediately switch off the diesel engine, the battery switch and protect the machine against re-start by external persons. Never carry out work on the electrics of any components without familiarizing yourself with these. Only qualified electricians may carry out work on the electrical system of the machine. If work on the live parts is necessary, a second person must be present who can operate the EMERGENCY OFF or main switch with shunt release in the event of an emergency. emergency Only use voltage voltage-insulated insulated tools tools. Electrical equipment within the system must be checked regularly. Damaged cables or loose connections must be repaired immediately. Use original fuses of the specified length and power. Lead L d connections ti or connections ti containing t i i l lead d are contained t i di in th the b battery tt poles l and d accessories. i Th These materials are carcinogenic. Observe the manufacturers instructions of the battery. Always wash your hands. Never short-circuit the battery poles. A short-circuit can cause fires and damage the electrical system. Battery acid can cause injuries. Avoid contact with the skin or eyes. Always wear gloves and goggles. Exhaust gases contain harmful combustion products. Work with the system in an open environment or divert the exhaust h gases i into the h open air. i Do not touch the motor and exhaust parts. Give the motor and exhaust system sufficient time to cool down before starting maintenance and repair work. Never refuel while the motor is running. Do not smoke while refuelling. Ensure that there are no exposed light sources in the vicinity. Do not spill any fuel or completely fill the tank. Spilt fuel must be removed properly and immediately.
III. SAFETY
Page 18
MAGNETIC FIELDS: There is a risk of magnetic radiation in systems which are equipped with magnetic separators. This affects: o Persons with heart pacemakers o Electronic devices o Electronic storage media Entry into the hazard zone can cause damage to health or irreparable damage to electronic appliances. Personnel must be informed of these hazards accordingly during instruction instruction. Explain this hazard to persons outside the company. Keep persons with heart pacemakers away from the system.
DUST, VAPOUR AND SMOKE: Grinding, burning or welding work may only be carried out on the machine if this is expressly authorized (danger of explosion). Clean the system and its environment of dust and flammable substances and ensure sufficient ventilation before burning welding or grinding (danger of explosion) burning, explosion). Safety guards must be fitted on the devices so that dust/materials cannot harm the machine user or persons in the immediate surroundings. Ensure that no dust enters the air when loading, adjusting or removing the material to be crushed. Recommended procedures for eliminating dust are: o Dust protection and dust extraction o Dust removal with water
III. SAFETY
Page 19
NOISE: The noise protection equipment must be in the protective position during operation. Wear the specified personal ear protection.
OILS, GREASES AND OTHER CHEMICAL SUBSTANCES: Observe the safety regulations applicable for the product when working with oils, greases and other chemical substances. Caution when working with hot operating and process materials (burning or scalding hazard).
BLASTING: The use of wireless remote control is strictly yp prohibited even during gp preparation p work for blasting. g Acute danger g of explosion. The use of a wireless remote control device is prohibited during blasting owing to the danger of explosion. The machine must be removed from the hazard zone before blasting blasting. Ensure that no explosive material can enter the system.
III. SAFETY
Page 20
FIRE FIGHTING:
If the slightest signs of fire occur, proceed as follows, depending on the situation: o o o o o o o Warn persons who are in the vicinity. Shut down the machine. Turn off the power with the main switch. Ensure that there is no hazard for persons, and lead everyone in the vicinity to a safe place. Begin fire fighting and, if necessary, call the fire brigade. Remove the machine from the hazardous area, if possible. Fire fighting.
If the unit has already caught fire, proceed as follows, depending on the situation: o o o o o Turn off the machine. Warn persons who are in the vicinity. seek shelter Ensure that there is no hazard for persons, and lead everyone in the vicinity to a safe place. Call the fire department, firefighting
III. SAFETY
Page 21
OPERATING THE SYSTEM: Only specialists or trained/instructed personnel may operate the system. Refrain from carrying out any work steps that may pose a risk to safety. Before positioning the machine and bringing it into operating position, the work environment must be carefully checked for possible obstructions. The load bearing capacity of the ground and traffic arrangement must also be checked. The operating instructions must have been read and understood before commissioning. Several labels are on the system; spare some time to become familiar with the warning instructions. Note that the system has sharp corners and edges as well as rough surfaces in part. Check and ensure that all system parts are fully functional. o o o Check for defective and missing parts. Immediately repair or replace these parts. Ensure that all paneling is always correctly mounted and that all EMERGENCY OFF switches are functioning. Daily maintenance work must be carried out in accordance with the service plan. For a detailed list, see the service plan plan.
Walk round the machine before starting work, and ensure that no person(s) are on or under the system or in its vicinity or in danger areas. All persons who are in the immediate environment are to be informed if the system is to be started. Only start the machine if no persons are on or under the system or in its vicinity. All doors must be closed and locked. Keep all handles, steps, railings, platforms, stages and ladders free of dirt, in particular ice, snow, oils and greases. Never climb onto, over and/or under running conveyor belts. Always use the ascending aids and catwalks designed and provided for this this. The belt and chain tension must never be checked while the system is running.
III. SAFETY
Page 22
OPERATING THE SYSTEM (continued): Do not work or linger in the vicinity/environment of system parts; these can rise or lower. Never stay in the loading or unloading zone as long as the system is being loaded or unloaded. Always wear a protective helmet, for example as protection against stones falling/flying from the machine. Always observe all safety regulations. Operate all buttons and levers gently. Avoid jerky movements or sudden changes in direction. Only press EMERGENCY OFF switches in emergencies or during safety exercises. Check the machine for external signs of damages and defects at least once per shift. Immediately report changes that may have occurred to the person responsible. If required, immediately switch off the machine. The system must be shut down if malfunctions occur. Faults must be rectified immediately. On and off switching gp processes as well as monitoring g displays p y must be observed in accordance with the operating p g instructions. Parts of the power transmission system, such as the pulley of the drive shaft, flywheels, switches, V-belt pulley, V-belts etc, must be provided with safety guards so that nobody is endangered by rotating parts. Never remove material blockages if the machine is running. Before ending work, it must be ensured that the feeding hopper, crusher feed and conveyor belts are free of material. Never leave material on the machine. Otherwise the system will be overloaded on restarting.
III. SAFETY
Page 23
MAINTENANCE WORK: Only specialists or trained/instructed personnel may operate the system. Maintenance and repair work should always be carried out by at least two persons. We recommend to never work alone. alone Take personal safety precautions. Always wear a helmet, goggles, ear protection and other requisite protective equipment. Do not wear wide and baggy clothing and jewellery. This can become caught and/or pulled into the machine. Tie back long hair.
Move the system to an even and firm surface. Turn off the motor and remove the starter key. Depressurise the hydraulics. Secure hydraulic components. Disconnect the power supply before commencing maintenance work. Never carry out adjustment or repair work while the motor is running. Pay attention to the overrun of rotating parts. Only remove panelling which actually blocks access. Remove oil or grease that has escaped. Never leave the system unattended if the panelling is removed and the housing is open. Keep bystanders away from the system. Raised system parts must always be properly secured. Never work below system parts that have not been secured. If you are working at a height over than 2 m, you must wear an EN/ANSI tested safety harness. Use the catwalks, work platforms or other such safety (EN/ANSI) tested ascending aids and work platforms. provided for this. Do not use ascending aids or work platforms that have not been secured and/or approved.
III. SAFETY
Page 24
MAINTENANCE WORK (continued):
Only operate the motors in a well ventilated environment toxic hazard resulting from exhaust gases. Caution when looking for leakages in the hydraulic systems. systems Pressurized hydraulic oil can penetrate through the skin or cause injury to the eyes. Leaks in pressure pipes may not be visible to the naked eye. Never check leaks with your hands or fingers; use an aid, such as cardboard for example. Always wear goggles. If hydraulic oil comes into contact with the eyes, seek medical advice immediately. Damaged, illegible or missing warning signs must be replaced or cleaned. Special attention must be paid to the moving parts during maintenance work; these must be checked. Any damaged, worn or incomplete parts can fall out. This can lead to injury or death. Before finishing the maintenance work, all bolts, connections and joins must be tightened. All panelling must be mounted. Replace or repair damaged covers or panelling. Only fill or refill pressure systems with the specified fluids. fluids Start the motor and check for leakages leakages. Activate all control levers and ensure that the system functions correctly. After completing the tests, check the system for missing spring cotter pins, washers, lock nuts etc.. Check all fluid levels before starting work.
III. SAFETY
Page 25
Sid 2 Side Side 4

Seite 2 Side 6
Side 7

Hydraulic system
Side 54
IV TECHNICAL DATA IV.

R900 IMPACT CRUSHER
IV. TECHNICAL DATA
Page 26
Side 72
OVERVIEW: OVERVIEW
1. Crawler gear 2. Drive motor 3. Drive system 4. Feeding hopper 5. Vibration feeder 6. Pre-screening with reversible chute 7. Crusher cover 8. Impact crusher 9. Main discharge belt 10. Side discharge belt 11. Magnetic belt 12. V-belt protector 13. Panelling 14. Diesel tank 15. Hydraulic tank 16. Catwalk 17. Hydraulic switchbox 18. Electric switchbox 19. Remote control
IV. TECHNICAL DATA
Page 27
BUILDING GROUPS:
CRAWLER GEAR: The crusher system is mounted on a caterpillar crawler. The caterpillar crawlers are driven via a 2-stage gear which enables the system to move at two different speeds. The maximum hill climbing ability is 34. The chain tread consists of f 49 x 3 3-rib ib plates l t with ith 400 mm width. idth DRIVE MOTOR: Motor (Caterpillar 7.0/187 kW): see Caterpillar Manual g All filter and fluid displays p y are easily y accessible. The motor is housed in noise-insulated housing. COMBI-COOLER The blower wheel is mounted directly on the engine. The water cooler has an additional equalizing tank with a pressure control valve. OIL-COOLER The blower wheel is driven hydraulically and limited to 125 bar.
DRIVE SYSTEM: Both the hydrostat for the crusher as well as the hydraulic pump for the operating hydraulics are driven via a distributor gear unit which is flange-mounted on the drive motor.
FEEDING HOPPER: The feeding hopper is made from highly rear resistant Hardox 400 steel. The capacity of the feeding hopper is 4 m. VIBRATION FEEDER: The vibration feeder guarantees even material feeding into the hopper. It is lined with highly wear resistant Hardox 400 steel plates. The preliminary screening is integrated in the vibration feeder. The vibration feeder is driven via the vibration drive, which is driven hydraulically. The vibration feeder can be activated or deactivated using the hand lever or by remote control. The speed of the vibration feeder is controlled infinitely via a hydraulic valve.
IV. TECHNICAL DATA
Page 28
PRE-SCREENING WITH REVERSIBLE CHUTE:

The screening area of the preliminary screening is 1200 mm x 900 mm. The standard gap width of the zigzag grid is 32 mm. The pre-screened material can be directed onto the side belt via a reversible chute, or is directly y routed onto the main conveyor y at the crusher. The reversible chute is equipped with two side doors, to remove any blockages.
CRUSHER COVER:
Picture IV.1: Reversible chute
Picture IV.2: Reversible chute control lever
The crusher cover covers the crusher feed from above. The crusher cover serves for maintenance purposes only and may be opened only if the rotor is switched off and protected against rotation. It can be opened and closed hydraulically (by wireless remote control or manually) and serves as protection against falling/flying stones when closed with a chain screen and rubber skirt. An irrigation strip is integrated in the crusher cover. IMPACT CRUSHER R900: The impact crusher R900 has a 4-radial rotor and is equipped with 2 swing beams which can be adjusted hydraulically independently p y of each other. The g gap p widths of the upper pp impact p swing g can be hydraulically y y adjusted j from 0 to 170 mm, , he gap width of the lower impact swing from 0 to 100 mm. The rotor speed can be infinitely adjusted from 0 - 850 rpm and can be read on the display (page 37, picture V.3,item 10). In case of large raw material the adjusted rotor speed may not exceed 700 rpm (risk of hammer damage). A mechanical safety device prevents the rotor from twisting during maintenance work. The impact sphere diameter is 1020 mm. mm The hammer arms are available in the qualities standard standard, medium medium, hard and ceramic ceramic. The crusher housing can be unfolded hydraulically for maintenance purposes. Inspection doors are located on the side, which can be opened for maintenance purposes and inspecting the impact arms. ROTOR SPEED: The granulation of the final product as well as the wear behavior can be individually affected with the help of the rotor speed. The rotor speed can be set with the rotor speed adjustment button (see page 36, picture V.2: switchboard No 2).
Max. rotor speed: 750 rpm Higher rotor speed only after consultation with the producer
IV. TECHNICAL DATA
Page 29
MAIN DISCHARGE BELT: The main discharge conveyor is a solid steel construction with the dimensions: Length (centre line distance) Width (belt width) Height (discharge height) 7900 mm 1000 mm 3200 mm
The conveyor belt of the main discharge conveyor is located under the crusher where it is protected from impacts by SANPRO plates. The absorbing impact plates are fixed on rubber buffers (rubber mountings), which are additionally absorbing the impact effects. The conveyor belt is manufactured in RIP-STOP quality. The drive is hydraulic. The operating pressure is limited with 220 bar. The entire construction can be folded up hydraulically for transport purposes. Attention: Before folding release side belt (open tensioning spindle of driving drum). Retighten belt before operation and check that belt runs centrally, if necessary reset ! (see chapter VII Maintenance)
Attention: when changing the belt, make sure to use an original RIP-STOP-belt from the manufacturer. If using another belt with different qualities than the original, a smooth operation can not be guaranteed. Damages resulting from this will not be issues of warranty or guarantee.
IV. TECHNICAL DATA
Page 30
SIDE DISCHARGE BELT: The side discharge conveyor is a solid steel construction with the dimensions: Length (centre line distance) Width (belt width) Height (discharge height) 4100 mm 500 mm 2300 mm
The drive is hydraulic. The operating pressure is limited with 210 bar. The entire construction can be folded up hydraulically for transport purposes. Attention: Before folding, open safety screws, release side belt (open tensioning spindle of driving drum) and fix it with the transport safety screws. Before operation, tighten safety screws, retighten belt and check that belt runs centrally and, if necessary, Reset!
Picture IV.2: Safety screw
Picture IV.3: IV 3: Safety screw
IV. TECHNICAL DATA
Page 31
MAGNETIC BELT: The magnetic conveyor belt is mounted over the main conveyor belt. It separates all loose iron fragments from the crushed material and discharges the metallic impurities beside the main conveyor belt. The gap between the magnetic surface and material to be conveyed must be at least 200 mm. The magnetic conveyor belt should have around 25 mm of slack slack. Overtensioning can damage the bearings bearings. The drive is hydraulic. The operating pressure is limited with 80 bar. V-BELT PROTECTOR: The V-belt protector is a metal housing. The system must be shut down before checking or tensioning the V-belt. The V-belt protector and the side door must always be closed and secured after working on the V-belt.
PANELLING: The panelling on the crusher serves to provide operational safety and noise protection. It may only be opened and/or removed for maintenance and repair work. Crusher operation with dismounted panelling must be avoided at all times.
DIESEL TANK: The diesel tank is equipped with an electrical refuelling pump and is provided with a ventilation opening. This opening is covered with a filter cover. A diesel drain cock is located on the bottom of the diesel tank. The capacity is 330 liters.
IV. TECHNICAL DATA
Page 32
HYDRAULIC TANK: The hydraulic tank is fitted with an inspection glass,a level sensor and a temperature sensor. The level sensor switches off the vibration chute immediately if the level falls below the adjusted limit, the temperature sensor does the same, if the oil temperature is too high. Time-delayed (ca. 30 sec.) also the operating hydraulics switches off. The capacity is 420 liters. liters Upon filling the hydraulic tank, tank 10 cm must be left from the upper edge (hydraulic tank) to the liquid level level. On the underside of the tank a drain cock is located. CATWALKS: Catwalks serve for maintenance, revision and monitoring of the system. The catwalks are firmly attached to the system and do not have to be removed for transport. HYDRAULIC SWITCHBOARD: The most important manual valves for controlling the system are located in the hydraulic cabinet.
ELECTRICAL SWITCHBOARD: All the operating elements relevant to the user are located in the electrical cabinet. REMOTE CONTROLS: The wireless remote control can be used to move the machine, open/close the crusher cover, activate the hydraulic and activate/deactivate the vibration feeder. The system can also be operated with the cable remote control but only to move the machine. On both remote controls there are EMERGENCY-OFF switch.
IV. TECHNICAL DATA
Page 33
Sid 2 Side Side 4

Seite 2 Side 6
Side 7

Hydraulic system
Side 54
V START UP V.
R900 IMPACT CRUSHER
V. START UP
Page 34
Side 72
OPERATION DEVICES:
OPERATOR CONTROLS: The operator controls required for operation are individually described in the following: HYDRAULIC SWITCHBOARD: 1. Vibration feeder and side discharge belt 2. Main discharge belt 3. Side discharge belt - folding cylinder 4 Main discharge belt - folding cylinders 4. 5. Swing beams - adjustment cylinders (main valve) 6. Open/close crusher
1 2 3 4 5 6
Picture V.1: Hydraulic switchboard
V. START UP
Page 35
ELECTRICAL SWITCHBOARD:
1. Hydrostat left/right rotation (only valid, if Duplex System) 2. Set rotor speed 3. Activate hydraulics 4. Deactivate hydraulics 5. Warning lamp
2 4 6 1 3 5 17
6. Diagnostic lamp (drive engine) 7. Switchboard lock

7 8 13 11 9 10
8. Starting aid 9. Adjustment of engine speed 10. Switch for emergency mode (transport)
16
11. Screen box ON/OFF (option) 12. Water pump ON/OFF (option) 13. Vibration chute ON/OFF (manual/remote control) 14. Engine preheat lamp 15. Starter key 16. Tank display 17. Monitoring system (motor and crusher unit) 18. Headlight ON/OFF
18
12
14
15
Picture V.2: switch board
V. START UP
Page 36
MOTOR MONITORING SYSTEM:

1 2 3 4 3+4 5+6 7 8 ESC-Button
1 This button enables to return to a previous or higher level in the display.

ConfirmationButton
2 With this button error messages can be confirmed.

S Scroll ll Button B tt + / - Buttons Enter Button Indication of engine speed Indication of second parameter of engine Indication of crusher speed Operating-informationdisplay
8 9 12 10 13 12a 11
3+4 Used for navigation between the various menu items in the display. 5+6 Allow to select a value or to change the indication-parameter in the display (see point 9 ). 7 This button effects the confirmation of a selected adjustment as well as the changing of indication of display to a selected mode. 8 Indicates the current engine speed. 9 After selecting this indication item by using the scroll buttons (3+4) this item is going to be marked in grey colour. By pressing the + or button (5+ 6) the requested indication parameter (hours of operation, coolant temperature, etc) now can be chosen. By pressing the enter button (7) this selected parameter then remains active in the display and indicates the condition of this parameter during operation of engine. 10 After activating the crusher and running up the crusher with the crusherspeed-adjusting-buttons, the current crusher speed appears in this indication.
4 3
5 6 7
1 2
10
Picture V V.3: 3: Motor monitoring system

11
11 If the block menu is marked in grey and the enter-button (7) will then be pressed, you will get into a further submenu (inputs, outputs, alarm protocol and
12 12a Indication of arising problems of diesel motor Indication as per code number of engine manual Indication of arising problems of crusher control language). Within this menu field you can navigate with the scroll buttons (3+4). After selecting a menu field this one can be called by pressing the enter button (7). ( ) After f e.g. selecting the menu field f language the requested language can be adjusted by pressing the +// buttons. This one has to be confirmed f then with the enter-button (7). In the menu field alarms the last 100 error messages can be called by pressing the scroll-buttons (3+4). With the ESCbutton (1) you can return from this level in the display to the main menu (=standard indication).
12 The current problem (indicated as plaintext) appears in the display until the error is corrected or due to a change of the operating status of the engine the error is cleared. In case of critical operation conditions (e.g. excess temperature of the cooling water) the diesel engine will stop
automatically. An automatic cut-off due to lack of cooling water is not provided (a regular control of the coolant level is necessary).
13
12a Errors, which are not indicated as plaintext here appear with the appropriate code number. The meaning of this code can be read in the engine manual.
13 These notices / errors are also indicated as plaintext. If there are no notices, the display is empty.
V. START UP
Page 37
ERROR MESSAGES OF ENGINE CONTROL SYSTEM

The pressure in the hydraulic circuit of crusher drive has exceeded the adjusted limit value or the crusher speed went below the crusher limit value. The feeder stops immediately as long as this overload of crusher is active. When there is no more overload (hydraulic pressure again at a lower level) the feeder starts again automatically. Indication, that the level of hydraulic oil in the oil tank has reached a level below the limit value. The feeder stops immediately. After a short period of time (30 seconds) also the complete hydraulics stops. To start again the hydraulics, the oil level must reach a higher level (oil must be filled up in the tank or the function of level senor has to be checked). Indicates, that the temperature of the hydraulic oil has exceeded the adjusted limit value. The feeder stops immediately. After a short period of time (30 seconds) also the complete hydraulics stops. A new activation is only possible, if the oil has cooled down and reached a lower temperature range (under the adjusted limit value). Is indicated, when the load at the main conveyor (pressure in the hydraulic circuit) is too high. The feeder will stop automatically. For a further activation the hydraulic on button has to be pressed on the electrical switchboard or on the remote control (see page 36, picture V.2: electrical switchboard, item 3 or page 39, picture V.4 switch 11).
Crusher overload
Hydr. oil level too low
Oil temp. too high
Overload of main conveyor
Switch side conveyor
This message g is indicated, , if the safety y switch of side conveyor y has been activated. The complete p hydraulic y stops p immediately. For new start of hydraulics, this safety switch has to be readjusted. Is indicated, when the limit switch at the crusher cover or the switch board is not adjusted in the right position (distance between surface of switch and surface at crusher cover: 2 3 mm). If this happens during operating the crusher, the f feeder will stop immediately and after f some short time delay (5 ( seconds) ) also the crusher switches off. ff If f the error disappears (problem caused by bad contact or shaking of the plant) during this time, then the feeder will restart again automatically. pump p of sprinkling p g unit has switched of because of lack of water in the suction Indicates, that the electric motor of water p line (only if an optionally sprinkling pump was installed). The last 100 error messages can be seen in the error diagnostics (see page 37, point 11, operating-information-display).
Limit switch
Level of water
V. START UP
Page 38
WIRELESS REMOTE CONTROL:

1. Forwards left 2. Forwards right 3. Backwards left Left caterpillar crawler moves forwards
1 2
Right caterpillar crawler moves forwards

3 4
Left caterpillar crawler moves backwards

5 6
4 Backwards right 4. 5. Forwards fast 6 B 6. Backwards k d f fast t 7. Crusher cover open 8. Crusher cover close 9 10. Start 9. Hydraulic ON 10. Vibro on/off 11. EMERGENCY-OFF
Right caterpillar crawler moves backwards

7 8
Both caterpillar crawlers move forwards simultaneously in fast motion B th caterpillar Both t ill crawlers l move b backwards k d simultaneously i lt l i in f fast t motion ti Open crusher cover Close crusher cover Press buttons 9 and 10 simultaneously for two seconds until LED blinks green. The ON/OFF switch (no. 11) must be pulled. Activate operation hydraulics Activate and deactivate vibration feeder Pull for activating remote control. Press to switch machine and remote control off. The remote control has to be activated before the start-up of the machine!
11 9 10
Picture V.4: Wireless remote control
V. START UP
Page 39
CABLE REMOTE CONTROL:

1 5
1. Forwards left 2 Forwards right 2.
Left caterpillar crawler moves forwards Right caterpillar crawler moves forwards
Picture V.5: Cable remote control
For straight-ahead movement press both buttons (1,2) at the same time 3. Backwards left 4. Backwards right Left caterpillar crawler moves backwards Right caterpillar crawler moves backwards For straight backwards movement press both buttons (3,4) at the same time 5. Emergency OFF Switch Pull to activate the remote control. Press in order to stop the machine in an emergency.
Picture V.6: Connecting point
CRUSH HAZARD: Particular caution must be exercised in respect to operating chains when using the cable remote control control. Connecting the cable remote control to the crusher at the industry connecting point, see picture V.6/7. ATTENTION: Machine function is only guaranteed, if the circuit is closed via cable remote control or the industry connecting point.
Picture V.7: Connecting cable remote control
V. START UP
Page 40
TRANSPORT: UNLOADING THE SYSTEM: Check machine on loose parts or material accumulations. Activate remote control (see page 39) or plug in cable remote control (see page 40). Start the motor (see Caterpillar Manual) Manual). Press the hydraulic button on electrical switchboard (see page 36, point 3). Set ascent angle of the low-loader ramps to not more than 15 (or ratio 1:4). Carefully drive away from low-loader at low engine speed (below 1000 rpm). LOADING THE SYSTEM: Check machine on loose parts or material accumulations. Fold and secure side conveyor and catwalk ladders. Carefully drive onto the low-loader at low engine speed (below 1000 rpm) Observe angel of ascent Fasten s system stem with ith appropriate chains at the anchoring points points. After the loading reverse battery switch and pull off ignition key. ATTENTION: be serve transport dimensions. Set ascent angle of the low-loader ramps to not more than 15 (or ratio 1:4). U adequate Use d t l low-loader l d ramps (for (f steel t l chain h i crawlers). l ) Make sure to have a stable ground during the loading and unloading process. Remove snow, ice and material from ramps and caterpillar crawlers. Use outriggers of the trailer Machine tilts when it passes the ramp angle.
V. START UP
Page 41
TRANSPORT SAFETY: Observe the statutory transport dimensions currently applicable. Secure the system against slipping at the eight anchoring points envisaged for this.
Picture V.8: laterallashing points
Picture V.9: backwards lashing points
Picture V V.10: 10: frontlashing points
V. START UP
Page 42
SYSTEM SET UP: Ensure an even ground space, if necessary compact. Bring the crusher into position. Move the system as close as possible to the material to be crushed. A suitable ramp must be tipped for loading with a wheeled loader (although this is not recommended) A clear view onto the hopper and crusher feed must be provided for excavator loading. The material to be crushed must be located in the rear part of the hopper for excavator loading. ATTENTION: If an impact crusher is in use, there is an acute hazard from falling/flying stones (rock fall). Bring the main conveyor belt and side conveyor belt into the working position (see picture V.11; position 1+2). Att ti Attention: Open O safety f t screws and d tightening ti ht i screws! ! Check that belt runs centrally and, if necessary, reset (see chapter VII. maintenance). Check belt tension.
1 2
Picture V.11: V 11: Hydraulic switchboard
NOTE: The material cone under the main and side conveyor belt must not rise above the driving drums. RISK OF DAMAGE TO THE DRIVE UNIT AND THE CONVEYOR BELTS.
V. START UP
Page 43
MATERIAL PREPARATION: The crushing material must be pre-crushed, depending on the machine type. The process material (recycling material) must not exceed a max. length of 500 mm. If hard rock is used as feeding material, this value may only be max. 300 mm. Objects that cannot be crushed must not enter the crusher. Remove impurities such as iron, wood and similar from the material to be crushed. Metal objects larger than the gap width set must not enter the crusher.
CAUTION: Risk of damage to the conveyor belts cut iron pieces that are too long, max. length 500 mm, max. diameter 15 mm.
REMOVING BLOCKAGES: Switch S it h off ff the th machine, hi pull ll off ff i ignition iti k key and db battery tt switch. it h (Protect machine against re-start by external persons). The machine must always be switched off. The rotor must be brought to a standstill before removing any blockages g and must be secured against g turning. g Never step into the crusher Remove the blockage with extreme caution.
V. START UP
Page 44
1. A clear view onto the hopper and crusher feed must be provided for excavator loading. If an impact crusher is in use, there is a risk of flying/falling stones behind the crusher feed.
Point 1
Point 2
Point 3
2. Material preparation: As far as possible, remove all impurities from the process material. To large parts should be crushed to task size.
3. The material cone under the main and side conveyor belt must not rise above the driving drums Risk of damage to the drive unit and the conveyor belts.
V. START UP
Page 45
GAP ADJUSTMENT:
The particle size of the end product can be determined by setting the crushing gap width. This should be done only with secured rotor! If an impact crusher is in use, the crushing gap width must be set as follows: Remove mounting plates from the setting cylinders/plates (Picture V.13). Start the diesel motor. motor Activate the hydraulics. Activate the main valve of the swing beam (see page 35, picture V.1, point 5). Bring the setting cylinder into position (pocket adjusting clips, see picture V.15), move the setting cylinder into the required position using the manual valve (picture V.14) and adjust the baffle plates in this manner until the setting plates are loose and can be pulled out from the guide. Move setting plates. Forwards = Increase gap Backwards = Decrease gap
Picture V.13: Setting plates Picture V.12: Setting g cylinder y
Adjusting plates are available in thicknesses of 10 mm and 20 mm (Picture V.13) NOTE: Possible gap settings (with new blow bars) U Upper b baffle ffl plate: l t 0 170 mm Lower baffle plate: 0 100 mm
Attention: Pay attention to springs because of risk of injury! Attention: Danger of falling the gap adjustment must be done only from the catwalk!
Picture V.14: Setting plates
V. START UP
Page 46
SETTING THE CRUSHER (continued): Open inspection flaps.

[1,5-3] = y
CRUSH HAZARD: PAY ATTENTION TO OVERRUNNING PARTS! Check the gap between the hammer and the baffle plate. Setting from upper to lower baffle plate should be selected at a ratio of 1,5 :1 to 3 :1, depending on material, feeding size and crushing ratio. The setting for the gap sizes also depends on the material and impurities (see side 43 material preparation). NOTE: The smaller the crushing gap, gap the greater the wear in relation to the throughput performance performance. ATTENTION: Always check the crushing gap set and ensure that the rotor can run freely RISK OF DAMAGE TO THE ROTOR! Release setting cylinder Remove adjustment bolt Pull in piston rod of setting cylinder Bring the manual valve (page 35, picture V.1, point 5) into the neutral position. Attach mounting plate. plate
V. START UP
Page 47
Sid 2 Side Side 4

Seite 2 Side 6
Side 7

Hydraulic system
Side 54
VI. VI B ltmotor i t b Seite S it 56 48 Di Betrieb Diesel Sid Side Besondere Betriebshinweise Seite 49 Vibration feeder Side 56 Vorgangsweise Brecherbetrieb Seite 51 Caterpillar crawler Side 57
VI OPERATION VI.
R900 IMPACT CRUSHER
VI. OPERATION
Page 48
Side 72
SPECIAL OPERATING INFORMATION: VIBRATION FEEDER: Switch on the vibration feeder:

The vibration feeder is manually activated in the Manual position ( (see page 36, 36 picture i t V2 N V.2. Nr. 13 13, vibration ib ti f feeder) d ) The ball valve (see picture VI.1) in the control panel is closed (closed=vertical) The vibration feeder can be switched on and off via the ball valve (see picture VI.1) The rate governor (see picture VI.1) on the control station is used to control the required conveyor speed for the material on the vibration feeder. If the vibration chute does not work, the green Hydraulic-ON - switch must again be pressed. Switch on the vibration feeder via remote control: The vibration feeder can be activated via the remote control (see page 39) provided that the Radio" position is switched on (see page 36, picture V.2, Nr. 13) and provided that the ball valve in the control panel is closed. The vibration feeder can be activated and deactivated via wireless remote control. The ball valve must be closed in order to use the remote function of the vibration chute chute. THE CRUSHER CAN BECOME BLOCKED IF THE VIBRATION FEEDER TRANSPORT SPEED IS TOO HIGH. THIS CAN REDUCE PERFORMANCE, INCREASE WEAR AND LEAD TO INFERIOR QUALITY OF THE CRUSHED MATERIAL.
Picture VI.1: governor , white arrow rate g ball valve, red arrow
CRUSHER COVER:
The crusher cover can be opened and closed again by hand or by remote control, if required. This procedure is necessary if process material has become blocked in the infeed area of the impact crusher (observe process size) size). Opening the crusher cover increases the infeed and the material is able to enter the crusher space. The crusher cover serves for maintenance purposes only and may be opened only if the rotor is switched off and protected against rotation. DURING OPERATION OF THE MACHINE NEVER OPEN THE CRUSHER COVER. MATERIAL IS HURLED OUT BACKWARDS FROM THE CRUSHER!
VI. OPERATION
Page 49
SPECIAL OPERATING INFORMATION:

ROTOR: Always check the rotor for free running before starting operation. The quality of the final product, e.g. limestone, can be controlled by fine adjustment of the rotor speed: a higher rotational speed increases the degree of fines, a lower rotational speed reduces the degree of fines. REVERSIBLE CHUTE: The reversible chute guides the pre-screened material into the main discharge belt or the side discharge belt, depending on requirements. i t Only operate the reversible chute if the material flow for pre-screening is interrupted and the hopper has become empty, otherwise the reverse mechanism may become jammed. MAIN DISCHARGE BELT: The main discharge belt is protected from overloads by a pressure switch. This pressure balance deactivates the vibration feeder in the event of an overload. For a further activation the Hydraulic-ON button has to be pressed on the electrical switchboard or on the remote control. The most frequent causes of overloading for the main discharge belt are: a) Blockages of concrete iron between belt and crusher discharge b) Accumulation of material due to slow belt speed It is important to check the conveyor belt for iron pieces and other impurities that may have become caught several times during crushing. This minimizes downtimes of the belt (gaps). The main discharge belt can also be operated in the reverse direction for a short period period, if required required.
MAGNETIC BELT: With a ball valve the magnetic belt can be used independently from the manual valve be turned off and on. (see page 35, 35 picture i t V V.1, 1 position iti 2) 2). The Th magnetic ti belt b lt can b be reversed df for a short h t period i db by operating ti th the manual l valve in the opposite direction (spring offset). Short forwards and backwards movements can help release material blockages. The exchange of the hydraulic quick couplings on the magnetic belt engine enables the change of the direction of the magnetic belt.
VI. OPERATION
Page 50
PROCEDURE FOR CRUSHER OPERATION: IMPORTANT: FIRST CAREFULLY READ THROUGH THE SECTION "SPECIAL OPERATING INFORMATION". (see pages 49-50) Step 1: Start motor See Caterpillar p Manual. The starter key is located in the switchboard (see picture VI.2 item 14). In case of difficulties during the starting procedure, the button Starting Aid (item 7) must be pressed during starting. Press the hydraulic button in the switchboard (see picture VI.2 item 3). The operating hydraulics are activated in the idle mode.
16 1 2 3 4 5 6 17
7 13 11
8 7
9 8
10
Step 2: Start hydraulic Step 3: Start hydrostat
Turn the hydrostat switch (see picture VI.2 item 1) into the Impact crusher" position. Increase the rotor speed with the rotary knob (see picture VI.2. item 2) to appr. 100-150 rpm. The current rotor speed can be controlled at the display. Switch on the conveyor belts at the hydraulic switchboard (see picture VI.3) by pressing the hydraulic valves. Increase the motor speed with the switch (see picture VI.2 item 8). The crusher speed p increases p proportionally p y to the motor speed. p
18
12
14
15 14
Picture VI.2: switch board
Step 4: Start up rotor Step 5: Start conveyor belts Step 6: Increase motor speed
MOTOR SPEED DURING CRUSHING OPERATION MAX. 2000 RPM!
Picture VI.3: Hydraulic switchboard
VI. OPERATION
Page 51
PROCEDURE FOR CRUSHER OPERATION (continued):
Step 7: Adjust rotor speed Step 8: Start magnet
Set the required rotor speed, depending on the required crushing material, with the rotary knob (see picture VI.2. item 2). Close the ball valve on the crusher frame (closed=lever is vertical to the direction of flow, see picture VI.4). Turn the switch Vibro chute (see page 51, picture VI.2, item 13) to radio or manual operation. Adjust the speed with the rate governor at the operator console (see page 49, picture VI.1). When choosing radio operation, the ball valve (see page 49, picture VI.1) has to be closed. (closed=lever vertically to the direction flow). The crusher is ready for operation. You can now start feeding the material.
Step 9: Start vibr. Feeder

Pi t Picture VI.4: VI 4 ball b ll valve l
Step 10: Feeding
The sequence described ensures that no material blockage forms in the system to interrupt the workflow. Proceed in the reverse order when stopping the system.
VI. OPERATION
Page 52
Sid 2 Side Side 4

Seite 2 Side 6
Side 7

Hydraulic system
Side 54
VII MAINTENANCE VII.

R900 IMPACT CRUSHER
VII. MAINTAINANCE
Page 53
Side 72
HYDRAULIC SYSTEM: Replacing the return flow filter and overflow oil filter: First filter change 100 hours after first commissioning, further filter changes every 1000 hours or according to clogging indicator. Turn off diesel motor. Cl Clean filter filt h housing i ( (outer). t ) Remove filter cover. Pull out filter element (with disassembly handles). Insert new filter element. Replacing the filter of the hydrostat: First filter change 100 hours after first commissioning, further filter changes every 1000 hours (see picture VII.2). Changing the hydraulic oil: Change of hydraulic oil all 1000 hours or annually. Bring hydraulic oil to operating temperature. Turn off motor. Close main cocks (see picture VII.1). Open drain cock (see picture VII.3). D i oil. Drain il Close drain cock. Open main cocks. Clean filling cap open. (see picture VII.2.1) Pour in new oil until upper pp edge g of inspection p g glass. Vent pump: open (2-3 turns) ventilation screw (see picture VII.5). As soon as oil leaks from the ventilation screw, close it again. Start system. Activate load (ventilation) (ventilation). Check oil level. (see picture VII.2.1) Shut down system. Fill up further with oil below level.
Picture VII.1: Main cocks
Picture VII.4: Return filter
Picture VII.2: Hydrostat filter
Picture VII.3: Drain cock
Picture VII.5: Ventilation screw
Picture VII.2.1: filling gap and oil level indicator oil-level
VII. MAINTAINANCE
Page 54
Manometer 1 (picture VII.3: green arrow) : 60 bar, shows the charge pressure of the hydrostatic pump During operation the manometer has to show between 28-34 bar. Manometer 2 (picture VII VII.3: 3: red arrow) : 600 bar, shows the operating pressure of the hydrostatic pump During operation the pressure in this manometer ranges from 90 to 420 bar. Hydraulic oil cooler: In principle, the hydraulic oil cooler does not require maintenance. If required, blow out with compressed air from inside to outside. Pay attention to a clean cooler mesh!
Picture VII.6: Manometers
Attention: Danger of overheating if cooler is contaminated!
Charge air-, Watercooler: Water level = the distance from filler to water has to be 8 cm (Page 61, Picture VII.21) For further maintenance instructions see Caterpillar manual. Coolant temperature resistance has to be -35C After refilling coolant check temperature resistance Attention: Danger of overheating when Cooler is polluted
VII. MAINTAINANCE
Page 55
DIESEL MOTOR: See Caterpillar Manual. VIBRATION FEEDER: Checking the oil: Correct oil level = Lower edge oil-level plug (see picture VII.7). Open oil-level plug if no oil emerges, refill with oil. Oil change: h Open oil-level plug. Open oil drain plug. Drain oil. Close drain p plug. g Fill with new oil up to lower edge of oil-level plug or. 3.5 l. Close oil-level plug. Check fastening bolts of vibration gear for firm mounting once a week.
Picture VII.7: Oil level plugs
TRANSFER GEAR BOX: Open oil drain plug and bleeder screw. Picture VII. 8: Dip stick transfer gear box Drain oil. Close drain plug and bleeder screw. Fill with new oil (ca. 1 liter) - between mark (min and max) at the dip stick (see picture VII.8).
VII. MAINTAINANCE
Page 56
CATERPILLAR CRAWLER: The crawler gear chain and 3-rib base plates are maintenance-free. Weekly inspection for potentially loose bolts. The track rollers are maintenance-free. A weekly visual inspection must be carried out for possible leakages in the area of the duocone seals. The drive wheel unit is maintenance-free. It consists of the drive wheel with the sliding elements, the cross member with mounted spring assembly and integrated grease tension cylinder.
Picture VII.9: Chain tension
A weekly inspection must be carried out for possible leakages in the sliding elements of the drive wheel. The grease tension cylinder has the function of bringing the crawler gear chain into the operating position. Feeding is achieved by means of grease filling (via hand lever press). The chain is correctly tensioned if there is slack of approx. 25 mm on both sides of the chain support. It must be noted that only the drive wheel feeding or chain tensioning is initiated with the grease tension cylinder; the spring travel of the spring assembly is not shortened. The grease tension cylinder must be relieved by carefully unscrewing the filling valve. The pressurised grease then escapes via a groove in the filling valve in order to loosen the chain. The main ring gear is maintenance-free. maintenance free A regular visual inspection must be carried out, as incorrect chain tensioning can lead to premature wear. Accumulating material can become trapped between the track and carrying rollers as well as the lead and drive wheels. This material then obstructs the crawler gear parts from working together effectively, which can lead to increased wear and chain breakage. For this reason, it must be ensured that all crawler gear components are regularly cleaned and that foreign bodies and accumulated material are removed. Crawler gear unit Correct oil level with correct oil plug arrangement (see side VII.10).
Picture VII.10: Crawler gear unit
Filling volume: 6 litre
VII. MAINTAINANCE
Page 57
CONVEYOR BELTS: Check the conveyor belts for cracks, cuts etc as part of the daily visual inspection. Damage can be caused by foreign bodies (e.g. iron pieces) which become caught in the belt frame or between the track rollers. Crushing material may also have accumulated in the frame edges edges, which can have a considerable adverse effect on the belt running. Freezing temperatures in particular can lead to faults in and damage to the conveyor unit. All carrying rollers, track rollers, lower chord rollers and side guide rollers must run freely. The tail pulleys of the main conveyor must be checked for free running. Accumulated materials can cause the conveyor belt to stop and consequently lead to blockage in the crusher. This also applies for the driving drums of the main and side conveyor belts. Check the belt scrapers for correct mounting. Replace worn belt scrapers. Ensure correct belt tensioning.
MAGNETIC BELT: The belt must be checked regularly to ascertain whether it is running straight and, and if necessary corrected corrected. The bearings must be lubricated accordingly. Dedusting belts must be checked for damage and, if necessary, replaced.
VII. MAINTAINANCE
Page 58
V-BELTS: Check V-belts V belts for correct tensioning (see picture VII VII.10). 10) D = 0,016 . x D....[mm] x .... [m] F = FORCE = 50-65 N To tension the V-belts, open the door for the motor housing. The V-belts are tensioned by moving the hydraulic motor backwards using slide rails. Ensure correct belt tensioning. IMPACT CRUSHER: Open eyebolts (siehe Bild VII.12). Start diesel motor A ti t hydraulics Activate h d li Open crusher, secure with bolt (see picture VII.15) Stop diesel motor, remove starter key Remove battery switch Secure the rotor against twisting (see picture VII.14). O Open hammer h arm protection i on b both h sides id (see ( picture i VII VII.13) 13) Pull hammer arms sideways out from the guide Clean the guide noses, rotate or replace the hammer arms Push hammer arms into the guide noses Tighten g the hammer arm p protection on both sides Visual inspection of the wearing plates and rotor protection for abrasion and firm mounting Close crusher cover Tighten eyebolts Open inspection flaps Check gap between hammer arms and baffle plate, if necessary adjust (see commissioning set impact crusher) IF A GAP INSPECTION IS NOT CARRIED OUT, THE HAMMER ARMS CAN COLLIDE WITH THE BAFFLE PLATE - DAMAGE TO THE CRUSHER! Close inspection flaps. Crusher is ready for operation. After 2-3 hours of crushing process check eyebolts for firm mounting. To reverse or exchange the hammers pull them out in the direction of the catwalk.
Picture VII.11:V-belt tension
Picture VII.14: Rotor-protection p
Picture VII.15: Position fixing of open crusher cover
Picture VII VII.12: 12: Crusher eyebolts
Picture VII.13: Hammer protection
VII. MAINTAINANCE
Page 59
Preparation before Welding

Step 1: (A till C)
(A) (B) (C) Take care that all electrical connection-points to the diesel-engine and control-unit are disconnected Turn off the circuit breaker Nr.19 and 24 till 29 Disconnect both connector of the PLC (position 23)
A A
C
60
Page 60
Preparation before Welding continuation Step 2: (D till E)

(D) (E) Take off the main-fuse (pos. 31 and 34) Turn off the main-battery-switch (pos (pos. 32)
D D
E D
Page 61
61
Preparation before Welding continuation Step 3: (F)

(F) Pull out the connector for the remote-control
Page 62
62
OIL LEVEL MONITOR: Diesel motor
Hydraulic tank
Computer ohne einen Bildschirm verwenden
Picture VII.16: Dip stick diesel motor Bild VII.17: Oil level hydraulic tank
Vibration gear
Crawler gear
Picture VII.18: Oil level vibration gear
Picture VII.19: Oil level crawler gear
VII. MAINTAINANCE
Page 63
OIL LEVEL MONITOR:
Coolant Level Check
Transfer gear-box
Picture VII.20: Oil level Transfer gear-box
Bild VII.21: Coolant-compensating tank
VII. MAINTENANCE
Page 64
1000h or annually
200 h
100 h
50 h
daily
SERVICE AND REPAIR PLAN: Impact crusher: Check hammer arms wear status Check crusher gap Check hammer arms for firm mounting Check baffle plates for firm mounting Check impact swings wear Check rotor protection plate for firm mounting Check crusher housing reinforced plating wear status Check crusher housing reinforced plating for firm mounting Check crusher housing bolts for firm mounting Lubricate shaft bearing (5 pump lifts with grease press per lubrication interval) Vibration feeder and gear, pre-screening: Check bolts and connections for firm mounting Check wear Oil change (first after 100h, then annually or after 1000h) Chutes and hoppers: Check material clearance Check wear Main discharge belt: Check conveyor belt for damage Check conveyor route Lubricate bearings of the tail pulley and the driving drum (1-2 pump lifts with grease press) Check setting and belt tension Check safety guard Side discharge belt: Check conveyor belt for damage Check conveyor route Lubricate bearings of the tail pulley and the driving drum (1-2 pump lifts with grease press) Check setting and belt tension Check safety guard Magnetic separator: Check belt for damage Check conveyor route Lubricate bearings of the tail pulley and the driving drum (1/2 or every 2nd day 1 pump lift with grease press) Check setting and belt tension Check safety guard
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 x x x x x x
VII. MAINTENANCE
Page 65
1000h or annually
200 h
100 h
50h
daily
SERVICE AND REPAIR PLAN (continued): Caterpillar crawler gear: Visual inspection, according to instructions in Maintenance/Crawler track Chapter Check chain tension (25mm sag) Gear oil change, first after 500h, then annually or after 1000h Structures and platforms: Check structures and platforms for firm mounting Drive unit: Maintenance and repair work, see Caterpillar 7.0 Manual! Check V-belt tension Check firm mounting of components C Clean/Replace / the air filter f insert Replace the air filter safety cartridge Combi-Cooler: Clean cooling element Check water level Ch k the Check th coolant/antifreeze l t/ tif ( (see CAT M CAT-Manual) l) Oil-cooler: Clean cooling element Hydrostat: Replace filter first after 100 h, then every 1000 hours or annually (concerining filter display) L bi t h Lubricate hydrostat d t tb bearings i (3 pump lift lifts with ith grease press per lubrication l b i ti interval) i t l) Hydraulics: Change of return flow filter first after 100 h, then every 1000 hours or annually Change of overflow oil filter first after 100 h, then every 1000 hours or annually Funnel-air-filter Check system for leakages Pump transfer gear: Check oil-level Oil change first after 100 h, then annually or after 1000h V-belt drive: Check V-belt and V-belt tension Check V-belt pulley for firm mounting (one-time after 100h) Complete electrical system: Check cable and connecting plugs for firm mounting 8one-time after 100h) Check components for firm mounting Check emergency OFF switch for correct functioning
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 x x x
VII. MAINTENANCE
Page 66
RECOMMENDED OIL QUALITIES:
Gear oil
Blasia 220 Degol BG 220 Energol GR-XP 220 Alphamax 220 Engranajes HP 220 Falcon CLP 220 Epona Z 220 Spartan EP 220 Renep Compound 106 Gearmaster CLP 220 Kluberoil GEM 1 1-220 220 Mobilgear XMP 220 Ripress EP 220 Gear HST 220 Optigear BM 220 Rembrandt EP 2 S Super Tauro T 220 Omala 220 Meropa 220 Carter EP 220 1100-220
Hydraulic oil
Energol HLP 46 Tellus HLP 46 Renolin B15 VG 46 OSO 46
Grease
Aralup HLP 2 BP Energrease LS-EP2 Beacon EP2 Centoplex 2 Mobilux EP2 Shell Alvania EP Fett 2 Tribol 3030
Motor oil
Vanellus-Multigrad 15 W 40 Vanellus C3 Rimula Super 15 W 40 Titan Universal HD 15 W 40 Blitum T 15 W 40 ECL Cat-anti-freeze
Antifreeze
Use only antifreeze who is suitable for all kind of metal (aluminium, steel) and complying with the standard ASTM D4985 or ASTM D6210. D6210
protection
Rowe Hightec Antifreeze Arteco Havoline AFC Arteco Havoline XLC
Errors and printing errors excepted !!
VII. MAINTAINANCE
Page 67
Sid 2 Side Side 4

Seite 2 Side 6
Side 7

Hydraulic system
Side 54
VIII. STANDARD FORMS

R900 IMPACT CRUSHER
VIII. STANDARD FORMS
Page 68
Side 72
Page 69
VII. WARTUNG
Page 70
VII. WARTUNG
Page 71
Page 72
Page 73

Manual R900 With Mondial &amp; CAT 7.0

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Impact Crusher R900 - Manual

Sid 2 Side Side 4

I. Vorwort III Safety

Seite 4 Side 13 Seite 6 Side 26 Seite 7 Side 27 Seite 13 Side Seite 28 24

II INTENDED USE II.

II. INTENDED USE

Sid 2 Side Side 4

I. Vorwort III Safety

Seite 4 Side 13 Seite 6 Side 26 Seite 7 Side 27 Seite 13 Side Seite 28 24

III SAFETY III.

SAFETY HAZARD SYMBOLS:

SAFETY HAZARD SYMBOLS (continued):

Personal hearing protection must be worn.

SAFETY HAZARD SYMBOLS (continued):

SAFETY HAZARD SYMBOLS (continued):

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

SAFETY HAZARD SYMBOLS (continued):

SAFETY HAZARD SYMBOLS (continued):

OPERATING INSTRUCTIONS (continued):

HYDRAULIC SYSTEMS AND THEIR COMPONENTS:

ELECTRICAL SYSTEMS AND MOTORS:

MAINTENANCE WORK (continued):

Sid 2 Side Side 4

I. Vorwort III Safety

Seite 4 Side 13 Seite 6 Side 26 Seite 7 Side 27 Seite 13 Side Seite 28 24

IV TECHNICAL DATA IV.

IV. TECHNICAL DATA

IV. TECHNICAL DATA

PRE-SCREENING WITH REVERSIBLE CHUTE:

Picture IV.2: Reversible chute control lever

IV. TECHNICAL DATA

IV. TECHNICAL DATA

Picture IV.2: Safety screw

Picture IV.3: IV 3: Safety screw

IV. TECHNICAL DATA

IV. TECHNICAL DATA

IV. TECHNICAL DATA

Sid 2 Side Side 4

I. Vorwort III Safety

Seite 4 Side 13 Seite 6 Side 26 Seite 7 Side 27 Seite 13 Side Seite 28 24

Picture V.1: Hydraulic switchboard

6. Diagnostic lamp (drive engine) 7. Switchboard lock

Picture V.2: switch board

MOTOR MONITORING SYSTEM:

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

2 With this button error messages can be confirmed.

Picture V V.3: 3: Motor monitoring system

ERROR MESSAGES OF ENGINE CONTROL SYSTEM

Hydr. oil level too low

Oil temp. too high

Overload of main conveyor

Switch side conveyor

WIRELESS REMOTE CONTROL:

Right caterpillar crawler moves forwards

Left caterpillar crawler moves backwards

Right caterpillar crawler moves backwards

Picture V.4: Wireless remote control

CABLE REMOTE CONTROL:

1. Forwards left 2 Forwards right 2.

Picture V.5: Cable remote control

Picture V.8: laterallashing points

Picture V.9: backwards lashing points

Picture V V.10: 10: frontlashing points

Picture V.11: V 11: Hydraulic switchboard

Manual R900 With Mondial & CAT 7.0

Manual R900 With Mondial & CAT 7.0