lt95 - lt95s instruction manual (new addition)

8/17/2019 LT95 - LT95S Instruction Manual (New Addition)

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LOKOTRACK LT95/LT95S

INSTRUCTION MANUAL

140592-EN



SAFETY INSTRUCTIONS



Safety instructions

Table of Contents

09/2005

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-242.4.7 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.1.4 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



Safety instructions

Table of Contents

09/2005

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



09/2005 EN REV-A METSO MINERALS SAFETY INSTRUCTIONS 1-1

INTRODUCTION SECTION 1

1.1 General

This manual, together with specific instructionmanuals for individual equipment, has been

prepared by Metso Minerals Crushing andScreening Business Line to increase theknowledge and awareness of all personsinvolved in the operation, supervision, serviceand maintenance of crushing and screeningequipment with regard to safety andoperations. A copy of this manual must be

provided to and studied by each personentering the machine areas of the CrushingPlant, or otherwise involved in the operation ofthe Crushing Plant. It is the responsibility ofthe Owner to always keep this manual andother written instructions either in the

Crushing Plant or its vicinity for Operatorreference.

Knowledge of the machines and the potentialhazards they present are essential to a safeworkplace. Knowledge of and compliancewith all state, provincial, and federal safetylaws, safety regulations, and Crushing Plantsafety procedures, warnings and instructionsalso are essential to a safe workplace. Failureto 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 ofyour body into an operating machine. Neverreach over, around or beyond safety devices.

Never operate a machine if safety devices aremissing or disabled. Never replace an OEMsafety device with a non-OEM device.

Never service equipment until all potentiallymoving parts are secured and power has beenlocked out and tagged out to preventunexpected movement.

The Operator is responsible for using care and

common sense at all times.

Remember, safety is everyone’s business. Youare responsible not only for your safety, but forthe safety of those around you.

Please read this manual carefully. Know itscontents. If you have any questions, contactyour Metso Minerals representative withoutdelay for advice. Keep in mind that there aredifferent types of risks, hazards and injurytypes (see Section 2.3 Typical risks in Crusher

Plant working environment ), which are relatedto each other. Foresee and prevent such risksand hazards as well as resulting injuries andother consequences from occurring by allavailable means. Never compromise when the

question is about safety!Metso Minerals, as the machinerymanufacturer and supplier, regards safety as ofthe utmost importance, and deems thefollowing as essential prerequisites to the safeoperation of the Crushing Plant:

– That the Owner makes available thismanual, before using the machinery, toeach person involved with theoperation, supervision, service, ormaintenance of the Crushing Plant.

– That compliance with and adherenceto this manual be mandated andsupervised by the Owner.

– That all personnel involved in theoperation, supervision, service, ormaintenance of the Crushing Plant



1-2 METSO MINERALS SAFETY INSTRUCTIONS EN REV-A 09/2005

SECTION 1 - INTRODUCTION

become familiar with the contents ofthis manual prior to such involvement.

– That every person involved in theoperation, supervision, service, ormaintenance of the Crushing Plant be

properly trained and have adequate professional skills as required for the performance of the respective tasks.

– That all visitors to the Crushing Plant be properly informed of applicablesafety precautions and risks, and thatsafety precautions be adequatelymaintained and in connection with anysuch visits, including, but not limited

to, adherence to this manual. No changes shall be made in the operation ofthe machinery supplied by Metso Minerals orthe contents of this manual without expresswritten approval of Metso Minerals. Alloperation, service, maintenance, handling,modifications, or other use of Crushing Plantequipment and/or systems is the responsibilityof the Owner. Metso Minerals shall not beliable for any injury, death, damage or costcaused by any act or omission on the part ofthe Owner, Operator or other personnel,

agents, contractors, vendors, or others. Allapplicable safety rules, regulations, standards,instructions, and procedures must be compliedwith; as must be those of this manual as well asany other instructions, specifications, andrecommendations by Metso Minerals.

This manual is based upon the safety laws,rules and regulations in effect on the datehereof. The owner and operator bear soleresponsibility for complying with anyamendments, additions or other changes tosafety law, rules or regulations arising

subsequent to the date on which this manualwas drafted.

Although these instructions are intended to beas comprehensive as possible, there may behazards that cannot be anticipated, hazardsassociated with a particular work-site orhazards covered by special comany safety

programs. The information may also notinclude all practices that must be observed,such as insurance requirements or

governmental regulations.

If you have questions or concerns regardingsafety aspects of machinery supplied by MetsoMinerals, 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 beoperated only by knowledgeable and trained

personnel.





1.2 Definitions:

“Crushing Plant” means a combination or part of various equipment, components,systems and parts for crushing and/orscreening of rock, minerals, recycling or othercrushable materials. For the purposes of thismanual, the Crushing Plant means alsostand-alone crushing or screening equipmentas applicable. Throughout this manual, wordssuch as “machine”, “machinery”, “equipment”and “crusher” are used interchangeably to referto the Crushing Plant and its component parts.

“Owner” means the entities or individualswho own or lease the Crushing Plant and/orthe entities or individuals who are in charge ofoperating and/or servicing the Crushing Plant.

“Operator” means the individuals who eitheroperate the Crushing Plant or perform actualmaintenance, service, repairs, supervision orany other activity on or for it.

“This manual” means, as applicable, this gen-

eral safety instructions, together with any spe-

cific instructions for individual equipment, as

amended from time to time, provided by or on

behalf of Metso Minerals.





This Page Left Intentionally Blank.




GENERAL SAFETY INSTRUCTIONS SECTION 2

2.1 SAFE PRODUCTS AND THECRUSHING PLANT

All machines require human involvement.Like any other heavy machinery, a CrushingPlant has inherent dangers that must beidentified, understood and taken into accountin order to avoid accidents and injuries. MetsoMinerals, as machinery manufacturer andsupplier, is committed to promoting safety atthe Crushing Plant by providing safety devicesand features, and by providing training,

services, manuals and instructions.

2.2 SAFETY AND YOU

Safety is everyone's responsibility; safety isyour responsibility.

Safety is the concern of all personnel. Withyour actions, you participate in establishing thesafety of the working environment.

Metso Minerals products are designed andconstructed with safety in mind. The machinesincorporate high quality safety features used.

To assure safe operation, all personnel must bealert when operating or working on or aroundthe machine. Be aware of real and potentialhazards. Only properly trained personnelshould operate, supervise, maintain, or servicethe machine.

Personnel must carefully study all aspects ofthe specific machine, including:

– operating instructions

– service, trouble-shooting andmaintenance instructions

– automated features and motions of themachine

GENERAL SAFETY INSTRUCTIONS FOR A CRUSHING PLANT OR PLANT ENVIRONMENT




SECTION 2 - GENERAL SAFETY INSTRUCTIONS

– specific safety features andinstructions

2.2.1 Objective

The objective of these instructions is tominimize risks and to avoid or preventaccidents and injuries. Accidents are oftencaused by carelessness or disregard ofimportant instructions.

Knowledge of the machine operation and

continuous safety training are necessary for asafe working environment.

Safety can be summarized in three mainthemes:

– MACHINE KNOWLEDGE

– SAFE OPERATION ANDMAINTENANCE

– GOOD HOUSEKEEPING

IMPORTANT!

• If unsure of any procedure, check theoperation manuals and/or contact yoursupervisor before proceeding.

• Follow all lockout and safety procedures before entering the machine.

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

• Observe all safety instructions.

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





2.2.2 Safety Signs, Labels And Symbols

The following symbol is used in this manualand on the machine to call attention toinstructions, which will help prevent machinerelated injuries.

When you see this symbol on your machine orin this manual, be alert to the potential for

personal injury.

Figure 2.1 Alert Symbol

This manual uses the alert symbol, with wordssuch as DANGER, WARNING or CAUTION,to alert you and other Crushing Plant personnelof actions or conditions that pose a potentialsafety hazard, with an attending risk of

personal injury (including death) or propertydamage. The machine also displays safetysigns, labels and tags at appropriate points toshow safety risks that may exist.

Figure 2.2 Danger, Warning, Caution Signs AndTheir Meaning

Sign Description

DANGERImmediate hazards or unsafe practicesthat will result in severe personal injuryor death.

WARNINGHazards or unsafe practices that could

result in severe personal injury or death

CAUTIONHazards or unsafe practices that couldresult in minor personal injury orequipment damage

DANGER

CAUTION

WARNING





2.2.3 Some General Safety Instructions

1. Do not remove, cover or disable anyinstalled safety devices, guards, warningsigns or tags. They are attached toequipment to warn personnel of possibledanger and prevent injury. Use OEMreplacements in the event any safetydevices, warning signs or tags becomedamaged or unreadable. Observe allinstructions. Keep warnings signs andtags clean, visible and readable.(Warning signs are listed and theirlocations described in the machinesafety instructions.)

2. Make sure that all required walkways,handrails, barriers, safety devices, andguards are in place before starting themachine. Do not use non-OEMwalkways, handrails, barriers, safetydevices or guards, when such items areavailable from OEM.

3. Keep the machine itself and the areaaround the machine clean and clear ofobstructions. Be aware of dust, smokeor fog, which may obscure your vision.

4. Wipe up any substance, such as spilled

oil, grease, water or ice, which maycause a person to slip or fall. Goodhousekeeping practices prevent injuries.Be a good housekeeper. Keep themachine environment and walkwaysclean and free from oil, grease, rags,cables, chains, buckets, rocks and otherobstructions. Keep loose parts in atoolbox or return them there promptly.

5. Keep clothing and all parts of the bodyaway from nip points and rotating ormoving equipment. Be especially alert

to avoid contact with parts that moveintermittently.

6. Know the weight limitations of liftingdevices and their loads. Never detach alifting device from a load until the loadis stable and secured from unintendedmovement.

7. Do not climb or stand on equipmentother than in areas, which are designedfor that purpose. Do not overreach.

8. Emergency-Stop buttons should betested on a regular schedule for properoperation, as should electrical interlocksand related limit switches. Safetydefects should be repaired prior tocontinuing operation, and thereaftertested and certified for appropriateoperation by skilled personnel.

9. Personal protective equipment andsafety uniforms, safety shoes, helmets,safety glasses, heavy gloves, ear

protection devices etc. should be used atall times. Safety shoes should be used byall personnel entering into the CrushingPlant. Persons with loose clothing, neckties, necklaces, unprotected long beardor long hair should not go near themachine. Wrist watches and rings can bedangerous.Rings should be removed orcovered with tape. Keep your pocketsfree of loose objects.

10.Keep all non-operating and non-trained personnel clear of the Crushing Plant atall times. Injury or death may result ifthis is not done.

11.The equipment at the control panelshould be handled with care. Do not

place objects on the keyboard, colordisplay or other equipment. Allequipment can fail if put in contact withliquids, or excessive heat or excessivehumidity. Allow good air flow aroundthe equipment at all times. Keepmagnets away from computercomponents, particularly hard drives

and PLC cabinets.12.A knowledgeable and properly trained

Operator familiar with this manual,safety requirements, and automaticoperation of the machine should bestationed at the controls whenever themachine is operating.





13.Do not consume any alcoholic beverages or other intoxicants beforecoming to work or while on the job. Do

not operate the Crushing Plant aftertaking any medicines, tranquilizers orother drugs, which can impair thesenses.

14.Familiarize yourself with the safetysigns on the Crushing Plant. Neverremove or damage any safety signs,nameplates or other safety relatedwarnings, symbols or components.Replace them as necessary with OEMequipment.

15.Do not paint over safety signs, name plates or warnings.

2.2.4 Blasting

The use of the Crusher Plant’s radio controldevice is strictly forbidden during blastingoperations, as it may cause a prematureexplosion. Move the mobile Crushing Plant farenough away from dangerous area when

blasting. Do not store or transport explosiveson mobile crushing plant or screening plants.

2.2.5 Portable Plants

If the Crushing Plant includes of portableequipment (i.e. crushing and screeningequipment mounted on trailers), trailer footingor cribbing is extremely important for safeoperation. Your machine must be on as solidand level footing as possible. If the ground isnot naturally level, it must be leveled so thatthe unit will operate safely and effectively. Theground must support the weight of entire unitand keep it from sinking or shifting. Use heavytimber mats as needed. Trailers must be raisedso that trailer wheels do not touch the ground.

Place jacks at each corner of the trailer or asnear the corner as possible and to othersuggested support points at mid-frame. Allcorner jacks must be at an equal distance fromeach end. Adjust each jack until theunsupported portion of the trailer beams stopsvibrating or until vibrations are reduced to a

minimum. Lock jacks and adjustable supportlegs mechanically with locking pins whenapplicable.

Periodically recheck trailer footing forstability.

WARNING:

Only qualified and properly trainedoperators and servicemen shouldoperate or service the machine.Everyone else should stay clear ofthe machine when it is operating, orunder service or maintenance!





2.2.6 Mobile Equipment Transportation

Use only appropriate transportation and liftingequipment with adequate capacity. Provide asupervisor to direct lifting operations. Followall disassembly and assembly instructionscarefully. Disconnect all external powersupplies before moving any part of theequipment.Transport or hoist components andhandle any parts in accordance with theinstructions and advice provided. Fasten thelifting equipment only to the points meant forlifting. Use only proper means of transportwith adequate transporting capacity. Fasten theload carefully. For lifting use only thefastenings shown in instructions. Secure allcomponent parts of the equipmentimmediately after loading to avoid anyaccidental shifting. Attach required warningsigns to the load.

When moving your trailer, check bridges before crossing. Make sure they will supportthe weight of the machine. Check clearancesunder bridges, for overhead lines or anyoverhead obstruction. Never travel with nearcapacity loads. Check local laws, especially onweight limitations. When travelling on thehighway make sure all headlights, clearancelights and tail lights are on, as applicable. Use

proper traffic warning flags and signs.

Remove all shipping brackets beforere-starting the Crushing Plant. Carefullyassemble all of the parts previously

disassembled. Perform any start up inaccordance with the instruction manual.

After the system is running, check all gaugesand instruments to see that they are workingcorrectly. Check that all controls functionnormally and properly. Listen for unusualnoises. Shut system down immediately if anycomponent of the system does not operatenormally.





2.3 TYPICAL RISKS IN CRUSHING PLANTWORKING ENVIRONMENT

Even though every Metso Minerals machine isdesigned with many safety features, it isimpossible to design out all safety risks. Thereare potential hazards, that must be recognizedand avoided. Noise levels may interfere withnormal discussion when the machine isoperating. By their nature, Crushing Plant andauxiliary equipment can create dust. Crushingitself and some other machine processes maymomentarily obstruct the view of somemachine parts. In general, high levels ofrespirable silica and other dust in the air mayexpose Operator to health risks for lungdisease depending upon the length and amount

of exposure and type of material beingcrushed. In addition, there are some risks orhazards which cannot be completely guardedor avoided because of interference withmachine operations. Accordingly, working onthe Crushing Plant requires constant alertness

by all personnel in the area. Accidents happenunexpectedly. Below are some typical hazardsand types of accidents that everyone workingat, on or around the Crushing Plant should beaware of.

Typical Hazards

– nips, gaps, and pinch points

– poor housekeeping

– elevated or narrow working areas

– lifting and shifting heavy loads

– cranes and mobile cranes

– sharp edges

– high-pressure hydraulic equipment

– electrical equipment

– automatic functions and unexpectedstart-ups

– toxic and corroding agents

– machine inertia

– hot surfaces and fires

– zinc

– conveyor belts

– dust

– noise and vibration

– improper work methods

– rotating equipment and movingcomponents

– ejection of material from the crusher

– falling material from conveyors, andfrom loading, unloading and feedingoperations

– crushing cavity

These typical hazards are discussed more fullyin Section 2.3.1 of this chapter. Be aware ofthese hazards. All personnel working on oraround the machine should be properly trainedin avoiding these hazards.

Typical Injury Types

– crushing

– slipping, tripping and bumping

– falling

– cutting

– entanglement

– burns and electrical shocks

– respitary organ illnesses

– asphyxiation





2.3.1 Typical Hazards

Nips, Gaps, and Pinch Points

An ingoing nip is formed by drive devicessuch as belt and pulley, chain and sprocket orgears. Similarly, a pinch point may be formed

by rotating or moving equipment.

Poor Housekeeping

Promote good housekeeping. Keep machineenvironment, walkways, platforms etc. cleanand dry and free of debris. Oily or wet machineenvironment, walkways, platforms, steps and

hand rails are slippery. In cold weather, watchout for ice and snow. Wet spots, especially nearelectrical equipment, are dangerous. Returntools to their proper place after use. Even thenextreme caution should be used. Followestablished Crushing Plant safety procedures.Clean slippery deposits from walkways,

ladders and floors. Tidiness provides a saferworking environment by preventing or helpingreduce tripping, slipping, fire hazards and

electrical shocks.

Elevated or Narrow Working Location

Crushing Plants are tall structures. Thewalkways and platforms, designed to be usedduring machine operation, are furnished withrailings to help prevent falling.

When working on an elevated surface beaware of machine movements and otheractivities in the area. Do not run on thewalkways. Do not reach over or beyondwalkway railings while the machine is

running. Do not stand on railings or toe plates.

There may be narrow access routes formaintenance purposes. Do not use these routeswhile the machine is operating.

Do not enter any close quarters within theCrushing Plant when the machine is operating.

DANGER:

Nips and gaps are serious hazards ina Crushing Plant. They are usuallyguarded by nip guards, railings, orlocation. In all cases, extreme caremust be taken to avoid nips, gaps,and pinch points or serious injury oreven death may occur.





Lifting And Shifting Heavy Loads

• Cranes

Crushing Plants, like any other type ofmechanical equipment, require regular

periodic maintenance. One of the most flagrant

Crushing Plant safety violations is the use ofinadequate and unsafe lifting equipment.Although a Crushing Plant is a finely tuned

piece of equipment, the internal parts of aCrushing Plant should be assembled anddisassembled with crane facilities that have thecapability of gently and slowly lifting andlowering the various parts that make up aCrushing Plant.

Do not use chain hoists (chain blocks) toassemble or disassemble a Crushing Plant.These lifting devices lack the stability and

robustness required in lifting and positioningheavy components.

Do not use impact hammer boom or any otherequipment 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 loaduntil the load is stable and secured fromunintended movement.

When it comes to safety, don't compromise!

• Mobile cranes

Safe ratings are based on operating the craneon firm, level ground; outriggers must be

properly extended and/or lowered wheneverrequired. Avoid fast swings, hoists or sudden

braking; these can cause overloads. Do nothandle large, heavy loads in strong winds.When moving your crane, check bridges

before crossing, make sure they will supportthe total weight in question. Check clearancesunder bridges for overhead electrical lines andany overhead obstruction. Be sure your hitcheris clear before starting lift. Make sure the load

is securely attached.

IMPORTANT!

When using a crane, always operate withinthe rated capacity of the crane. The safe ratedcapacity includes weight of hook, block andany materials handling devices such ascables, slings, spreader bars, etc. Subtract theweight of all these items from the ratedcapacity to find the true weight of the loadthat can be handled safely. Always followthe crane manufacturer's operational andsafety instructions.

IMPORTANT!

The weight indicated in machine plates tellsthe weight of standard configuration. Inmany cases the actual weight may differgreatly from that indicated in machine platedue to, e.g., options or ancillary equipment.Always verify the weight of the object youare lifting before attempting to lift it.

IMPORTANT!

When using a mobile crane, always operatewithin the rated capacity of the machine toavoid buckling the boom or tipping.





Take the following precautions when liftingheavy loads:

– Follow all established Crushing Plant procedures.

– Follow all instructions and safety procedures recommended by the cranemanufacturer.

– Plan the lifting and maintenance procedures in advance. Read andunderstand specific instructions for

proper use of lifting equipment priorto using (e.g instructions of themachine, lifting device and localregulations).

– Clean the working environment beforehand to prevent slipping andtripping hazards.

– Make sure that the crane and otherlifting devices such as chains andslings have sufficient capacity and arein good working order.

– Do not attempt to ride or sit on movingloads.

– Be sure that crane operators, riggersand other personnel have been

properly trained.

– Rig the load firmly to prevent anyunintened movement and assure stableand accurate positioning.

– Make sure nobody is below or on the path of the load and that the transferroutes are clear and proper protectiveclothing and gear are used.

Sharp Edges

Sharp edges may occur on any metalstructures. Equipment damage may uncover or

produce unexpected sharp edges. Sharp edgesmay inflict deep and serious cuts. Wear

protective gloves when handling materials, parts, etc. with sharp edges. Repair or guarddetected sharp edges immediately.

High-pressure Equipment- Hydraulic or Air

High pressure oil can be dangerous. Relieve all pressure before opening or removing anyhydraulic or air pressure lines, valves, fittings,etc. Do not touch pressurized componentssince the pressure from a pin hole leak is sostrong that it can easily penetrate the skin oreyes. Always exercise caution when handlinghydraulic devices.

Regularly check the condition of hoses, pipes,

valves and various connections. Replace themas necessary.

Before starting any maintenance work, stop allhydraulic pumps, lock out pump motors, anddepressurize the system, bringing allcomponents to a zero energy state. Rememberto also depressurize the accumulators through





the bleed valve for each accumulator. Do notdisconnect any hoses until the actuator has

been brought to a zero energy state and

properly secured.

Bleed the hydraulic system regularly toremove entrapped air that may interfere withnormal expected machine operation or cause ahazard during maintenance.

Electrical Equipment

Be especially cautious when working with ornear electrical equipment. An electric shockcan be fatal. Crushing Plant electrical outletsmust be grounded and have ground faultinterruption protection. Tools plugged into theoutlets must be double insulated. Never exposeelectrical equipment to mechanical damage orhumidity. Protect all electrical equipment from

direct contact with water or high humidity.

Protect electrical devices that move as part ofthe machine from dirt and mechanical damage.Regularly check the operability of thesedevices.

The lockout program, locks, tags and the blocking/restraining devices provided aredesigned for your protection. Yourresponsibility is to follow the program and usethe proper equipment.

Remember:

– Follow procedures.

– Stay alert.

– Do not take anything for granted.

– Verify lockout.

– Each person working on the unit musthave his own lock with only 1 key.

WARNING!

Poorly tightened or damagedhydraulic components may injectdangerous jets of fluid. Beforerestarting the machine, be sure thatthe hydraulic system is ready foroperation, and personnel are clear ofaffected areas.

WARNING!

Machine parts may moveunintentionally and cause a risk ofinjury. Before restarting the machine,make sure that all personnel are clearof affected areas where machinemovement may occur.

DANGER:

There is a risk of an electric shock, ifsufficient precautions are not taken.An electric shock can be fatal.

For maintenance work, disconnectall devices from electric andhydraulic power sources and followCrushing Plant lockout procedures.





– Tag must identify the work being doneand the person(s) who locked andtagged the control.

– Locks and tags are changed with eachshift that comes on.

Work to prevent injury or death. Follow proper procedures at all times!

Maintenance, repair and installation ofelectrical equipment must be performed only

by qualified personnel who are familiar withthe machinery and equipment in question.

Automatic Functions and Unexpected

Start-ups

Unexpected start-ups during maintenance:

– Lock out and tag machine controls before performing maintenance orrepairs to avoid unexpected start-up.Failure to properly lock out themachine can lead to injury or death.Someone may accidentally start themachine from the control room or anunexpected occurrence may activate acontrol. For example, a power surgemay alter the logic of the controlsystem status causing an unexpectedmachine movement or sequence.

WARNING:

Machine parts may moveunintentionally and cause a risk ofinjury. Absence of safety functionsmay cause dangerous machinemovements.

Do not tamper with limit switches orother safety devices included in thesystem.

DANGER:

If danger zones are not respectedduring machine operation ormaneuvres there is a risk of seriousinjury or death.

Many devices operate automatically,following certain sequences whichhave been programmed into the logicsystem (i.e. programmable logiccontroller, microcontroller, relaysystem or similar). The danger zoneis any area within the confines ofmoving machine elements, feed

material or beneath any objects beinglifted. Do not enter these dangerzones unless the machine has been

properly safeguarded according tothe Crushing Plant lockout procedureand manufacturer's instructions.





Welding Equipment

Weld repairs are to be performed only byqualified personnel. Welders and welder’shelpers must wear protective clothing andequipment.

Precautions must be taken when torch cutting

and/or welding due to the health hazards posed by many metals. Anyone performing thesetypes of procedures should avoid breathing thefumes. Such procedures should be doneoutdoors or in a well ventilated area with eithera separate clean air supply provided to themechanic or with local exhaust of fumes.Please refer to EU, OSHA, MSHA or otherapplicable standards as appropriate. One of themost frequently used tools around theCrushing Plant is the cutting torch. CrushingPlants which are equipped with hydraulic

components and/or conveyor belts and/orv-belts should have these componentsdepressurized and adequately covered withflame-proof material so that sparks, weldspatter, etc., cannot reach theses areas.Ruptured high pressure hydraulic lines willquickly vaporize the hydraulic fluid as itreaches the atmosphere. This vaporized fluidcan quickly become a mass of flames, resultingin severe burns for personnel in the immediatearea. Adequate precautions should be made toavoid contact with these components. Never

perform welding or torch cutting activities inthe presence of flammable materials.

Toxic, Corroding and Irritating Agents

Before handling chemicals, carefully read thesafety instructions from the supplier of therespective chemical. Hazardous chemicalsmay be in use. Wear protective clothing,gloves, boots, glasses, and respirator whennecessary.

Refer to the MSDS (Material Safety DataSheets) and Crushing Plant procedures forhandling of these materials.

Avoid prolonged contact with fluids, such asgasoline, diesel fuel, hydraulic oil and cleaningsolvents, which may cause skin irritation orother reactions.

WARNING:

Risk of injury. Fire may break out. Never perform welding or torchcutting activities in the presence offlammable materials.

IMPORTANT!

All maintenance personnel who use cuttingand/or welding torches should be advised ifthere are hydraulic components in theimmediate area in which they are working.

IMPORTANT!

Contact Metso Minerals or its authorizedrepresentative prior to any welding of majorCrushing Plant components such as mainframe, adjustment ring, bowl, etc.

Performing welding on the Crushing Plantcomponents can be detrimental. Beforewelding, always verify that material isweldable! Failure to do so may result inweldment failure and present a risk of injuryand/or property damage.





Machine Inertia

Due to the large inertial forces of the CrushingPlant and Crushing Plant components, themachine can not be stopped abruptly. This is

potentially hazardous to personnel. All personnel must stay clear of rotating elementsand other moving parts until the machine has

come to a complete stop. Regularly inspect thestructural elements to maintain safe operation.

Hot Surfaces and Fires

There are hot surfaces on Crushing Plants.Protective gloves and coveralls help protectagainst burns. Be aware of hydraulic system,hoses, fittings, and pipes. Regularly inspectand observe high temperature lines, and fluidlines for leaks or damage. On mobileequipment be cautious around the engine

because of exhaust gases.

When in contact with hot temperatures, orwhen heated themselves, some hydraulic oilsmay ignite at around 392°F (200°C). Attention

must be paid to the condition of hydraulichoses and couplings. Remove immediately oilspills from floor, walkways, and pits. Fix allsources of oil leaks and clean up spills.

In case of a fire, the machine must be equippedwith a fire extinguisher or fire extinguishingsystem, and marked according to theregulations. Legislation and regulations aboutsuitable equipment may vary by country.

Familiarize yourself with applicable standards.Personnel must also be trained properly to beable to use fire extinquishing equipment.

A trained person with sufficient fireextinguishing equipment must be presentduring welding maintenance work. Cold wateron hot metal surfaces may cause a violentexplosion. Monitoring after welding must bearranged as required by laws and regulations.If no other regulations apply, monitoring timeis a minimum of one half hour.

Fire Hazards

– 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 thefiller neck to avoid static electricspark.





– Do not use gasoline or diesel fuel forcleaning parts. Good commercial,nonflammable solvents should be

used.

– Do not smoke while using flammablecleaning solvents. Whenever possible,use non-flammable cleaning solvents.

– Do not let greasy, oily rags accumulatein a poorly ventilated area. Store oilyrags and other combustible material ina safe place.

– Never use an open flame to check fuel, battery electrolyte or coolant levels, orto look for hydraulic leaks anywhere

on the equipment. Use a flashlight.Know where fire extinguishers arekept, how they operate, and for whattype of fire. Check regularly, at leastmonthly, to be sure they are in theworking area.

– Do not weld or cause open flame inthe presence of flammable materials.

– In the event of a fire, shut down theCrushing Plant, hydraulic power unitand lubrication system if this can be

safely done. Warn other people in thearea and commence fire fightingactivities according to applicablerules. It is the responsibility of theOwner to maintain proper training andinstructions 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

completely eliminated the possibility ofworkers being accidentally burned due tomolten zinc either spilling or exploding when

it comes in contact with wet surfaces. Whenepoxy backings are used, care should also betaken when removing the liners with a cuttingtorch . Do not use molten zinc as backingmaterial. Use epoxy only according to specificinstructions from the manufacturer.

Conveyor Belts

WARNING:

Do not use conveyor belts aswalkways. Do not climb on them.Always stay clear of any falling ordropping materials or components.

Never attempt to stand on, walk on,

or step across a conveyor. Neverstand below a running conveyor. Donot use loose clothing, neck ties,necklaces or other loose items whennear conveyors or other moving orrotating equipment. Emergency pullcords should be used only in case ofemergency -do not use them forroutine stoppage of conveyor. Neverattempt to service the conveyorwhile it is energized. Keep in mindhazardous nip points.





Crushing Plant Dust

By their nature, Crushing Plant and auxiliaryequipment such as chutes, transfer stations,screens, etc. can create dust and, if notcontained, the dust can escape into the air. In

general, high levels of dust (particularly,respirable silica) in the air can create a hazardof lung disease, depending upon theconcentrations of dust, the length of exposure,and the type of material being crushed. Dust

protective devices and dust warnings may berequired by OSHA, MSHA or local laws.

The Owner and Operator of the Crushing Plantmust identify the material being crushed andascertain whether respirable dust from theapplication poses a health hazard to personnelin the vicinity of the Crushing Plant.If the

material presents such a hazard the Owner andOperator must take all necessary measures toensure that personnel are protected from thedust. Such measures include, but are notlimited to providing dust collection system,using water spray bars at the feed anddischarge points, crusher transfer points andscreens and providing adequate personalrespiratory protection devices to workers.

Crushing with a choke level may also reducethe amount of dust issuing from the CrushingPlant itself. Because the configuration of each

rock crushing installation is different, MetsoMinerals recommends that the Owner andOperator consult Metso Minerals or a dustconsultant about possible alternative means ofdust reduction.

IMPORTANT!

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

WARNING:

Breathing dust may be hazardous tothe health of anyone working at, on,or around the Crushing Plant. It cancause serious or fatal respiratory

diseases including silicosis! It is theresponsibility of the Owner andOperator to determine the necessityand adequacy of protective devicesand warnings, to provide them, andto ensure that they are used andfollowed!





Noise and Vibration

• Crushing Plant Noise

Crushing Plant by its very nature is noisy andthe auxiliary equipment found at, on or aroundthe Crushing Plant such as chutes, transferstations, screens, etc., can at times be noisier

than the Crushing Plant itself. TypicalCrushing Plant noise level while crushingrange from 100 - 110 dB measured at 1 m (3ft)from the Crushing Plant.

Metso Minerals recommends wearing ear protection at, on and around Crushing Plant, particularly when the noise level exceeds85dB. It is recommended that the Ownerdevelop a signaling communication system innoisy environments to reduce the risk ofaccidents. Proper machine maintenance andreplacement 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 areregulated 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 thoseregulations.

• Vibration

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

is an increased risk of falling on a vibrating platform. Avoid standing on a vibratingOperator's platform or walkway.

Unexpected or excessive vibrations may be asign of wear and/or maintenance needs.Excessive vibrations associated with a portablecrushing or screening plant is frequentlycaused by improper cribbing.

It is recommeded to regularly monitorvibration levels of machine componentsincluding, but not limited to:

– bearings

– shafts

– rollers

– structural members (includingconveyor frames, walkways,

platforms, hoppers, chutes, etc.)





Improper Work Methods

Improper work methods and motions maycause physical injuries. Use suitable tools,cranes or jacks for moving large and heavyobjects. Overreaching and improper supportfor loads may lead to injuries to the back orother parts of the body. If you are unsure of

proper work methods, contact your safety

director or other person responsible forensuring the safety at your work place.

When lifting equipment by hand, protect your back by lifting close to your body and usingyour legs without twisting. Use hoistswhenever possible. Stand clear of hoistedloads and lifting cables.

Rotating Equipment and MovingComponents

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. Donot use any body part, tool or other foreignobject to attempt to stop, adjust, clear, or clean

any area in proximity to moving equipmentsuch as vibrating feeder, conveyor belts, drivesor other rotating parts of the crusher. Engagingin such activities can result in severe personalinjury, including death.

Crushers, designed to operate within a specificRPM range for maximum efficiency, are

typically checked with a tachometer. Makesure that any access openings have a protectivecover in place at all times except when RPM

readings are being taken. Never change sheavecombinations without first consulting yourMetso Minerals representative.

Ejection of Objects from the Crushing Plant

Ejected objects from the Crushing Plant maycause bodily injury. For example rock can bethrown several meters (several yards) into theair out of the crushing cavity during operation.Ejected materials may include rock, trampmetal, metal rods and work implements. Donot look into crushing cavity while crusher isin operation. Never attempt to clear jam onfeeder, crushing cavity or conveyors whensystem is energized.





Falling Material from Conveyors, Loading,Unloading and Feeding Operations

Rocks or other objects may fall fromconveyors during loading, unloading andfeeding operations. Impact of falling materialmay cause serious bodily injury. To assure safeoperation, all personnel must be alert whenoperating or working at or around the machine.

Wear proper protective clothing (includingalso helmet) and protective devices. Keep allnon-operating and non-trained personnel clearof the Crushing Plant at all times.

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

2.3.2 Typical Injury Types

Crushing

In general, avoid areas where you may beexposed to expected or unexpected machinemovements. Crushing injuries typically occureither between two rotating or moving parts, or

between a moving component and a stationaryobject.

Keep all body parts, clothing and tools awayfrom areas where they may get trapped,

pinched, or crushed, or otherwise come intocontact with moving parts on the CrushingPlant. When moving equipment, be sure the

path is clear. Horns and lights, where provided,

are for your safety to alert you of movingobjects. Pay attention to all such devices.

Slipping, Tripping, and Bumping

Items such as hoses, tools, etc., on walkways

and Crushing Plant floors impede movementand create a tripping and slipping hazard.Good housekeeping reduces the risksconsiderably.

Personnel should wear safety shoes that reducethe risk of slipping and provide protectionagainst falling objects or crushing. Hydraulicoil leaked or spilled on the floor must becleaned up immediately.

To help avoid injury, be aware of parts positioned close to the floor level or protrudingmachine components, changes in elevation of

platforms, walkways, and narrow access points. It is recommended that safety shoes beworn at all times. Wear safety helmets andother safety equipment as appropriate.





Falling

Use only designated access routes designed forthe purpose, for example walkways and

platforms. Walkways and platforms arefurnished with railings designed to meetapplicable standards. However, in some work

phases, railings or platforms may have to be

temporarily shifted aside. In those cases,special caution signs or temporary barriersmust be used when working on the machine.Use personal fall protection gear , temporary

barriers, interlocks, or other warning deviceswhere appropriate. Never attempt to operate,service, or repair the Crushing Plant withoutfirst ensuring proper protection against falling.Guards that are moved aside must be installedimmediately after maintenance work and

before the machine is returned to operation. Never climb or stand on areas of the CrushingPlant not specifically designated for that

purpose.

KEEP THE AREA CLEAN!

Cutting

Do not reach in or enter:

– the movement paths of cuttingequipment

– between moving machine components

– between moving loads and machinestructures

Entanglement

To avoid entanglement, avoid wearing looseclothing that could be caught by rotatingshafts, conveyors, and other moving parts .andmaterials. Remove neckties, necklaces, rings,

and other jewelry before performing workassignments. Also protect a long beard or hairfrom entanglement.

Do not touch a rotating roller, sheave, pulley,idler or moving conveyor belts with any body

part or work implement, as you may becomeentangled and pulled into a hazardous area.

Never attempt to service, repair, ortroubleshoot any moving part of the CrushingPlant while it is energized or otherwise capableof movement.

WARNING:

Do not operate any equipment untilall guard rails and safety deviceshave been re-installed or returned totheir proper operating condition.Failure to do this could result inserious injury or death.

WARNING:Keep safety gates, shrouds, guards,and other protective devices in placeand in good working condition at alltimes. Test emergency stop,electrical interlocks, and related limitswitches frequently.





Burns and Electrical Shocks

Protective gloves and coveralls help protectagainst burns. Be cautious around and nearhydraulic system hoses, fittings and pipes.Regularly inspect and repair leaking ordamaged high temperature lines and fluidlines.

To avoid electrical shocks: – Power must be shut off and locked out

before any servicing or maintenancework is done. Unplug or disconnect allauxiliary motors and equipment.

– DO NOT drill blindly into beams,electrical cabinets or other enclosures.

Avoid any contact between moisture or otherfluid and electrical equipment.

Impact from Ejected Materials

There are several hazards related to falling,flying or otherwise ejected materials when theCrushing Plant is being operated or serviced.For example, rock can be thrown several

meters (several yards) into air out of crushingcavity during operation. Ejected materials mayinclude rock, tramp metal, metal rods andwork implements. Keep the safety grate downduring the operation. Wear proper protectiveclothing (including helmet) and protectivedevices. Always use properly maintained andapproved tools and work methods. Stay clear

from the path of ejected materials, also duringlifting, assembly and dissassembly operations.

Removal of tramp iron jammed between thecrushing members is extremely dangerous.Follow the instructions in the instructionmanual.

Do not look into crushing cavity while crusheris in operation.





2.4 PERSONAL PROTECTIVE EQUIPMENT AND CLOTHING

Personal protective equipment and clothing

such as foot protection, helmet, hearing protection, dust protective devices, safetyglasses or other personal protective clothingand equipment should be worn at all times. Allequipment should be maintained in accordancewith applicable standards. Respirators,goggles, protective masks, gloves, boots, andother such equipment shall be cleaned anddisinfected before being used by anotheremployee. The Owner and Operator areresponsible for ensuring that all eye, head,respiratory, and ear protection conforms to

applicable standards.

2.4.1 Hearing Protection

Noise level in the machinery area may exceed85 dB, and exposure to the machinery area insuch circumstances without adequate hearing

protection may lead to hearing loss.Therefore, users must be provided with

appropriate hearing protection of the type andto the extent required by law.

2.4.2 Eye And Face Protection

General requirements should include:

– The Owner should ensure that personnel for the machine area use

appropriate eye or face protectionwhen exposed to eye or face hazardssuch as flying material, molten metal,liquid chemicals, acids or causticliquids, chemical gases or vapors.

– The Owner should ensure that affected personnel use eye protection thatincludes side protection from flyingobjects.

– The Owner should ensure that affected personnel who wear prescription

lenses while engaged in operationsthat involve possible eye hazards weareye protection that incorporates the

prescription in its design, or wear eye protection that can be worn over the prescription lenses without disturbingthe proper position of the prescriptionlenses or the protective lenses.

IMPORTANT!

Always use right size of protectiveequipment.

IMPORTANT!

It is the responsibility of the Owner andOperator to determine the necessity and

adequacy of protective devices and warnings,to provide them, and to ensure that they areused and followed.





2.4.3 Respiratory Protection

Respiratory protection is required when the aircontains contamination such as harmful dusts,fogs, fumes, mists, gases, smokes, sprays, orvapors. The primary objective is to protect thehealth of workers.

Respiratory protection must be provided by the

Owner when such equipment is necessary to protect the health of personnel. The Ownershall provide the respiratory protection andtraining programs, which are applicable andsuitable for the purpose intended and complywith the latest requirements andrecommendations of health authorities andregulatory agencies.

2.4.4 Foot Protection

The Owner shall ensure that affected personneluse protective footwear when working in areaswhere there is a danger of foot injuries due tofalling or rolling objects piercing the sole, andwhere feet are exposed to electrical orchemical hazards.

2.4.5 Head Protection

The Owner should ensure that affected personnel wear a protective helmet approved by OSHA, MSHA (or by other applicableauthority) when working in areas where thereis a potential for head injuries from fallingobjects or walking throughout areas with low

head clearance.

The Owner should ensure that a protectivehelmet designed to reduce electrical shockhazard is worn by personnel when nearexposed electrical conductors which couldcontact the head.

IMPORTANT!

The enormous degree of convenience as well

as the high safety factor involved when using plastic backing agents has made the use ofmolten zinc for Crushing Plant liner backingobsolete. See 2.3.1

IMPORTANT!

The area should be well ventilated. Epoxyfumes can cause nausea or eye or skinirritation.

IMPORTANT!

Breathing dust may be hazardous to the

health of anyone working at, on, or aroundthe Crushing Plant.

IMPORTANT!

Metso Minerals highly recommends thatadequate dust-protective devices such as arespirator be worn by anyone exposed toairborne dust, particularly silica dust, to

prevent its inhalation.





2.4.6 Hand Protection

The Owner should ensure that personnel use properly sized appropriate hand protectionwhen hands are exposed to hazards such asthose from skin absorption of harmfulsubstances, cuts or lacerations, abrasions,

punctures, chemical burns, thermal and

electrical burns, and harmful temperatureextremes.

2.4.7 Safety Harnesses

The Owner should ensure that any personworking on elevated areas not protected byrailings, or on hazardous places must wearsuitable safety equipment, including safetyharnesses, if there is a risk of falling. Confinedspaces may also require safety harnesses.

2.4.8 Work Clothing

The Owner should ensure that personnel wearappropriate clothing to help protect againsthazardous material and hot surfaces. Looseclothing can get caught in a nip, shaft, or othermoving machine components.

2.4.9 Tools

The Owner should ensure that personnel useappropriate tools for the job. Use tools that arespecially designed to break away or are easilyreleased to help avoid certain accidentsituations such as unexpected movement at anip point or a rotating shaft. Under nocircumstances must tools be allowed to comeinto contact with moving parts while theCrushing Plant is energized.

When working in humid or dampenvironments, use hydraulic tools or electricaltools that are suitably grounded, doubleinsulated, or have ground fault interruptioncircuits.





2.4.10 Safety Locks And Tags

Follow all lock-out tag procedures. Refer toappropriate standards and instructions

provided by Metso Minerals.

The lockout program, locks, tags and the blocking/restraining devices provided aredesigned for Operator’s protection. Operator’sresponsibility is to follow the program and usethe 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 andtagged the control.

– Locks and tags are changed with eachshift that comes on.

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

DANGER:

For maintenance work, disconnectall devices from electric powersources. Bring all hydraulic gravityor spring loaded devices to azero-energy state. Follow lockout

procedures.




MACHINE SAFETY SECTION 3

3.1 PROTECTIVE DEVICES AND ACCESSORIES FOR MACHINE SAFETY

3.1.1 Overview

The machine system has many built-in safetyfeatures. Owners and Operators should makethemselves familiar with the function and

purpose of each feature and make sure all ofthe features are enabled. Owners andOperators should never attempt to defeat,

bypass or disable any safety features. If any ofthe features are defeated or become disabled,the machine should not be operated untilcorrective action is taken and all safetyfeatures are restored.

3.1.2 Emergency-Stop (E-Stop)

Use the emergency stop when injury mayoccur or human life is in danger fromcontinued operation of the machine. This

provides the quickest, most sure way to stopthe machine. Due to the large inertial forces ofthe Crushing Plant and Crushing Plant partsand components, the machine can not bestopped abruptly.

Large red emergency stop buttons are typicallylocated in control panels near the vicinity ofdanger points.

Emergency stops can be, and often are, in theform of pull cords that run paraller to

conveyors and surround hazards.

The location of local E-stop buttons may varyon different machines; therefore the locations

of these buttons must be verified from theoperating and maintenance manuals specific tothe equipment and/or from proper training.

In emergency stop situations, the objective isto stop the machine as soon as possible tominimize potential injuries while maintainingthe structural integrity of the machine.

NOTE: It may be necessary to engagereset switches before movement canresume.

3.1.3 Safety Interlocks

A safety interlock is a device that will interruptthe supply of electricity, hydraulic oil orcompressed air to an actuator or motor. Amachine already in operation may need to stopquickly due to Operator error, safetyviolations, or an unexpected machine event.For example, a safety gate may be interlockedto stop a machine if the gate is opened whilethe machine is running.

Interlocks can also be used to prevent suddenunexpected movement of a machine functionor 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 limitswitches and other sensors to help assure

proper machine operation.

WARNING:

On large complex systems, theE-stop may control only thosecomponents that are in theimmediate area.

CAUTION:

Emergency stop not only stops themachine but often it may initiate

other protective sequences.




SECTION 3 - MACHINE SAFETY

THEREFORE IT IS IMPORTANT THATINTERLOCKING ARRANGEMENTS ARE

NOT REMOVED, MODIFIED OR

BYPASSED, AND THAT THEY ARECORRECTLY ADJUSTED. LIMITSWITCHES, AND OTHER SENSORSMUST BE KEPT IN GOOD WORKINGORDER.

Electric Motors

Electric drives and motors may be controlled

to stop or reduce speeds, as determined by thesafety interlocks at a particular location.

Hydraulic System

Components that help protect the hydraulicsystem include certain valves, such as hose

burst valves, pressure relief valves,counterbalance valves and pilot-controlledthrottle valves as well as pressure transducersand drain valves for pressure accumulators.Metso Minerals uses these components whereapplicable in the hydraulic systems tominimize the potential for hazardous situationsto occur.

A hose break valve functions to lock up if fluidflow is discharged too rapidly from an

actuating cylinder, as happens if a hose breaksand the loads react to gravity.

The pressure relief valve prevents the system pressure from rising beyond systemcapabilities. It helps protect the entire fluidsystem and any operators in the vicinity from

bursting hoses and components.

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

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

Safety Gates

Some safety gates are designed so that openingor closing of the gates will prevent or stop a

specific machine function in that area.Hydraulic, hydraulic or electric limit interlockswitches may cut off the drive or actuator

power or initiate an emergency stop mode.

For specific operation, see later sections of thismanual.

Safety gates may also be opened formaintenance purposes when the machine has

been stopped. Follow all lockout procedures.

Cable Switches

Cables or ropes connected to the electricalswitches can be used as interlocks also. Theymay stop machine function in areas wherecontrol panels cannot be closely located butwhere Operators may be working . Know thelocations of e-stop pull cords for conveyors.

WARNING:

Safety gates must not be openedduring normal machine operation.

Exceptions to this rule are defined inthe operating instructions.





3.1.4 Additional Warning Devices

Horns and Lights

If visual contact between work places isobstructed or if communication is difficult,sound and/or light signaling devices may beused before starting the machine or a machinefunction. The warning device for start-upshould operate so that personnel are givensufficient time to move to a safe distance fromthe machine. It is the responsibility of theOwner to ensure that the Crushing Plant isalways equipped with required horns andlights.

Safety Signs and Labels

Safety signs have colors to determine thedegree of hazard in particular areas. Thesesigns must not be removed. Temporary

placement of safety signs and danger tagsshould also be used on the control panels towarn of maintenance work and lockoutsituations.

Obey all warning and safety signs on themachine and in the manual.

Safety Warning Colors

Color of safety warnings are typically safetyyellow.

3.1.5 Walkways, Service Platforms,Ladders And Railings

The design of walkways, ladders and railingsfollow standards and regulations for theapplication. The walkways provide access tothe machine. Safe operating procedures must

be followed when on walkways. Never stand,

walk or climb in or on any area of the CrushingPlant not designated for such activity. If anarea of the Crushing Plant must be accessedand cannot be reached by designatedwalkways, ladders, or platforms, then theOwner and Operator must make all necessaryarrangements for safe access to the area,including but not limited to safe lifting devicesand fall protection.

CAUTION:

Extreme caution must always beused on machine walkways.





3.2 TRANSPORT

Observe the following precautions beforetransporting the Crusher Plant:

1. Chock chassis tires securely wheneverconnecting or disconnecting chassis fromtractor or dolly.

2. Check tire pressure. Use a protective cage ora clip-on type air chuck and remote in-linevalve and gauge when inflating tires. Neverexceed maximum inflation pressures of thetire or rim.

3. Check tightness of wheel lug nuts beforetransport and check frequently duringtransport.

4. Check that brake system operates correctly.5. Observe maximum axle and tire loading

capacities.

6. Protect components being transported usingappropriate shipping braces and blockingmaterial.

7. Travel may be limited to daylight hoursonly, depending on your specific plant andapplicable state regulations.

8. Follow recommended limits on towingspeed.

9. Make sure all lights are on and that they areoperating correctly.

10. Use traffic warning flags, signs and lights asrequired.

11. Before moving the Crushing Plant, check allroadways and bridges on the route forweight limits.

12. Check clearance of bridges, overhead linesand other overhead obstructions.

13. Follow all applicable laws and regulations.

3.3 TOWING

Observe the following precautions beforetowing the Crusher Plant or its components:

– Check if towing is allowed for eachindividual equipment.

3.4 AT THE WORK-SITE

3.4.1 Precautions

Observe the following minimum precautionsat the work-site:

1. Know the locations of underground andoverhead powerlines and other potentialhazards.

2. Select the work-site with care. The groundmust be firm, level and able to support theweight of the entire plant. Make sure there isenough room for loading ramps, loaders,conveyors, etc. and for safe maneuvering oftrucks and loaders.

3. Check that cribbing is secure and that plant

has not shifted or settled.

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

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

3.4.2 During operation

Keep watch

Do not rely too much on automated systems.

Observe Crushing Plant equipment while thesystem is running. Pay attention tounauthorized persons approaching the site aswell as any unusual behavior of the equipment(uncommon noise, vibration, smell, reducedoutput, etc.).

Clearing

Crushers Plant equipment can become pluggedand stall because of power failures, surges ofmaterial or other unplanned events. ClearingCrusher is potentially very hazardous. Shutdown the system completely, lock and tag out

all applicable controls and follow allinstructions in the instruction manual of yourspecific crusher.




SAFETY DURING MAINTENANCE AND REPAIR SECTION 4

4.1 GENERAL INFORMATION AND SAFETYLOCKOUTS

Detailed instructions for the operation of themachine can be found in following sections ofthe manual. Because each machine sectionmay incorporate unique functions, some ofwhich may be automated, maintenance

personnel should be knowledgeable of theoperation of the machine sections in order to

perform the maintenance and repair work assafely as possible.

DO NOT COMPROMISE SAFETY DUE TOTIME PRESSURES.

FOLLOW ALL CRUSHING PLANTSAFETY AND FIRE PREVENTION

PROCEDURES.Before starting any repair, maintenance ortroubleshooting work on the machine, ensurethe following:

– If you have not been trained to perform the required repairs,maintenance or troubleshooting, oryou are unsure how to safely performthe activity - STOP! Never attempt torepair, maintain or troubleshoot anyaspect of the Crushing Plant unlessyou are thoroughly trained for theactivity and understand how to

perform the activity in a safe manner.

– Be sure to coordinate all repair andmaintenance work with other CrushingPlant operations.

– Use lockout and warning signs toinform others that maintenance andrepair work are in progress. Thesesigns should only be removed (after allwork has been completed) by the

person who has placed them there.

– Transmit all knowledge of themaintenance work to the succeedingshift.

– Know the whereabouts of all personnel in, on, at and around themachine.

– Never service any machine orcomponent without first referencing itsmaintenance manual.

– Before handling chemicals, refer to theMSDS (Material Safety Data Sheets)and Crushing Plant procedures forhandling of these materials.




SECTION 4 - SAFETY DURING MAINTENANCE AND REPAIR

4.2 MECHANICAL SAFETY DURINGMAINTENANCE AND REPAIR

4.2.1 General

DANGER:FOLLOW ALL ESTABLISHEDLOCKOUT PROCEDURES. REFERTO THE APPROPRIATESTANDARDS.

For repair, maintenance ortroubleshooting work, disconnect alldevices from electric, pneumatic andhydraulic power sources and followlockout procedures.

The lockout instructions, locks, tagsand the blocking/restraining devices

provided are designed for your protection. Your responsibility is tofollow 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 beingdone and the person(s) wholocked and tagged the control.

• Locks and tags are changed witheach shift that comes on.

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

IMPORTANT!

Be sure all mechanical components are brought to a zero energy state including allspring 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, ortroubleshooting work on or in proximity toenergized mechanical components.

IMPORTANT!

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





4.2.2 Fire Safety During Maintenance AndRepair

Observe all regulations on fire safety. Sourcesfor fires include, but are not limited to thefollowing:

– sparks from grinding

– flames and molten metal from weldingor torching

– electrical arcing – spontaneous combustion

– smoking.

Before starting any work take the followingsteps to prevent a fire hazard:

– Properly dispose of rags withcombustible material to avoidspontaneous combustion.

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

hazard. – Clean up all debris.

– Clean up all oil spills and leaks.

– Remove any source of flammablegases, liquids or solids.

– Use proper electrical groundingtechniques for welding.

– Provide adequate fire extinguishingequipment; inspect such fireequipment regularly.

– Arrange for qualified personnel toguard against fire while welding,cutting, or heating operations are

being performed, as well as asufficient period of time after the workis completed.

– Protect yourself and others fromsparks with proper personal protectiveequipment and clothing.

4.2.3 Preventive Maintenance

Preventive maintenance will both increasesafety and be economically beneficial. It ismore safe and economical to replace a worn

part during a scheduled shut-down than torepair a broken device in the middle of a

production cycle. A machine or device that isnot in proper condition, and that has been leftwithout 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 orcause skin burns.

Some preventive maintenance suggestions fora machine include:

– observing the maintenance andlubrication instructions of the machineand equipment suppliers

– keeping the machine and surroundingarea clean and orderly

– monitoring the vibration levels of themachine and to help predict bearingfailures

– monitoring the power consumption ofmotors to help detect early failures

– repairing all leaks as soon as possibleto prevent more serious conditions thateventually may occur

– monitoring the condition of pipes andtubes 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 assignedwork; and

2. has limited or restricted means for entryor 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

3. is not designed for continuous employeeoccupancy.

Certain confined spaces may require an entry permit program to allow entry. Be sure that allapplicable procedures are followed. If youhave questions contact your Crushing Plantsupervisor for more information.

4.3 ELECTRICAL SAFETY DURINGMAINTENANCE AND REPAIR

4.3.1 General

Be sure all electrical components are broughtto a zero energy state including capacitors andsimilar electrical devices.

Before maintenance work:

DANGER:

Confined spaces may contain highconcentrations of gases which maycause injury or death. Follow allestablished safety procedures.

DANGER:

Follow all established lockout procedures.

For maintenance work, disconnect

all devices from electric, pneumaticand hydraulic power sources andfollow lockout procedures.


provided are designed for your protection. Your responsibility is tofollow the program and use the

proper equipment.

Remember:

• Follow procedures

• Stay alert


• Verify lockout








– Be sure all control power supplies areturned off, disconnected, and lock out

procedures have been followed.

– Confirm that ALL power sources aredisconnected. Some electrical devicesmay be supplied by more than one

power source.

– Be aware that multiple voltage levelsmay exist in some junction boxes.

– Ensure that during lockout procedures,locks and signs are appropriatelyattached, and subsequently removedonly by the person who installed themafter all work is completed. Follow

Crushing Plant lockout instructions for placement and removal.

– For testing and troubleshooting, clearall personnel from the machine just asthough the machine were beingreturned to production mode.Reactivate the necessary powersupplies and perform the tests. Thenagain disconnect all power suppliesand follow lockout instructions beforefurther maintenance work is

performed.

– Be sure electrical supply voltage isdisconnected before drilling into anystructural frame members. Electricalcables may be inside.

– Verify that electric motors aredisconnected before starting anymaintenance work, thereby preventingthe supply of electricity to the motor.Generally the disconnects are locatedin the drive control room. Each person

performing maintenance work should

install their lock and sign the lockouttag.

4.3.2 Electrical Fault Situations

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

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

IMPORTANT!

Electrical connections can and do loosen dueto vibration in transit and thermal expansionof the wires and lugs in operation. This isespecially trua after initial delivery, break inand after major relocation. Looseconnections increase current draw, which can

result in false trips, intermittent circuits, and burned-out components. As part of thestart-up, check and retighten as necessary allelectrical connections in the elctricalenclosure. Repeat after the first forty to fiftyhours of operation. This work must be

performed by properly trained personnel.

IMPORTANT!

Improper phasing will damage backstops inconveyor drive reducers and may damagehydraulic system components.





4.3.3 Program Changes

An electric outlet may be supplied in the logiccenter and control cabinet for programming

purposes only. Do not connect any electricaltools to this outlet. The tool may causeelectrical disturbances in the machine controlsystem. This could alter the machine control

program and cause unpredictable machineoperation.

NOTE: Do not use the logic center or controlcabinet’s outlet for anything other than a

programming device!

4.4 HYDRAULIC SAFETY DURINGMAINTENANCE AND REPAIR

Before proceeding with any repair,maintenance or diagnostic procedures on thehydraulic system, bring all components to azero energy state, including cylinders,

WARNING:

Changes to Metso Minerals' suppliedcontrol program should be madeonly by Metso Minerals personnel.Faulty program code may cause themachine to behave unexpectedly.Any changes to interlock circuitrymust be made with extreme cautionand be reviewed and approved inwriting by Metso Minerals beforeimplementation.

DANGER:

Follow all established lockout procedures.

For maintenance work, disconnectall devices from electric, pneumaticand hydraulic power sources andfollow lockout procedures.


provided are designed for your protection. Your responsibility is tofollow the program and use the

proper equipment.

Remember:

• Follow procedures

• Stay alert


• Verify lockout








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

– Mineral and other oils and additivescan cause skin irritation. Inhaled oilmist can also cause internal irritation,headache or nausea. Avoid repeatedexposure to these materials. Useappropriate personal protectiveequipment.

– Purge entrapped air from the hydraulicsystem. Entrapped air in the hydraulicsystem can cause erratic andunexpected movements.

– Oil mist in the work area or oil leaking

onto floors and walkways will cause aserious risk of slipping. Clean up allspills and repair leaks immediately.

– Hydraulic oil temperature may beextremely high;

– A mixture of air and oil mist mayexplode at higher temperatures.Hydraulic oil spilled on hot machinesurfaces may start a fire.

– Pressurized hydraulic hoses should not be handled with bare hands sincehigh-pressure leaks may easily

penetrate the skin. Hydraulic fluid

pressure in the hoses may exceed 3000PSI/210 bar/21MPa.

Hydraulic hoses are subject to wear and tear.Pressurized hoses tend to straighten up, bendor twist due to reaction forces. Replace allweakened or deteriorated hoses promptly.Keep hoses properly clamped and secured to

help prevent being whipped by broken hoses.

– Avoid letting dirt and other impuritiesinto the system while doingmaintenance work. Use lint free clothsfor cleaning the hydraulic componentssystem.

– When changing a cylinder, or otherhydraulic device, plug all open portsand hose ends. Catch spilled oil in asuitable storage device and avoidintroducing dirt into the system.Dispose of all waste fluids as

presented by law.

– Tighten disconnected pipe and hosecouplings immediately afterreinstallation. Before finishing thework, check all parts and connectionsthat have been serviced or repaired.

– Before starting up the pumps, makesure that maintenance work iscompletely finished in all work areas.When starting up the pumps, stay at adistance from the areas which were

repaired.

– Before opening the main valves, makesure that there is no one working

between any parts of the machine,since pressurization of the system maycause machine motion.

WARNING:

Elevated temperatures levels can behazardous and may cause severe

burns. Wait until machine cools

down before doing maintenance orrepair.

WARNING:

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





– Once the system is in the pressurizedstate, test repaired system for properoperation before putting system back

into production.

Check the system for possible leaks afterrepair. Leaking fittings must not be tightenedwhen under pressure. To seal threaded fittings,use appropriate sealing rings or a sealingcompound suitable for hydraulics.

4.5 GENERAL MAINTENANCE WORK

The following are some of the do's and don'tsto be followed as part of normal CrushingPlant procedures

– Do not perform any maintenance onmoving machinery. This includes suchitems as adding lubricating oil orgreasing parts while the crusher is inoperation.

– Never clear a jam on or in the feeder,crushing cavity or conveyors whensystem is energized.

– Do not put hands or feet on the releasecylinders, which protect the crusherfrom tramp iron overloads while thecrusher is in operation.

– Do check the manufacturer'srecommendations for periodicmaintenance procedures. Thesemaintenance procedures are designedto not only avoid damage to theequipment but also to avoid harm tothe Operator.

– Do avoid spillage around the crusher.Operator should make it a habit to

keep the area immediately adjacent tothe crusher free from spillage, whichcould cause people to trip and fall.

– Never look into the crushing cavitywhile crusher is in operation.

– When using a crane or other liftingdevice to raise or lower a load keep all

personnel clear of the area.

– Never detach a lifting device from itsload until the load is securely affixedat its designation, or steps have been

implemented to prevent the load fromunintended shifting or falling.

– Never walk, stand, crawl or lay underany load hanging from a crane or otherlifting device.



LOKOTRACK LT95/LT95S

INSTRUCTION MANUAL

140592-EN



01/05 0-57-EN LOKOTRACK LT95/95S INSTRUCTION MANUAL 0-1

Lok otrac k L T95/95S CHAPTER 0

This Instruction Manual is valid for Lokotrack LT95 and LT95S primary crushing units manufactured byMetso Minerals from the serial number 72087. Lokotrack LT95 and LT95S are diesel engine operated

primary crushing units equipped with crawler chassis. They are intended for use in the crushing of recyclable materials.

Technical information and illustrations related to the structure of the crushing units presented in thisInstruction Manual are not binding or conclusive. Due to the continuous development of the machines, wereserve the right to make changes to the manual without prior notice.

This is the first edition of the Instruction Manual, published in February 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



0-2 LOKOTRACK LT95/95S INSTRUCTION MANUAL 0-57-EN 02/03

CHAPTER 0 - LOKOTRACK L T95/95S




LT95/95S

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23.7 OPTIONAL EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

CONTROL PANELS

4.1 OPERATING PANEL SWITCHES/BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 DRIVE CONTROL DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 PICKING STATION CONTROL (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.8 CONTROL LEVERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25.5 EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3



LT95/95S

Table of Contents

6/05

TRANSPORT

6.1 SAFETY IN THE TRACK DRIVE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 SELECTING THE DRIVING SPEED RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.3 DRIVING THE LT95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.4 TRANSPORTING THE LT95 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7.5 BY-PASS CHUTE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7.6 FEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7.7 MINIMUM SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7.8 CLEARING OF THE BLOCKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7.9 REMOVAL OF THE STEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7.10 INSTRUCTIONS FOR RADIO CONTROL (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7.11 RECYCLING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

SCREEN MODULE

8.1 SCREEN UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1



LT95/95S

Table of Contents

MAINTENANCE

9.1 PERIODICAL MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.2 RUNNING-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

9.3 HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

9.4 AMOUNT OF FUEL/ADDING FUEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

9.5 FILLING VOLUMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

9.6 TRACKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

9.7 LUBRICANT RECOMMENDATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

9.8 FLUID CHANGE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

9.9 ENGINE FILTER CHANGE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

9.10 REPLACING THE HYDRAULIC OIL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

SERVICE INSTRUCTIONS

10.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10.2 BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

10.3 OTHER ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

10.4 WELDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

10.5 PRESSURE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

10.6 SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

TROUBLESHOOTING

APPENDICE

A Symbols

B Additional Information

C Noise

D Recycling

E Transport Drawing



01/95 1-00-EN INSTRUCTION MANUAL 1-1

PREFACE SECTION 1

This instruction manual is intended to assist ownersand 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. Followingthese instructions will help to avoid possibledanger, reduce repair costs and breakdowns and toincrease the reliability and life of the equipment.

This manual must be complemented by thoseinstructions necessary because of existing nationalmandatory rules relating to accident prevention andenvironmental protection.

A copy of this manual must be kept at theequipment's location and made available to theoperators as required.

In addition to this manual and accident prevention

regulations mandatory in the country of use and atthe equipment's place of operation, generallyrecognized rules for safe and professional operationmust be observed.

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

– operations, including installation, startup,

operation, application engineering,materials handling, site labour,environmental engineering and safetydepartments.

– maintenance, including inspection andrepair.

– transport, materials handling and rigging.

Note that this instruction manual containsinformation and instructions on alternative andoptional equipment. Normally the machines haveonly some of them. Before maintaining andservicing, find out which alternative and optionalequipment your machine has.

See separate instruction manuals for more detailedinstructions when servicing the main components.

There may be optional equipment which haveseparate instruction manuals. Those manuals must

be read and used by each person who works withthe equipment.



1-2 INSTRUCTION MANUAL 1-OO-EN 01/95

SECTION 1 - PREFACE




02/05 2-00-EN SAFETY 2-1

SAFETY SECTION 2

Please refer to the general SafetyInstructions in Part A of thisInstruction Manual folder.



2-2 SAFETY 2-00-EN 02/05

SECTION 2 - SAFETY





MA IN COMPONENTS CHAPTER 3

3.1 MAIN ASSEMBLY

Figure 3.1 Main assemly

Callout Description Callout Description

1 Diesel engine 5 Main conveyor

2 Tracks 6 Side conveyor (optional)

3 Crusher 7 Magnetic separator

4 Feeder




CHAPTER 3 - MAIN COMPONENTS

3.2 DIESEL ENGINE

The operating power of the LT95 crushing unit isgenerated by its Cummins diesel engine. The

engine runs on hydraulic pumps.

3.3 TRACKS

The LT95 crushing unit moves on a set of tracks.The tracks ensure a safe and speedy operation of the machine even in rough terrain.

3.4 CRUSHER

The Lokotrack C95 jaw crusher is the heart of theLT95 unit. The materials fed into the crusher are

crushed into smaller pieces by the machine.

3.5 FEEDER

The feeder ensures an even and uninterrupted flowof materials into the crusher. Any feed materialsmaller than the opening of the feeder grizzly goesthrough the grizzlies, bypassing the crusher. Thisincreases feed capacity and prevents materials fromaccumulating and obstructing the crusher.

3.6 MAIN CONVEYOR

The main conveyor transfers the crushed materialfrom the crusher to the stock pile or onwards for further treatment.

3.7 OPTIONAL EQUIPMENT

3.7.1 Side Conveyor

The optional side conveyor transfers the materialthat has bypassed the crusher through the feeder grizzlies and on to the stock pile located next to themachine.

3.7.2 Magnetic Separator

The optional magnetic separator is installed abovethe main conveyor. It separates magnetic objectsfrom the crushed material and transfers themonwards to a separate pile located next to themachine.

3.7.3 Level Indicator

The purpose of the level indicator is to control thelevel of the feed material that enters the crusher.

The indicator stops the feed process when thematerial level is too high. The indicator resets itself automatically.

Keep the level indicator clean to ensure that itfunctions properly.

Refer to the IC500 Instruction Manual for further information on the level indicator.

3.7.4 Hydraulic Output

The hydraulic output can be set on, off or “on withthe process”. The selection is done by the process

option selection page.

Refer to the IC500 Instruction Manual for further information on the hydraulic output.

3.7.5 Intermediate Cable For SecondaryUnit

The unit is equipped with a 6-pin socket allowinginformation flow between the primary and thesecondary unit. The socket has three differentfunctions:

Pins 1&2: When connected, LT95 gets information

on the connection of the secondary unit.

Pins 3&4: Feeder ON/OFF information (secondaryfeed/emergency functions can be connected to this).

Normally open contact is required.

Pins 5&6: For the level sensor of the secondaryunit. Normally closed contact is required.




CONTROL PANELS CHAPTER 4

4.1 OPERATING PANEL SWITCHES/BUTTONS

Figure 4.1 Operating panel


1 Emergency stop 6 Process ON

2 Lubrication unit 7 Key switch

3 Radio control key 8 Signal horn

4 Water pump 9 Process OFF

5 Display 10 Work light




CHAPTER 4 - CONTROL PANELS

4.2 DRIVE CONTROL DEVICE

Figure 4.2 Drive control device


1 Track, left-hand 3 RPM of diesel engine

2 Track, right-hand 4 Emergency stop





4.3 REMOTE CONTROL

Figure 4.3 Remote control


1 Emergency stop 7 Crusher start

2 Feeder stop 8 Crusher counter-clockwise swing

3 Feeder start 9 Crusher clockwise swing

4 Feeder speed - 10 Crusher setting - increase

5 Feeder speed + 11 Crusher setting - decrease6 Crusher stop





4.4 HYDRAULIC MODULE CENTER

Figure 4.4 Hydraulic module center


1 Safety switch for conveyors 4 Emergency stop

2 Fuel pump (optional) 5 Hand valves

3 Socket for screen module 6 Socket for service light





4.5 RADIO CONTROL (optional)

l

Figure 4.5 Radio control

4.5.1 Radio components

Transmitter, receiver, two batteries, chargingdevice for the batteries, two key switches.

For functions of radio control refer to Chapter 7.10.

4.6 IC500 CONTROL SYSTEMRefer to a separate IC500 Instruction Manual for information on usage of this control system. Themanual is attached to this Instruction Manualfolder.

4.7 PICKING STATION CONTROL


1 Engine rpm UP-DOWN/ feeder ON-OFF 6 Battery voltage level indicator

2 Battery 7 Selector switch tracking/crushing

3 Feeder speed increase/decrease 8 Right track forward-backward

4 Remote STOP 9 Key switch

5 Left track forward-backward





(optional)

Figure 4.6 Picking station control


1 Emergency stop 4 Feeder speed -

2 Feeder stop 5 Feeder speed +

3 Feeder start 6Control place selector switch(Remote / Picking)





4.8 CONTROL LEVERS

4.8.1 Hydraulic Module

Figure 4.7 Location of the hydraulic valves


1 Conveyors folding up / down 4.2 Hydraulic PTO

2.1 Pressurization of the return rod 4.3 Magnet / Fast drive

2.2 Adjustment wedges in / out 4.4 Left track

2.3 Crusher accumulator shut-off valve 4.5 Right track

2.4 Pressure sensor 4.6 Feeder

3.1 Screen module connect socket 4.7 Side conveyor / Manual valves3.2 Socket for service light 4.8 Device pump pressure sensor

3.3 Fuel filling pump 5 Pressure gauge of the device pump

3.4 Emergency stop 6 Left feed hopper wall up/down

3.5 Conveyors maintenance switch 7 Rear feed hopper wall up/down

4.1 Main conveyor / Manual valves 8 Right feed hopper wall up/down




STARTING AND STOPPING CHAPTER 5

5.1 BEFORE STARTING

Check the condition of the machine.

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

Figure 5.1 Turn the light pole up

Check the tension of the crusher V-belts. The beltdeflection is 22 mm (4/5") for a force value of 50 N(11 lb) (figure 5.2).

Figure 5.2 Check the crusher V-belt tensions

Make sure that the machine is always operated in asafe manner, and that it is in good mechanicalcondition. Make sure that the machine is firmly

positioned and that there is no risk of its inclination.

Operation of the machine is permitted only whenall necessary protective and safety devices, e.g.guards, emergency stop devices, silencers,aspirators etc. are in place and in full operating

condition.

Figure 5.3 Do not initiate the process before thefeeder side panels have been raised.

IMPORTANT!

Before starting the machine, make sure that thereare no personnel in the vicinity of the machinewhose safety may be endangered! Walk aroundthe machine and make sure that there is no-oneon, next to or under it. Before starting themachine, caution everybody in its vicinity thatyou are about to start the machine.

IMPORTANT!

Do not initiate the process before the feeder side panels have been raised in order not to damage therubber rams! (figure 5.3)




CHAPTER 5 - STARTING A ND STOPPING

5.2 STARTING THE DIESEL ENGINE

Start the diesel engine as follows:

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

2. Wait until the unit centre display is visible.Reset possible display messages with F1function key.

3. Turn the key switch to START position andhold it that way until the engine is running.

NOTE: Hold the key switch at start position untilthe diesel engine starts.

Figure 5.4 RPM speed of the diesel engine canbe controlled with the RPM control switch

located in the drive control box

5.3 STOPPING THE DIESEL ENGINE

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

NOTE: Before stopping the diesel engine, makesure that the engine idles for a few minutes.

5.4 ADJUSTING DIESEL ENGINE RPMSPEED

The automatic control of the machine monitors andadjusts the diesel engine RPM during the start andthe crushing process. During this time, the user cannot adjust the RPM speed. When the process isnot running, the RPM speed of the diesel enginecan be controlled with the RPM control switchlocated in the drive control box (ref. fig. 5.4) If themachine has radio control (optional), the RPMspeed of the diesel engine can be adjusted withradio control in the same way as with the drivecontrol box.

If you use manual control, be especiallycareful. The fact is that a manuallyactivated device will not run until thediesel engine is running. But the devicewill start to operate immediately whenthe engine is started, if the manualcontrol is on.





5.5 EMERGENCY STOP

In the event of an emergency, press the emergencystop button to stop the machine or the conveyor

(figure 5.5). For instructions on operation of theemergency stop relay, see Chapter 10.

Figure 5.5 Emergency stop buttons

Emergency stop button Function

A Stops the machine

B Stops the discharge conveyor

C Stops the main conveyor





ENSURE THAT THE SUCTION VALVES OFTHE HYDRAULIC TANK ARE FULLY OPEN

If the suction valves are not fully open, the position

switch of the suction valves will activate theemergency stop function.

Figure 5.6 Ensure that the suction valves of the hydraulic tank are fully open.




TRANSPORT CHAPTER 6

6.1 SAFETY IN THE TRACK DRIVE MODE

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

Normally the LT95 unit can be moved to itsworking 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 inclinationdo not prevent driving.

In the track drive mode, the maximum inclinationallowed for the machine is 5 degrees in lateraldirection and 15 degrees in longitudinal direction.

Make sure that the load-bearing capacity of theunderlying ground is at least 15,000 kg/m2 (3,072lbf/sq f).

Start the engine according to the instructions provided in Chapter 5.2.

6.2 SELECTING THE DRIVING SPEEDRANGE

It is possible to use three different speed ranges for driving the machine; fast, slow and normal. Selectthe required speed range with the engine rpmcontrol switch. Recommended driving speeds are

shown in Table 6-1:

Table 6-1 Recommended drive speeds

• 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 thetracking distance is relatively long. In other

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

6.3 DRIVING THE LT95

Drive the LT95 with the help of the drive controlslocated in the drive control box. If the machine isequipped with a radio control feature (optional), itis also possible to drive the unit with the help of theradio control feature. Drive with the radio controlin the same manner that you would drive if youwere using the drive control box.

Connect the drive control cable into one of thecable connecting sockets (figures 6.1 and 6.2).

The LT unit can now be moved in either directionusing the drive control levers located in the remote

control unit (figure 6.2).

Figure 6.1 Connect the drive control cable toone of the cable connecting sockets.

NOTE: Make sure that no-one is near the unit before attempting to drive it. Avoid making anysudden moves while driving.

NOTE: In the case of longer driving distances(over 100 m / 328 ft), the LT95 must be driven withits feeder end first. This ensures that the track chainremains tight and prevents the chain from skippingover the drive pulley teeth.

Engine speed Drive speed

Idle - 1499 Slow

1500 - 2099 Normal

2100 - max Fast

IMPORTANT!

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




CHAPTER 6 - TRANSPORT

NOTE: In the case of longer driving distances,monitor the temperature of the hydraulic oilcontinuously. The oil temperature should not

exceed 90°C (194

°F). If the oil is too hot, it maydamage the seals.

If no crushing is required, stop the engine accor-ding to the instructions provided in Chapter 5.3.

If crushing is required, refer to section 5.2 for instructions.

A few tips to make turning the LT95 unit easier:

• It is easier to turn the LT95 on hard surfacesthan on soft surfaces.

• If the LT95 cannot be turned while drivinguphill, drive downhill for a short distance,turning the unit at the same time.

NOTE: When driving on an uneven surfaceor in the event that the LT unit is connected toLokolinks, moving the LT requires extreme

caution.• Avoid turning the machine in situations where

the upper segment of the crawler chain acts asthe driving end. The crawler chain may loosenif the tightening spring located inside the craw-ler chassis gives way, which in turn may causethe traction wheel to skip over the chain.

• Always select an appropriate surface for turning the LT unit. Only attempt to turn theLT in a location where the ground surfacesupports the whole length of the unit's tracks.This ensures that the traction force isconcentrated on the lower section of the

crawler chain.

NOTE: If manual valves are active it will preventtrack driving.

Figure 6.2 The LT95 unit can be moved in either direction with the help of the drive controls.





6.4 TRANSPORTING THE LT95 FROM ONELOCATION TO ANOTHER

REQUIRED PRE-TRANSPORT

MEASUREMENTS

REQUIRED EQUIPMENT

– Transport platform, minimumload-bearing capacity 30 t (34 st).

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.

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

3. Place the light pole into transportposition.

4. See 7.10 Extended discharge conveyor if necessary.

IMPORTANT!

When transporting the LT95 on public roads,make sure that you have received the permitsrequired for special transports from theappropriate authorities. Check the localregulations, as they vary from one country toanother.





6.5 DRIVING ONTO/OFF THE TRANSPORTPLATFORM

NOTE: Drive the LT95 onto/off the trailer with

great care.

Fix a suitable ramp against the trailer so that itsmaximum inclination does not exceed 1:4 whendriving the LT95 onto the trailer.

The LT95 can be driven onto the transport platform by driving it either straight or in reverse, dependingon the type of transport platform in question.

Always make sure the hydraulic oil surface level isright before driving the LT95 onto/off the trailer.

Figure 6.3 Driving the unit onto a trailer.

Table 6-2 Weight of LT95/95S optional equipment LT95/95S.

NOTE: The actual weight of the unit can becalculated by adding the weight of the optionalequipment to the weight of the basic unit. (Note:The weights are indicative. Actual weights mayvary due to manufacturing tolerances.)

WEIGHT OF THE BASE UNIT (WITHOUT FUEL): 27 000 KG / 78 000 LBS

Weight of LT95/95S optional equipment kg lbs

Side conveyor H 5-4 440 970

Bracket for magnetic separator 210 460

Magnetic separator 900 1990Feed hopper (6m3) 570 1300

Hydraulic setting adjustment 100 220

Hydraulic protector 250 550

Recycling plate 70 154

Long conveyor H8-12 620 1370

Dust cover 140 310

Hammer & Pedestal 1500 3300

Screen unit 3300 7280




CRUSHING CHAPTER 7

7.1 CRUSHING SITE

The unit should be located near the material pile tomake loading easy and quick. Shape the feedmaterial pile with a wheel loader or excavator so

that it is distributed over a small area and piled highenough for easy loading (figure 7.1).

Figure 7.1 First shape the material pile.

The location of the discharge pile must be chosenso that it doesn't cause any danger to workers or

passers-by. Make sure that there is enough spacefor the discharge pile, the discharge machinery(wheel loader or excavator) and the lorry (figure7.2).

Figure 7.2 Spread some fine-grained material onthe ground and even it out.

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 onthe 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 General measures taken on the site.

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




CHAPTER 7 - CRUSHING

During the crushing process, make sure that theunit is in horizontal position. The maximuminclination allowance is 1 degree in lateral direction

and 2 degrees in longitudinal direction (figures 7.5and 7.6).

Figure 7.5 The maximum lateral inclinationpermitted during the crushing process is 1

degree.

Figure 7.6 The maximum longitudinal inclinationpermitted during the crushing process is 2

degrees.

For purposes of maintenance, it is recommendedthat you dig a hole under the unit unit (figure 7.7).

Figure 7.7 Dig a hole under the unit for

maintenance purposes.

7.2 FEEDING MEASURES

7.2.1 Loading Equipment

The unit can be loaded with the help of either anexcavator or a wheel loader.

• LOADING USING AN EXCAVATOR

The unit can be loaded from the side or the rear.

Find a suitable loading site and move the excavator bucket to its loading position. Then drive the unitinto a suitable position below the excavator bucket.

The operator of the excavator must have fullvisibility to the upper part of the feeder (figure 7.8).

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





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

Figure 7.9 Load the material into the rear of thefeeder, on top of the solid base.

If the feed material contains metals, someoneshould stand next to the feeder and remove themetal pieces before they are able to enter thecrusher.

• LOADING USING A WHEEL LOADER

The unit can only be loaded from the rear. Themaximum 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 loadingramp to ease access to the feeder.

Drive the unit as close to the pile as possible tomake loading quick and easy.

NOTE: The feeder has two basic applications:

a. stabilising the feed rate.

b. separating the fine material before itenters the jaw crusher.

If the feeder is too full, it will not separate the finematerial, which in turn will result in decreasedoperating capacity.

NOTE: Do not drive the excavator bucket into thematerial or try to force the material into the jawcavity.

7.3 DISCHARGE MEASURES

• ALTERNATIVES

– Wheel loader – Stack conveyor

– Secondary process

– LT (secondary)

Check the height and volume of the discharge pile.Do not let the pile grow so high that it reaches theconveyor. The distance between the pile and theconveyor must always be at least 200 mm (9")(figure 7.10).

Figure 7.10 The distance (h) between the pileand the conveyor must be always at least 200

mm (9").

When discharging with the help of the wheelloader, be careful not to damage the conveyor.Discharge from the side, do not push the materialunder the unit.

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





7.3.1 Extended Discharge Conveyor

• FROM TRANSPORT TO CRUSHING1. 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 headof 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 (*).

• FROM CRUSHING TO TRANSPORT

1. Activate conveyor control lever (*).

2. Remove crushing position locking pins fromtheir places. Lift the conveyor slightly toease 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 (*).

(*) Ref. 4.4 # 4.5

Figure 7.11 Transport position

Figure 7.12 Crushing postion

IMPORTANT!

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

IMPORTANT!

The discharge conveyor can only be folded on top of an even surface.





7.4 CRUSHING

1. Release the transport locks from the sideconveyor (optional). Turn the side conveyor down with the help of the controls located inthe hydraulic valve section (figures 7.13 and7.14).

Figure 7.13 Turn the side conveyor down withthe help of the control levers.

Figure 7.14 The control lever for the side

conveyor is located in the hydraulic valvesection (2). NOTE! Control switch for the hand

valves, see Chapter 4.4.

2. Turn up the side walls of the feed hopper and lock them in place with the help of thewedges (ref. fig. 7.15).

– Lift both of the side walls (1 and 2) intotheir uppermost position.

– Lift the rear wall (3) into its uppermost position and lock it in place with the helpof the wedges (4). The upper wedges areeasiest to lock in place from the directionof the feeder. NOTE! Turn off the dieselengine before moving over to the feeder.

– 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 thelifting ropes of the crane first. Once youhave done this, you can proceed to removethe wedges in reverse order.

Figure 7.15 Turn the rear wall of the feed hopper upwards.





Figure 7.16 Automatic transport lock

7.4.1 Starting the Crushing Process

Before starting the crushing process, always makesure that the crusher cavity is empty. If there is

material in the cavity, clear the cavity as instructedin chapter 7.8.

When the crushing process has started, the RPMspeed of the diesel engine cannot be adjusted by theoperator before the crushing process has beenstopped again.

NOTE: Initiate the crushing process by pressingthe “Process ON” button (figures 4.1 and 4.2).

NOTE: When starting the crushing process, theautomatic control function takes care of starting thedevices, monitoring any possible problems andadjusting the RPM level of the diesel engine. Theinitiation of the crushing process takes about oneminute after the process button has been pressed.

– Connect the water supply (if needed).

– Turn on the lights if required.

Stop the crushing process by pressing the “ProcessSTOP” button.

NOTE: When stopping the crushing process, theautomatic control function takes care of turning off the equipment, monitoring any possible problemsand adjusting the RPM level of the diesel engine.The termination of the crushing process takesapproximately 1 minute.

Process options eg. side conveyor, magnet

separator or hydraulic PTO must be selected beforethe process start.

You can stop the feeder and the crusher in order tosafely remove uncrushable objects from the feeder.Both the crusher and the feeder can be restartedfrom the service platform.

IMPORTANT!

Make sure that the crusher is always operated in asafe manner, and that it is in good mechanicalcondition. Make sure that the crusher is securelystationed so that there is no risk of its inclination.

IMPORTANT!

Operation of the crusher is only permitted when allnecessary protective and safety devices, e.g. guards,emergency stop devices, silencers, aspirators etc. arein place and in full operating condition.

BEFORE STARTING THEMACHINE, MAKE SURE THATNO-ONE IS ON, NEXT TO ORUNDER THE CRUSHER. CAUTIONEVERYBODY IN ITS VICINITYTHAT YOU ARE ABOUT TOSTART THE CRUSHER.

IMPORTANT!

Only initiate the crushing process once you have

made sure that the feeder side panels have beenraised and locked in place with the help of thewedges.





Load some material into the feed hopper while thevibrating chute is running. For further instructions,refer to Chapter 7.6 "Feed control".

When loading with the help of a wheel loader, thefeed hopper must be almost empty before any morematerial can be loaded into it. When loading withthe help of an excavator, more than one bucketfulcan be loaded in to the hopper at a time.

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

Do not attempt to crush stones that are too large tofit inside the cavity. Having to reposition rockswastes time, reduces capacity, and imposesunnecessary loads on the crusher.

You can stop the feeder and crusher in order tosafely remove uncrushable objects from the feeder.Both the crusher and the feeder can be restartedfrom the remote control box located in the service

platform.

NOTE: Clay, wood and any non-stone-basedmaterials must be prevented from entering thecrusher. This may overload and damage thecrusher. Also make sure that no explosives enter the crusher.

Figure 7.17 "Emergency stop" - buttons (for

more information, refer to 5.5)

Figure 7.18 Do not switch the side conveyor onwhile it is in a transport position.

7.4.2 Additional Safety Instructions for Useof the Hammer and Beam When They AreAttached to the Lokotrack LT95/95S

• Installation of the equipment in working position:

1. Ensure that the crushing process is switchedoff.

2. Turn the hammer switch on.

3. Remove the transport locking.

4. Lift the beam up and lower it onto the

process rest stand.

5. Install the crusher cavity protection.

6. The hammer and base are now ready for use.

7. If you are not using the hammer at this point, turn the hammer off.

IN THE CASE OF AN EMERGENCY,PRESS THE "EMERGENCY STOP"-BUTTON TO STOP THE UNIT.

IMPORTANT!

The side conveyor must not be switched on if it isin transport position





• Usage


2. Turn the hammer off after use.

• Installation of the equipment in transport position:

1. Stop the crushing process.


3. Lower the beam and turn it into transport position.

4. Engage the transport locking.

5. Ensure that the beam and base do not exceedtransport measurements.

6. Turn the hammer switch off.

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 thematerial flow. When using the centre position, lock the lever in place using a bolt.

Figure 7.19 The chute has been directedtowards the main conveyor.

Figure 7.20 The chute has been directedtowards the side conveyor.

Figure 7.21 The flow of materials has beenscreened and directed either to the sideconveyor (pass-through) or to the main

conveyor.

IMPORTANT!

A helmet, goggles and hearing protectors must beworn when using the hammer.

IMPORTANT!

Protect yourself from flying rocks.

IMPORTANT!

Neither the user nor other people are allowed inthe working area.





7.6 FEED CONTROL

The feeder can be stopped and restarted againduring the crushing process. The “feeder start” and

“stop” buttons are located in the remote control boxon the service platform. If the machine is equippedwith a radio control feature (optional), the feeder can be started and stopped using the radio controlfeature.

To stop and restart the feeder do the following:

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

2. Restart the feeder after it has stoppedcompletely by pressing the "feeder start"

button.

NOTE: The feeder starts automatically when the process is started and stops when the process isstopped. If the hydraulic temperature of the unit isextremely cold (-5oC/23oF), the system will ask tocarry out a cold start of the process. The feeder willnot start until the temperature of the oil has reacheda certain temperature.

In order to stabilise the feed rate, the feeder alwaysstarts at minimum speed regardless of the speedsetting. After a while the speed changes to the setvalue.

In order to control the capacity, the feeder speedcan be adjusted using the crusher speed +/-switch.The switch is located in the control box on theservice platform.

NOTE: When the process is running, the auto-matic control takes care of stopping and restartingthe feeder. The feeder will stop if the speed of thecrusher decreases or the level indicator (optional)of the crusher indicates an alarm.

NOTE: If the feeder speed is too high, stones mayfall over the flanks of the hopper.

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

platform.

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

7.7 MINIMUM SETTINGS

The hardness of the feed material will affect theminimum settings. Refer to the C-Jaw instruction

manual for the setting ranges.

7.7.1 Feed Material

Feed sizes depending on the material in question:

– Concrete 0-450 mm (17.5").

– Concrete with rebars 0-450 mm,maximum rebar length 500 mm (20") andmaximum diameter 20 mm (3/4").

– Construction rubble (mixed, including finematter) 0-450 mm (17.5").

– Bricks 0-450 mm (17.5").

– Rock 0-450 mm (17.5").

– Asphalt 0-450 mm (17.5") (only if thetemperature is below +10oC (50oF) andthe bitumen content is low).

– Slag 0-450 mm (17.5").

The size of the material is measured as illustrated infigure 7.22.

Figure 7.22 Measurement of the materialdimensions.





7.7.2 Setting Adjustment

• Manual setting adjustment:

– refer to the C-Jaw instruction manual for instructions on setting adjustment.

• Hydraulic setting adjustment:

– Settings can only be decreased when thecrusher is in the maintenance/adjustmentmode.

– 10: increases the setting

– 11: decreases the setting

– 6: crusher stop -button: crusher inmaintenance/adjustment mode

The process does not have to be stopped completelywhen changing settings.

The process is restarted with the crusher start but-ton (7) and the feeder start button (3), see chp. 4.3.

Figure 7.23 Setting adjustment

7.8 CLEARING OF THE BLOCKAGE

If the process is initiated with material in the cavity,the crusher tries to start with a slow ramp and if therock is strong enough to prevent the crusher fromstarting, the alarm # 3 (“Crusher pressure rising toofast on start”) will be shown in the display.

The process will be fully activated but the feeder and the crusher will not function. You can swingthe crusher clockwise and counter clockwise withthe buttons 8 and 9 (fig. 7.23) of the remote control

box, located on the service platform.

When the cavity is clear, switch on the crusher using the “Crusher start” -button (# 7, figure 7.23).

Start the feeder.

7.9 REMOVAL OF THE STEEL

Always stop the machine (feeder, crusher,

conveyors and engine) before removing metalfrom it. Make sure that it can not be started duringremoving metal from it.

Use a hook to remove iron bars and wires. Be very

careful not to hurt yourself. Never use a hook when the machine is running.

IMPORTANT! Never try to clear the blockage with an excavator.





7.10 INSTRUCTIONS FOR RADIOCONTROL (OPTIONAL)

7.10.1 Selecting the Radio ControlFunction

The control panel has a selector switch, Radiocontrol ON/OFF (ref. fig. 7.24, switch 3.). In ON

position, the radio control mode is activated.

NOTE: The feeder can only be controlled with thehelp of the radio control device when the radiocontrol mode has been selected.

7.10.2 Starting the Radio Remote ControlFunction

The radio transmitter can be switched on by turningthe key switch (fig. 4.5, switch 9) located on theright side of the radio (the key can be removed inthe 0 position.)

Turn the key switch to position 1. The radiotransmitter will indicate the turning of the keyswitch by emitting two peeps. By turning the keyswitch to START position after the acoustic signalshave been emitted, the radio can be activated.

NOTE: The radio transmitter is equipped with anautomatic battery saving function and the radiotransmitter will be automatically switched off if thethe radio functions have not been used for 10

minutes. The radio must be switched on again if radio control is required.

7.10.3 Battery Voltage Level

1. Voltage level indicator

LED indicator 6 indicates the voltage level byflashing. When the voltage level decreases, theflashing becomes less frequent.

The radio will not function if the voltage leveldecreases too much.

Try to utilise the full capacity of the batteries inorder to increase the battery lifetime.

2. Voltage level alarm

The transmitter emits an acoustic signal when thetransmitter battery capacity is nearly exhausted.

7.10.4 Using the Radio Control Features

Select the track driving mode or crushing modewith switch # 7.

• Tracking Mode:

– Switch 1: Engine RPM level up/down.

– Levers 5 & 8: Track controls.

– Switch 3 does not have a function intracking mode.

• Crushing Mode:

– Switch 1: Feeder ON/OFF.

– Switch 3: Feeder speed adjustment.

– Levers 5 & 8 do no have any functions in

the crushing mode.

• Remote-controlled STOP Function:

– The unit can be quickly stopped with thehelp of the remote-controlled stopfunction.

NOTE: The remote-controlled stop functionrequires that the radio transmitter is active. Use of the remote-controlled stop function is not possibleif the radio has not been activated or if the batterycapacity of the radio transmitter has beenexhausted.

Figure 7.24 Radio control (ref. fig. 4.5)





7.11 RECYCLING

In carrying out recycling processes with thecrusher, all metal objects should be removed from

the feed before they enter the crusher.

Someone should stand next to the feeder andremove the metal pieces. Be very careful whentouching the feed material. The feeder must bestopped when removing larger objects. Never climbon top of the feeder.

The most efficient method is to prepare the feedmaterial for the process and remove all the metal

pieces from it before loading it to the LT95.

The optional magnetic separator can be used for theremoval of small metal objects. The maximumdiameter allowance for steel objects entering thecrusher is 20 mm. The maximum length allowanceis 0,5m.

Figure 7.25 Removal of metal objects during the crushing of recyclable materials.




SCREEN MODULE CHAPTER 8

8.1 SCREEN UNIT

8.1.1 Main Assembly

The screen unit is powered with the hydraulic po-wer of the LT95S. The control system of the LT95Sunit will recognize the screen unit automaticallywhen the

electrical socket is connected. The crushing processof the LT95S starts with the screen if the socket andhydraulic hoses are connected.

Figure 8.1 Screen unit

Weight 3300 kg 7280lbs

Transport position

Width 2500 mm 98”

Length 3520 mm 139”

MAKE SURE THAT ALL HYDRAU-LIC CONNECTIONS ARE PRO-PERLY CONNECTED BEFORESTARTING THE DIESEL ENGINE!


1 H5-5 Oversize conveyor 4b Rear mechanicals legs (2pcs)2 Screen TK11-20S 5 Hydraulic legs

3 H6.5-4 Undersize conveyor 6 Cylinder for H5-5 UP-DOWN movement

4a Front mechanical legs (2 pcs) 7 Main conveyor and chute




CHAPTER 8 - SCREEN MODULE

8.1.2 Connection Parts of the Screen Unit

• Electrical connections:

1. Connection socket for the screen module: 24DC power (refer to fig. 8.2, #3).

2. Connection socket for the screen modulecontrol panel (located on the hydraulicmodule of the screen unit, refer to fig. 8.3).

Figure 8.2 Hydraulic control module (HCM)panel

• Hydraulic connections:

Figure 8.3 Hydraulic connections

NOTE: Connect or disconnect the quick connectors only when the diesel engine is shut off.

Callout Description

1 Connection socket for the service light

2 Fuel pump (optional)

3 Connection socket for the screen module

4 Emergency button

5 Switch for hand valves

6 Safety switch for conveyors

Callout Description

1 Return line from valve block

2 Pressure line to valve block

3 LS connection

4 Drain line





• Mechanical connection:

– The screen unit is mounted with 4 pins tothe LT frame. The pins are secured with

locking rings.

Figure 8.4 Mechanical connection

8.1.3 Hydraulic Valve Module

Figure 8.5 Hydraulic valve module

8.1.4 Functions of the Screen Unit ControlPanel

Figure 8.6 Screen unit control panel

The control panel socket is located close by thehydraulic valves of the screen unit.

NOTE: Make sure that all hydraulic connectionsare properly connected before using the control

panel for screen unit.

8.1.5 Manual Controls with Screen Unit

The screen and screen unit conveyors can be forcedmanually ON/OFF from the process options/manual control menu (refer to the IC510 InstructionManual).

Callout Description

1 Screen module conveyors

2 Screen3 Side conveyor in-out

4 Lift of the side conveyor

5 Support leg, left

6 Support leg, right

Callout Description

A H5-5 conveyor in-out

B H5-5 conveyor swing up-down

CHydraulic support leg (left)up-down (at hydraulic module side)

DHydraulic support leg (right)up-down (at conveyor side)





8.1.6 Folding the Screen Unit to a CrushingPosition

1. Connect the screen module control panel for

folding to the control socket.

2. Release transport lockings.

3. Release the hydraulic support legs and support the screen module against the ground.

4. Lower the conveyor H5-5.

5. Extend the H5-5 to an operating position(ref. fig. 8.7).

6. Lift the side walls of the conveyor H5-5 to

their place and lock the conveyor joint withthe locking pin.

7. Start the crushing process and observe belttracking and support leg balance.

Figure 8.7 Extend the H5-5 to an operating position.

8.1.7 Processing with the Screen Unit

The conveyors and the screen will startautomatically during the process start.

For emergency stop, both conveyors are equippedwith trip wire switches. If a trip wire switch is acti-vated, the feeder of the LT95 will stop immediately

and the material in the main conveyor is collectedto the screen.

Screening efficiency is higher when the rotationdirection of the screen is against the material flowdirection. Due to reduced material flow it mightreduce the tonnage of the unit.

Standard rotation direction is along the materialflow, this will give the highest tonnage.

The screen unit running direction can be selectedfrom the IC500 process options page (ref. IC500instruction manuals).

Maximum feed to the screen unit is 150 mm (6").

Minimum mesh hole size # 10 mm (2/5").Maximum mesh hole size 50 mm (2").

If a mesh larger than 50 mm (2") is used, the unit

capacity is limited due to the return conveyor capacity. The maximum speed of the feeder has to

be adjusted to such a level that overloading is prevented.

IMPORTANT!

The screen unit has to be in a crushing position before the process is started.





8.1.8 Tracking on Site with LT95S

1. Stop the process.

2. Lift the hydraulic support legs to an upright posi tion.

3. The unit is ready to be moved on site.

8.1.9 Folding the Screen Unit to TransportPosition

1. Remove the side walls of the H5-5 conveyor from their place. Undo H5-5 securingclamps. Draw the frame in.

2. Lift the conveyor to a vertical position andsecure it with transport locking.

3. Raise hydraulic legs to an upright positionand lift them to a transport position.

Figure 8.8 Screen unit to transport position

8.1.10 Disconnecting the Screen Unit fromthe LT95S

1. Lift the H5-5 conveyor to transport position.

2. Extend the hydraulic legs to the point wherethe screen module weight is supported bythe hydraulic legs and the upper pair of locking pins are free.

3. Remove the upper pair of locking pins.

4. Screen mesh change position. Retract thehydraulic legs so that the screen module will"open" downwards. Make sure that the

weight of the screen module is supportedwith the furthest pair of legs in order toremove the lower pair of pins.

Callout Description

1 Draw the conveyor frame in

2 Lift the conveyor to a vertical position

IMPORTANT!

Find a plain surface to disconnect the screen unit





5. Lower the front mechanical legs and lock them to a 50 mm distance from the ground.Lengthen the hydraulic legs so that thelower pair of pins can be removed.

6. Retract the hydraulic legs. The S-modulewill be separated from LT-frame.The me-chanical legs will now support the screenmodule completely.

NOTE: Stop the engine.

7. Disconnect the hydraulic hoses andelectrical cables.

8. Start the engine and drive the LT95Sdirectly away from the screen unit. Use

crawling speed and observe that the unitmoves directly and does not damage theframe of the screen unit.

8.1.11 Connecting the Screen Unit toLT95S

1. Drive the LT95S directly above the screen

unit.

NOTE: Stop the diesel engine.

2. Connect the electrical cable of the screenunit to the LT95S.

3. Connect the hydraulic hoses.

4. Start the engine.

5. Insert the locking pins to their places. (Usehydraulic support legs for fine tuning thehole alignment).

6. Extend the hydraulic support legs fully out.

7. Keep the mechanical support legs in their place.

8.1.12 Screen Mesh Change or Cleaning

The mesh can be changed or cleaned withoutseparating the screen unit from the LT95S.

1. Drive the LT95S to a plane surface.

2. Push the hydraulic support legs down to theground so that the upper locking pins can beremoved.

3. Extend the furthest mechanical legs (item4b, fig. 8.1) so that they will leave enoughgound celarance under the screen unit.

4. Lower the screen unit by retracting thehydraulic legs equally.

NOTE: Obey special carefulness whendoing this.

5. The screen meshes are now ready to beserviced.

To raise the screen back to it's place just push thescreen back with the hydraulic support legs and

mount the locking pins in their places.

Never go under the screen module whenit is in maintenance position.





NOTE: Use the mechanical support legs (item 4b,fig. 8.1) when supporting the screen unit to theground for maintenance purposes.

NOTE: Do not drivethe LT when the screen unit isin maintenance position.

NOTE: Do not keep the engine running during thescreen maintenance.

Figure 8.9 Use the mechanical legs (furthest pair) under the frame.




MAINTENANCE CHAPTER 9

9.1 PERIODICAL MAINTENANCE

It is recommended that you carry out the periodicmaintenance of the machine based on the operatinghours rather than after set time periods.

NOTE: Grease lubrication specification NLGI EP2.

D a i l y

W e e k l y

M o n t h l y / 2 0 0 h

E v e r y 6 m o n t h s

E v e r y 1 2 m o n t h s

A s r e q u i r e d

DIESEL ENGINE

Change the engine oil every 200 operating hours. X

Change the oil filter every 200 operating hours. X

Drain water from fuel. X

Change the primary fuel filter every 200 operating hours. X

Change the fine fuel filter every 200 operating hours. XCheck the service indicator of the air filter.Change the cartridge if necessary.

Change the safety cartridge every third time.X

See the engine operating manual for other maintenance. X

Replace the fuel tank breather. X

JAW CRUSHER

Check V-belt tension. X

Check the tightness of the jaw bolts daily during the first40 operating hours after jaw installation. Then weekly.

X X

Check the tightness of cheek plate bolts. X

Check the side guide plates and theprotection rubber of the toggle plate.

X

Lubricate the crusher drive jack shaft 10g / 40h / bearing. X

Check for wear on the jaw plates. X

Check the sound, temperature (max. 75oC/ 167oF)and grease flow in the eccentric bearings.

X

Lubricate the eccentric shaft bearings. X

Check for wear on the cheek plates. X

Check the toggle plate for alignment,straightness and cracks.

X

Check the toggle seats, clean as necessary. X

Check the tightness of the mounting bolts of the labyrinth covers and the frame bearings.

X

Check the tightness of the frame tie rods. X

Check the mounting of the flywheel. X

Check the tightness of the framemounting bolts on the side plates.

X

Check the bearings on the eccentric shaft. X

Check for any wear on the contact surfacesof the pitman and the front frame.

X

Check the rubber damper condition of the jaw crusher. X




CHAPTER 9 - MAINTENANCE

Check the mounting of the crusher (no horizontal movement).Check the locking mechanism.

X

Check for any wear on the contact surfacesbetween the side plates and the cheek plates.

X

MECHANICAL SETTING ADJUSTMENT

Lubricate the cap nuts of the setting adjustment device. X

Check the rubber covers. X

AUTOMATIC LUBRICATING DEVICE

Check operation and grease amount

(add grease if necessary).X

VIBRATOR UNIT

Oil change (1000 h) Ref: 8.7. X* X

Check the oil level. X

Replace the breather every 1000 h. X

FEEDER

Clean the vibration unit from the outside. X

Check the tightness of the vibration unit joints. X

Check the wires/hoses. X

Check the tightness of the screen deck mounting bolts. X

CONVEYORS

Lubricate the bearings of the head and tail pulleys.

5g / 40h / bearing. XCheck the belt tension. X

HYDRAULICS


Check the oil temperature (max 90ºC / 194ºF). X

Check the fixing bolts of all components. X

Check the pipes and hoses. X

Change the hydraulic oil every 2000 operating hours. X

Change the hydraulic oil filter every 2000 operating hours X

Clean the hydraulic tank every 2000 operating hours. X

Check the breather of the hydraulic tank.Replace every 6 months. X X

FINAL DRIVE


Change oil. X

BATTERY

Check the fluid level. X

Check the cleanliness of the battery terminals. X

D a i l y

W e e k l y

M o n t h l y / 2 0 0 h

E v e r y 6

m o n t h s


A s r e q u i r e d





NOTE: Daily log sheet in an appendix to thismanual.

9.2 RUNNING-INSee the Crusher instruction manual for further information.

9.3 HYDRAULICS

Basic requirements for the hydraulic oil quality:

– the viscosity index should be at least 150.

– minimum viscosity of 16 cSt at operatingtemperature.

– maximum viscosity of 900 cSt at startingtemperature.

Unless otherwise indicated, the factory fill oil is aspecial hydraulic oil belonging to the ISO VG 46class. The maximum operating temperature allowed

TRACKS

Check the tension of the track chains. X

Check the tightness of the track bolts. X

MAGNETIC SEPARATOR

Lubricate the bearings. 3g / 40h / bearing. X

Check the belt tension. X

FUEL TANK

Breather replacement. X

Fuel fill pump filter replacement (optional). X

H5-5 CONVEYOR (SCREEN UNIT)

Belt tracking & tension X

Greasing: 5 g / 40 h / each bearing. X

Check the roller condition. X

Grease the folding joints. X

H6,5- 4 CONVEYOR (SCREEN UNIT)

Belt tracking & tension. X


Check the roller condition. X

TK11 - 20S SCREEN (SCREEN UNIT)


Mesh condition & cleanliness. XListen to the sound of the screen. X

Check the support springs. X

Check the wear parts. X

Check the bolt torques. X

Check the bearing temperature & sound. X

* First oi l change

D a i l y

W e e k l y

M o n t h l y / 2 0 0 h

E v e r y 6

m o n t h s


A s r e q u i r e d





for this oil type is approximately +80°C (167°F)and the minimum starting temperature allowed isapproximately -20°C (-4°F), which makes it

suitable for use all year round under most operatingconditions.

The following is a list of some oil brands that meetthe requirements:

In winter, e.g. in cold climaticconditions when the operatingtemperature of the oil remainsunder +60°C (140°F), the use of aspecial hydraulic oil belonging tothe ISO VG 32 class is recommen-ded. The maximum operating

temperature allowed for this oil type is approxi-mately +65°C (149°F) and the minimum startingtemperature allowed is approximately -30°C (86°F)degrees.

The following is a list of some oil brands that meetthese requirements:

In summer, e.g. in hot climaticconditions when the ambienttemperature exceeds +35°C (95°F),the use of a special hydraulic oil

belonging to the ISO VG 68 class isrecommended. The maximum

operating temperature allowed for this oil type is

approximately +90°C (194°F) and the minimumstarting temperature allowed is approximately -9°C(14°F).

The following is a list of some oil brands that meetthese requirements:

The amount of oil is 370 litres (98 gal).

NOTE:

The hydraulic oil must be replaced every 2000 h of

engine operation.

9.3.1 Hydraulic Adjustments

All components have been set to operate atoptimum speed. If adjustments are required, theyshould only be carried out by persons authorised byMetso Minerals.

Table 9-1 Factory speed settings

Brand Type

BP Energol SHF 46

ESSO Univis N 46

Shell Tellus Oil T 46

Teboil Tebo Hydraulic Oil 46

Mobil DTE 15

Brand Type

BP Energol SHF 32

ESSO Univis N 32

Shell Tellus Oil T 32


Mobil DTE 13

Brand Type

BP Energol SHF 68


Mobil DTE 16

Device rpm

Crusher 330 - 335

Engine 2300Feeder 500 - 1150

Screen 950 - 1190

Devicem/s(f/s)

Main conveyor 1.7 - 2.0

(5.6 - 6.6)

Side conveyor 1.8 - 2.0

(5.8 - 6.6)

Magnetic separator 1.5 - 1.7

(5.6 - 6.6)

Oversize conveyor 1.6 - 1.8

(5.6 - 5.9)

Undersize conveyor 2.0 - 2.2(6.6 - 7.3)





9.4 AMOUNT OF FUEL/ADDING FUEL

The amount of fuel can be checked from the fuelamount indicator (display). The fuel tank capacity

is 500 l (132 gal).

To add fuel to the tank, open the hatch located onthe service platform as well as the fuel tank cap (3).

You can pump the fuel from the tank using anoptional equipment pump (4) (ref. 4.4).

Figure 9.1 Fuel level inspection

9.5 FILLING VOLUMES

Table 9-2 LT95/95S

Table 9-3 Engine

Callout Description

1 Fuel level probe

2 Breather 3 Fuel tank cap

4 Suction hose

5 Fuel transfer pump

6 Fuel pressure filter

AMOUNT TYPEl gal

Hydraulics 370 98 ISO VG 46

Final drive 4.5 1.2 ISO VG 220

Fuel tank 500 132 -

Feeder vibration unit

4 1 ISO VG 150

CUMMINS QSB 5,9 - 240 C

l gal

Engine oil 14 3.7

Engine water 28 7.5





9.6 TRACKS

9.6.1 Tension

• Check that the track chains are properlytensioned. Adjust them if necessary. For thecorrect chain deflection, refer to illustration9.2. Measure the deflection value from

between the main pulley and the idler. Toincrease the chain tension, pump more greaseinto the regulating cylinder with the help of agrease gun. Correspondingly, to decrease thechain tension, allow grease to flow out throughthe opened grease nipple and, if required, bymoving the LT.

• Check for signs of damage on the track shoes.

9.6.2 Frame

• Check the welded structure for signs of cracksor welding errors and carry out any necessary

repairs immediately.

• Track shoe bolt torque:

– With lubricant: 229-281 Nm / 169-207ft/Lb.

– Without lubricant: 286-350 Nm / 211-258ft/Lb.

9.6.3 Final drive

Change the final drive oil after every 2000operating hours. The amount of oil is 4.5 l (1.2 gal).

The oil quality is ISO VG 220.

Figure 9.2 Check that the crawler chains have been correctly tightened. The correct deviation is 25mm (0.98")





9.7 LUBRICANT RECOMMENDATIONS

This section contains information and instructionson several alternative and optional pieces of

equipment. Normally a LT unit will only beequipped with some of these optional devices.Before carrying out maintenance and servicingwork on the unit, find out which pieces of alternative and optional equipment your LT isequipped with.

9.7.1 Crusher

For further information, refer to the crusher instruction manual.

9.7.2 Feeder / Screen

For further information, refer to the feeder/screeninstruction manual.

9.7.3 Track Gear (Final Drive)

– Oil designation DIN 51517, part 3: CLP220.

– ISO viscosity DIN 51519: ISO - VG 220.

– Kinematic viscosity at 40°C (94°F)degrees: Min. 198 mm2/s (cSt). Max. 242

mm2 /s (cSt).

– FZG test A /8.3/90 for DIN 51354, p. 2:Min. breakdown load stage 12.

Suitable brands include:

Table 9-4 Recommended oil brands

9.7.4 Grease

The grease type must be NLGI EP 2. The use of greases containing molybdenum additives is notrecommended.

Brand Type AGIP Blasia 220

ARAL Degol BG 220

AVIA Gear RSX 220

BP Enersyn HTX 220

CASTROL Alphasyn T 220

CASTROL Alpha ZN 220

DEA Trion EP 220

DEA Intor HCLP 220

ELF Reductelf SP 220

ELF Elf Epona Z 220

FINA Giran L 220

FUCHS Renolin AWD 220

KLÜBER Lamora 220

KUWAIT Q8 Goya 220

KUWAIT El Greco 220

MOBIL Mobilgear 630

MOBIL SHC 220

PANOLIN EP Gear Synth 220

TEXACO Syngear 220

TOTAL Varter EP 220





9.8 FLUID CHANGE INFORMATION

9.8.1 Adding Hydraulic Fluids

Figure 9.3 Adding hydraulic oil

Adding hydraulic oil:

1. open the oil addition plug (2)

2. add the oil through the return filter in order to prevent impurities from entering thehydraulic system

Callout Description

1 Hydraulic oil tank breather

2 Oil addition plug

3 Hydraulic return filter

4 Return fil ter pressure sensor





9.8.2 Adding Engine Fluids

Add the engine oil through plug 3. Check theamount of oil with dipstick 1 (see chp 9.5. Filling

volumes).

Figure 9.4 Adding engine fluids


1 Engine oil dipstick 4 Starter engine

2 Fuel filter 5 Engine oil filter

3 Engine oil plug (addition) 6 24 V charger





9.8.3 Removing Engine / Hydraulic Fluids

Observe the following instructions:

– remove the plug – open the valve

Make sure that the drain pan will be able to hold allthe fluid (See 9.5 Filling volumes).

Figure 9.5 Draining engine fluids

9.9 ENGINE FILTER CHANGEINFORMATION

9.9.1 Replacing the Engine Fuel Filter

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

Remove the sheet metal plate between the magnetand the engine to make room to carry out the filter

replacement.Remove the fuel filter as instructed in the engineinstruction manual (refer to Cummins InstructionManual, pages 5-6 to 5-9).

– Drain the water/fuel into a container anddispose of it in accordance with localenvironmental regulations. Use the filter

drain valve to drain fuel out of the filter for approximately 5 seconds. This willeliminate fuel from running over the top of

the filter upon removal. – Clean all debris from around the fuel filter

head.

– Disconnect the water-in-fuel sensor fromthe wiring harness.

– Remove the fuel filter.

– Drain the fuel filter and remove thewater-in-fuel sensor from the fuel filter.

– Inspect the water-in-fuel sensor for cracksand damage.

– Install the water-in-fuel sensor into thenew fuel filter.

– Fill the filter with clean diesel fuel.

– Install the filter as specified by the filter manufacturer.

– Connect the water-in-fuel sensor.

– Crank the engine for 1 to 2 seconds. If theengine does not start, then release the keyor starter button back to the RUN position(do NOT turn the key back to the OFF

position). The electric fuel transfer pumpwill continue to run and purge air from the

system for about 25 seconds. After 25seconds, attempt to start the engine again.

NOTE: If the engine cranks for 30 secondswithout starting, vent the fuel supply lines.

– To vent the fuel supply lines, loosen the banjo fitting on the fuel pump inlet. Runthe electric fuel transfer pump until all theair has been bled. When all air has been

bled from the system, tighten the fitting.

Operate the engine and check for fuel leaks.

9.9.2 Replacing the Engine Oil Filter

Engine oil filter must be replaced every 200 h of engine running hours or at least once a year

Callout Description

1 Coolant valve (under the cooler)

2 Engine oil

3 Hydraulic oil





9.9.3 Engine Air Filter Change

The condition of the filter must be observed every 8

hours of operation.

The air filter is a three stage filter :

– Precleaner

– Primary cartridge

– Safety cartridge

The filter assembly contains an indicator. If theindicator shows red, the primary filter must bereplaced.

The safety cartridge must be replaced in every third primary filter replacement. (fig.9.6).

Undo the filter housing latches to remove the cover (fig. 9.7).

Draw the primary cartridge out from its place(fig.9.8).

If needed, draw the safety cartridge out from its place.

Install new cartridges in their place (always check that the replacement filter size is correct. If thereplacement filter is shorter than original it might

cause serious engine damage) (fig. 9.9).Close the air filter housing cover correctly in its

place and make sure that all latches are properlyclosed (fig. 9.10).

Figure 9.6

Figure 9.7

Figure 9.8

Figure 9.9





Figure 9.10

9.9.4 Fuel Tank Breather Change

The breather is located next to the engine cover.The breather is a spin-on-type. The breather must

be replaced every 2000 hours or once a year.

Figure 9.11

9.10 REPLACING THE HYDRAULIC OILFILTERS

The first hydraulic oil filter change should take place at 2000 h of engine operation. Before startupof the unit, the filter replacement is not necessary asthe 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

9.10.1 Crusher Drive Pump Filter Change

Filter location: The filter is located on the pumpitself. The filter is a spin-on-type replaceable filter.The crusher drive pump is the hydraulic pumpcloser to the engine.

Replacement information:

Work must be carried out when the engine is stopped and the main switch in off position. Close thesuction valves under the hydraulic tank. Undo thefilter by turning the filter counter-clockwise. Dis-

pose the used hydraulic filter according to countrylegislation. Lubricate the O-ring of the new filter.Spin the new filter to hand tightness and turn 30°(1/12 of the round ) to secure filter installation.

The filter must be replaced every 2000 h of engineoperation or whenever the filter condition indicator gives out alarms.

Figure 9.12





9.10.2 Device Pump Circuit Pressure Filter Change

Filter location:

The filter is mounted on the frame on the left sideof the unit. The filter is a replaceable element insidethe spin-on-type housing.


Work must be carried out when the engine is stopped and the main switch in off position. Close thesuction valves located under the hydraulic tank.Undo the filter by turning the filter counter-clock-wise. Dispose the used hydraulic filter according tocountry legislation. Undo the filter housing byturning the housing counter-clockwise with a 41mm wrench (fig. 9.13). Remove the filter elementfrom the housing and install a new element to thefilter support (fig. 9.14). Lubricate the O-ring of thehousing and spin the housing carefully in it's place.Tighten the housing with 40 - 50 Nm torque (fig.9.15).

The filter must be replaced every 2000 h of engineoperation or whenever the filter condition indicator gives out alarms.

Figure 9.13

Figure 9.14

Figure 9.15





9.10.3 Device Pump Circuit Return OilFilter Change

Filter location :

The filter is mounted on the hydraulic tank. Thefilter is a replaceable element, under a cover.


Work must be carried out when the engine is stop-ped and the main switch in off position. Close thesuction valves located under the hydraulic tank.Undo the cover of the return filter. Open the four nuts (13 mm wrench) and remove the cover (fig.9.16). Be careful when doing this as there is aspring under the cover (fig. 9.17). Pull the filter assembly out from the filter housing (fig. 9.18).

Open the filter assembly by opening the 36 mmlock nut (fig. 9.19). Remove the filter element.Clean the magnets before installing a new filter element (fig. 9.20). Use 20 - 25 Nm torque whensecuring the filter element. Insert the filter assem-

bly in its place and close the cover. Observe theO-ring condition and lubricate it before instal-lation (fig. 9.21). Use 15 Nm torque for the cover mounting nuts.

The filter must be replaced every 2000 h of engineoperation or whenever the filter condition indicator gives out alarms. If the device pump pressure filter

must be replaced due to an alarm, the return filter must be replaced at the same time.

Figure 9.16

Figure 9.17

Figure 9.18

Figure 9.19





Figure 9.20

Figure 9.21

9.10.4 Hydraulic Tank Breather Change

The breather is mounted on top of the hydraulictank. The breather is a spin-on-type. The breather must be replaced every 2000 hours or once a year.


Work must be carried out when the engine is stopped and the main switch in off position. Close thesuction valves under the hydraulic tank. Undo thefilter by turning the filter counter-clockwise.Dispose the used breather according to countrylegislation. Undo the breather by turning the

breather counter-clockwise. Spin the new breather to hand tightness and turn 30 °( 1/12 of the round )to secure the breather installation.




SERVICE INSTRUCTIONS CHAPTER 10

10.1 GENERAL

Only skilled and experienced mechanics must beallowed to service the plant.

When carrying out any work related to the ope-

ration, application and modification or adjustmentof the LT and its safety equipment, as well as whencarrying out the inspection, maintenance and repair of the crushing unit, observe the starting andstopping procedures outlined in the InstructionManual and monitor the unit to see if there are anyindications that maintenance work is required!

Secure the area of maintenance work as thoroughlyas 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 andfasten a caution plate on the main switch.

Smoking and lighting fires is prohibited in thevicinity of the machine when refuelling or servicingthe fuel system.

Diesel fuel is highly flammable - do not use it as acleaning fluid. Use solvents of accepted qualityonly.

Always switch the engine off during maintenancework unless the Instruction Manual specificallydirects 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 themanufacturer.

Always ensure adequate ventilation when runningthe engine in a confined area.

Remember that some solvent types may cause skinirritation and may be extremely flammable. Avoid

breathing in any solvent fumes.

Service and maintenance facilities must be kept

clean. Oil and water can make floors slippery andtherefore hazardous. Avoid using severely soiledfabrics, as these can be highly flammable.

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

Be careful when using the pressure cleaningequipment. Even low pressures and lowtemperatures 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 flammablematerials.

Always have a fire extinguisher on hand whencarrying out welding or whetting operations.

Familiarise yourself with the location and the use of the fire extinguishers.IMPORTANT!

In the event of a fire:

Move the LT unit away from the hazardous area.

Switch off the engine.

Turn off the main switch.

Begin extinguishing the fire and sound the firealarm if necessary.




CHAPTE R 10 - SERVICE INSTRUCTIONS

10.2 BATTERY MAINTENANCE

Fluid level inspectionThe battery fluid level must be checked every 100operating hours (figure 10.1). The level should beapproximately 10 mm (1/4") above the plates. Addclean, distilled water as required. Monitoring thefluid consumption rate will give an indication of thecharge status of the battery, but a separate testindicating the amount of acid present will provide amore reliable picture of the charge status. If thefluid consumption rate is high, it could be an indi-cation that the alternator charging rate is too high.

Figure 10.1 Check the battery fluid level every100 operating hours. Add clean distilled water in

the accumulator as required.

Battery inspection

The battery charge level must be checked regularlyusing a hydrometer. Do not carry out thisinspection immediately after adding distilled water to the battery; the water and the acid will havemixed 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. Thesevalues correspond to a battery temperature of around +20°C (68°F).

Batteries must always be maintained fully chargedfor as long as possible. If the charge level isallowed to remain low, the cells will becomesulphated, reducing the capacity and efficiency of the whole battery.

Remember that a half-charged battery will freeze ata temperature of -25°C (-13°F), while an empty onewill freeze at only -10°C (68°F).

Never use an open flame when inspecting the acidlevel of a battery. The gases given off by thechemical reaction that occurs during the recharging

process are highly flammable.

The fluid used in lead-acid batteries is dilutedsulphuric acid. This acid is corrosive, and it maycause severe burns to exposed skin as well asdamage clothing. Be very careful when handling

batteries.

Always wear protective goggles and gloves whenhandling the batteries.

Cleaning batteries, terminals and cables

Batteries and terminals must be cleaned at leastonce a year. The terminals and cable ends should becleaned with the help of special tools that helpmaintain the correct size and shape of the contactsurface. After cleaning, the terminals and cableends should be covered with petroleum jelly to

protect them against oxidation. Also inspect thefollowing: fastening of the battery earth cables tothe main frame; engine starter cables; and electricalconnections to the alternator. Clean and tighten thewiring as required. Keep the battery cases clean anddry.

10.3 OTHER ELECTRICAL EQUIPMENT

10.3.1 Charging Circuit

– Check and tighten the connectionsregularly.

– The alternator requires only periodicmaintenance.

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

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

– Never start the engine if any wire in thecharging circuit is disconnected or hascome loose.




CHAPTER 10 - SERVICE INSTRUCTIONS

– Whenever the batteries are charged usingan external source, the earth lead to theframe must be disconnected from the bat-

tery. When reconnecting batteries or whenusing jumper leads or a charger, make surethat the cables are connected to the correctterminals.

– Always disconnect the battery cableswhen 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 aninstrument that has a low internalresistance.

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 correctlyconnected.

10.3.2 Starter Engine Circuit

Under normal conditions, the starter circuit requireslittle attention, but all components should be keptclean and electrical connections tight. The batteriesare an essential part of the electrical system andthey must be kept fully charged, clean and properly

filled to maintain the correct acid level. Batterycables must also be checked for tightness and keptclean and well-greased.

10.3.3 Fuse List

Table 10-1 Fuse location in the control panel

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

Table 10-3 Fuse location next to the main switch

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

IMPORTANT!

Use only fuses with required size as oversize fusecan damage components in the electrical circuit.

Fuse ID Fuse Size Description

1F01 10A Control key

1F02 20AControl fuse, secondary

main

1F03 10A Options

1F04 10A Power for I/O-modules

1F05 15A Optional water pump

1F06 10A Radio control

1F07 10A Not in use


2F01 30A Control main fuse

2F02 50A Start motor pilot

2F03 10A Not in use

2F04 10A Engine + bat Switched

2F05 10A Optional drive lights

2F06 15A Work lights2F07 10A Engine control

2F08 15AService light sockets +

optional enginepre-heater

2F09 15A Fuel cooler

2F10 15A Oil cooler S- models

2F11 15A Not in use

2F12 8A Engine

2F13 8A Engine

2F14 8A Engine

2F15 10A Engine


2F20 100A Main fuse

2F21 100A Engine grid heater

2F22 20AEngine control main

fuse

2F23 10A Main switch


3F01 10A Screen module

3F02 20A Fuel pump


1F01 10A Control key





10.4 WELDING

If any welding is to be done on the machine, caremust be taken to protect sensitive electrical

equipment.

– Switch off the engine.

– Turn off the main switch.

– Disconnect the earth lead to the batteries.

– Fasten the earth cable of the welding ap- paratus as close as possible to the sectionto be welded and make sure that no wel-ding current coming from the welding ap-

paratus is able to pass through to any of the bearings or electrical equipment.

10.5 PRESSURE ACCUMULATOR

Before removing / repairing any components belonging to the hydraulic setting control circuit,release the pre-charge pressure by opening theshut-off valve. Make sure that the pressure gaugelocated above the accumulator indicates NO

pressure. Make sure that the security valve of thegauge is open.

10.6 SENSORS

10.6.1 Crusher Speed Sensor

10.6.1.1 Operation

The crusher is equipped with a speed sensor. Thesensor controls the movements of the pitman andemits one impulse per one pitman revolution (idlespeed 330-335 rpm). If the rotation speed of the pit-man falls below the set alarm limit for light over-load, the feeder speed slows down to minimumspeed, after which this reduced speed is maintainedfor the pre-set time.

Possible reasons for light overload / heavy overloadalarms include:

– Clogged fuel filter

– Clogged air filter

– Loose/sliding V-belts

– Worn V-belt pulley

– The setting is too small for the material being crushed

– Worn cavity

– Faulty hydraulic drive component

10.6.1.2 Assembly

The sensor has been mounted on the reverse side of the pitman, close to the eccentric shaft. To locatethe sensor, lift the rubber cover behind the pitman.

The sensor has been mounted on its support with a plastic clamp. The correct distance from the sensor end to the pitman is 3-5 mm (the minimum distancewhile the crusher is running). When replacing thesensor, there is no need to adjust the sensor itself.

The sensor is equipped with a LED indicator. Thefunctions of the device can be controlled with thehelp of this LED indicator.

10.6.2 Pressure Sensors

0 - 600 bar (8700 PSI) / 4 - 20 mA.

10.6.3 Trouble Shooting of the LevelSensor Circuit

Make sure that the wire harness of the transmitter &the receiver is undamaged.

Make sure that the wire harness plug is properlyconnected to the remote control box socket.

Clean the lenses of the transmitter & the receiver.

If the function of the level sensor is not correct, dothe following test to determine the problem.

1. Turn the power off. Unplug the amplifier from the socket.

2. Disconnect the sensors from the socket

(wires connected to pins 5, 6, 7, and 8).

3. Plug the amplifier into the socket. Turn the power on.




CHAPTER 10 - SERVICE INSTRUCTIONS

4. Make sure the amplifier is plugged tightlyinto the socket. A loose connection maycause intermittent operation. If there is

excessive movement in the fit, replace thesocket with a Carlo Gavazzi socket number ZPD11.

5. Using a voltmeter, check for the proper supply voltage of pins 2 and 10.

6. Verify the green 'SUPPLY' LED is on (lit).

7. Verify the output relay changes state(switches).

a. Remove the plexiglass window located below the LEVEL potentiometer.

b. Verify the left dip switch is in the UP posi tion (100% power sett ing).

c. Place the right dip switch in the UP po-sition. The 'RELAY' LED should be on.

d. Place the right dip switch in the DOWN posi tion. The 'RELAY' LED should beoff. NOTE: You should hear the mecha-nical relay change position. Also check the input indicator on the PLC or con-troller (if being used). It should also turnon and off verifying that the signal fromthe amplifier is being received.

8. Connect the sensors into the socket.a. Turn the power off.

b. Connect the transmitter - the sensor withthe gray colored outer cable jacket.

– Black wire to pin 5

– Shield to pin 7

c. Connect the receiver - the sensor withthe black colored outer cable jacket.

– Black wire to pin 6

– Shield to pin 8

9. Turn the power on.

10. Place the right dip switch in the DOWN position.

11. Turn the LEVEL potentiometer clockwise tothe maximum setting of 10. The 'RELAY'and 'LEVEL' LEDs should be activated.

12. Turn the LEVEL potentiometer slowlycounter-clockwise. Note the position of the

potentiometer setting when the 'RELAY'LED turns off.

a. If the relay turns off above the potentio-meter setting of 1.5, the photoeyes aremisaligned or partially blocked.

b. If the relay turns off below the potentio-meter setting of 1.5, then turn the poten-tiometer slowly clockwise. If the relayturns on below the potentiometer settingof 2, the photoeyes are in proper a lign-ment and are functioning properly duringthis test procedure.

1. Check to see if the photoeyes are exposed todirect sunlight. If exposed, a hood or shadeshould be mounted to block the sunlight if the eyes cannot be repositioned away fromthe direct sunlight.

2. Check for cross-talk between multiple setsof photoeyes. It may be possible that the

photoeyes are signaling each other due tothe beam spread of each unit. If the units donot have hoods to block signals from other units, then mount these accordingly.

3. Check that the sensor cables are not wire-strapped to high voltage power cables.



SECTION 11 TROUBLESHOOTING

1

All modules not up

Engine stop solenoid

output ON

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

ENGINE READY FOR START

LICENSE TO START

ENGINE

Main switch ON

Key switch ON

Remote stop

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

control

Hydraulic oil temp

Main valve Alarm 16 Check : ECM XM2 input 18

Check suction valve position

Oil level

Closed

Alarm 10 Check: ECM XM2 input 17

Check actual oil level at hydraulic tank add oil if needed

Alarm 17 Check: ECM XM3 input 13

Check cooler and hydarulic oil temperature

OK

Down

Yes

Yes

High

Open

OK

No

No

No

Check:

Fuse 2F03

Key switch contact

Battery voltage

No




2

ENGINE START

Key switch to start

position

Signal horn output ON

for 3 sec.

Engine start output ON

max 30 sec.

Engine to min rpm

Engine to max rpm

All modules not upEngine stopping

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

Remote stop

Engine stopping Remote stop alarm

Check ECM XM1 input 15 with radio control

Check DCM XM3 input 22 with cable control

Hydraulic oil temp

Engine stopping Alarm 17Check: ECM XM3 input 13Check cooler and h darulic oil tem erature

Yes

Yes

High

Engine start continue

No

No

OK

Check DCM XM1 input 4

Check the key switch contact

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

Check ECM XM2 output 5

Check fuse 2F02




3

Engine start motor

running

Releasing key switch

from start position

Main valveEngine stopping Alarm 16Check : ECM XM2 input 18

Check suction valve position

Hydraulic oil level

Closed

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

Down

Engine start continue

J1939 bus fault Engine stopping Alarm 11

Check fuse 2F07Check fuse 2F06

Check ECM XM2 out ut 6 & rela 2K03

Yes

OK

OK

No

Yes

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

ENGINE RUNNING

Yes

No

Check ECM XM2 output 5Check fuse 2F02




4

ENGINE CONTROL

WHILE ENGINE RUNNING

All modules not upEngine stopping

Module missing alarm 37,38 or 39 Check function of

the emergency relay

Radio

selected

Engine stopping

Alarm 27Check ECM XM1 input 15

Radio

remote stop

Drive boxconnected

Engine stoppingAlarm 26

Check DCM XM3 input22

Drive boxremote stop

Hydr oil temphigh

Yes

Yes

YesProcess running

YesDisable processAlarm 1

Hydr oil mainvalve closed

YesEngine stopping

Alarm 16Check : ECMXM2 input 18Check suction

Hydr oil leveldown

Engine stopping Alarm 10Check: ECM XM2 input 17

Check actual oil level at h draulic

Yes

Yes

Yes

Yes

Engine running

Emergency stop

Engine stoppingAlarm 28 ES from control panelCheck HUB XH4 input 11à repair wiring or contact

Alarm 29 ES Service platformCheck HUB XH4 input 12 à repair wiring or contact

Alarm 30 ES from engine moduleCheck HUB XH4 input 13 à repair wiring or contactAlarm 31 ES from hydraulic center

Check HUB XH4 input 14 à repair wiring or contact

Yes

Engine stoppingAlarm 17Check: ECM XM3 input 13Check cooler and hydarulicoil temperature

No




5

SCREEN ENABLE

Safety switch

(over size) off

Force screen conveyors onfrom display

Force screen on fromdis la

Process running

Screen

enable

Alarm 22Check HCMXM1 input 19If not activerepair wiring

or switch

Screen not enable

Forced control of screen and screen

conveyors is possible

from display.

Yes

Yes

Yes

Yes

Safety switch

(under size) off

Alarm 23Check HCMXM1 input 20If not activerepair wiring

or switch

Yes




6

MAIN CONVEYOR ENABLE

Main conveyor left

safety switch

Main conveyor right

safety switch

Conveyor maintenance safety

switch

Alarm 18Main conveyor not enable

Reset trip wire switchCheck steel cable tension

HCM XM1 input 23 - "1" ok ( "0" not ok ) - Check wirin & contact

Alarm 19Main conveyor not enableReset trip wire switchCheck steel cable tensionHCM XM1 input 22 - "1" ok ( "0" not ok )

- Check wirin & contact

Alarm 21

Main conveyor not enableCheck position of themaintenance switchCheck contacts - 1 – 2 feed back contact

- 5 – 6 solenoid

Main conveyor

enable




7

CRUSHER START UP AND

STARTING BY PROCESS

Engine control

Crusher drive pressure probe failure

Pressure OK ? High over allowed delay

Speed OK ?

Low over allowed delay

Crusher StoppingAlarm 6

Crusher not enableCheck: V-belts,

pressure sensor

Low over crusher

starting time

Crusher Stopping

Alarm 7Crusher not enableMaterial in the cavity

Start crusher from

service platform

Crusher running

Crusher StoppingAlarm 3Material in the cavity

Start crusher fromservice platform

Fault

Yes

NoYes

No

Yes

Yes

Crusher start from process ?

Start OK ?

Clamping pressure not between limits

Yes

Crusher not enableContact to Metso

mierals service dept.

Yes

Yes

No

Crusher not enableAlarm 41Check wiring if ok Replace sensor

Crusher not enableAlarm 4 Low Alarm 5 HighAlarm 36 Probe failure

Check charging circuit operating chargingvalve manually. à does the pressure change

at UCD page 1.2 à if not check sensor Check HCM XM2 output 22 if on check thevoltage in the Danfoss valve plug if ok thedanfoss valve control head failured

Yes

No




8

CRUSHER START FROM

SERVICE PLATFORM

Forced control fromdisplay ?

Crusher stopped

by process ?

Swing normaldirection ?

Swing reverse

direction ?

Yes

No

Yes

No

Run crusher to

reverse directionStop crusher Run crusher to

normal direction

Yes

Yes

No

No

FaultEngine control Crusher Stopping

Swing reversedirection ? 1)

Yes

No

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




9

CRUSHER CONTROL

IN RUNNING MODE

Crusher stop request from process ?

Clamping pressure not

between limits

Crusher drive pressure

probe failure

Crusher speed low

Main conveyor not

running

Crusher pressure high

Crusher running

Alarm 18, 19 or 21 Crusher stoppingCrusher not enable

Check main conveyor trip wire switchesreset if nesessary.Check conveyors maintenance switch

position

Fault

Yes

Yes

Yes

Yes

Yes

Engine control

Crusher stopping

Yes

Alarm 4 or 5 Crusher stoppingCrusher not enable. Check charging circuit

operating charging valve manually. à

does the pressure changeat UCD page 1.2 à 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

Alarm 41 Crusher stoppingCrusher not enable

Check wiring if ok Re lace sensor

Alarm 8 Crusher stopping

Crusher not enableCheck crusher V-belt tensionCheck used setting à open if nesessary

Check / adjust the crushing speed à

Parameter C1 à increase the mA valueCrusher should run 300 rpm (avg.) with thematerial

Alarm 2 Crusher stoppingCrusher not enableCheck used setting à open if nesessaryCheck / adjust the crushing speed à

Parameter C1 à increase the mA value

Crusher should run 300 rpm (avg.) with thematerial




10

SETTING CONTROL WHEN

OVERLOAD PROTECTION TYPE

IS TOGGLE PLATE

Processrunning

Crusher

stopped

Yes

Yes

Process control mode:DO Return rod pre relief valve OFFDO Setting increase valve OFFDO Setting decrease valve OFFDO Return rod pre valve ON, if

pressurization needed else OFF

Increase setting

DO Return rod pre relief valve ONDO Setting increase valve ON

DO Return rod pre valve OFF

Yes

Decrease setting

No

DO Return rod pre relief valve ONDO Setting decrease valve ON


Yes

No

DO Return rod pre relief valve OFFDO Setting increase valve OFFDO Setting decrease valve OFF

DO Return rod pre valve ON, if


No




11

SETTING CONTROL WHEN

OVERLOAD PROTECTION TYPE

IS HYDRAULIC

Increase setting

DO Return rod pre relief valve ON


Yes

Decrease setting

DO Return rod pre relief valve OFFDO Setting decrease valve ON

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

Yes

DO Return rod pre relief valve OFFDO Setting increase valve OFFDO Setting decrease valve OFFDO Return rod pre valve ON, if


No

No




12

CRUSHER OVERLOAD:

DETECTION AND

SETTING CONTROL

Ultrasonic sensor

in range

Crusher

overload

Alarm 33

Yes

Yes

Crusher load

normal

No

Ultrasonic sensor

movement over 8 mm

Crusher pressure high

No

DO Return rod pre relief valve OFFDO Setting decrease valve ON

DO Return rod pre valve ON, if


Alarm 2 Crusher

stopping, Page 9




13

SIDE CONVEYOR

ENABLE

Side conveyor left

safety switch

Side conveyor right

safety switch

Conveyor

maintenance safety

switch

Alarm 24Side conveyor not enableReset left side safety switchHCM XM1 input 21 - "1" ok ( "0" not ok )

- Check wiring & contact

Alarm 25

Side conveyor not enableReset right side safety switch

HCM XM1 input 4 - "1" ok ( "0" not ok )

- Check wiring & contact

Alarm 21

Side conveyor not enableCheck position of themaintenance switch

Check contacts - 1 – 2 feed back contact

- 3 – 4 solenoid

Side conveyor

enable




14

FEEDER START UP

Engine control

Feeder stop ?

Feeder start fromradio ?

Feeder start fromservice platform ?

Feeder start fromrocess ?

Feeder start for-

ced from dislay ?

Feeder power &

control ON

Feeder running

Feeder not

able to start

Fault

Yes

Yes ( radio contrtol on & active )

Yes

Yes

Yes

Feeder ready for

material feed

Yes

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 valveoperation. Replace valve control head if

nesessary.

No




15

FEEDER STOP

Device pump probefailure

Device pump

pressure high ?

Fuel level belowalarm level ?

Feeder stop fromrocess

Feeder stop fromradio

Feeder stop from

service latform

Feeder

stopped

Feeder start fromrocess ?

Feeder power

OFF

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Second LT alarmsto

Yes

Alarm 35

Check: sensor & wiring // HCM XM3analog input 7 ( 4 – 20 mA = "ok" )

Replace sensor if nesessary

Alarm 40 Check the reason for high pressure. Material leakage under theconveyor. If hydraulic pto is "on" arethe hoses connected. If magnet selected

"on" is it running.

Alarm 10

Add fuelCheck fuel sensor o eration & wirin




16

Feeder running

Feeder stop ?

Crusher speed low

Crusher level high

Crusher pressure

high

Hydraulic oil

temperature high

Crusher overload

Secondary LT level

high ?

Feeder paused Feeder stopped

Engine control

Fault

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Check crusher V-belt tensionCheck used setting à open if nesessary

Check / adjust the crushing speed à

Parameter C1 à increase the mA value

Crusher should run 300 rpm (avg.) with thecrushed material

Check the cleanness of the sensors

Check the function of the crusher level

detector

Check used setting à open if nesessaryCheck / adjust the crushing speed à

Parameter C1 à increase the mA valueCrusher should run 300 rpm (avg.) with thecrushed material

Check hydraulic cooler cleanness

Check function of the hydraulic returnoil circuit thermostat




17

Feeder paused

Feeder stop ?

Crusher speed low

Crusher level high

Crusher pressure

high

Hydraulic oil

temperature high

Crusher overload

Secondary LT level

high ?

Feeder

running

Feeder stopped

Engine control ?Fault

Yes

No

No

No

No

No

No

No

Yes

Yes

Yes

Yes

Yes

Yes




18

Process start up

Engine control

Crusher enable

Fault

No

Screen moduleconnected

NoMain conveyor

enable

Screen enable

Yes No

Side con.veyor connected

Side conv.eyor enable

YesProcess stop

Process not

enable to startProcess enable

to start

Yes No

No

Page 5

Page 6

Return rod pressure not correct:

- manual valve position ?

Cruher drive circuit pressure sensor

not in range.

Page 13




19

Process start

Engine control

Signal horn

Engine to max rpm

Screen moduleconnected

Screen enableProcess

stopping

Screen conveyors hydr. valve ON

Screen hydr. valve CW/ CCW ON

Magnetic separator

present

Magnetic separator

output ON

Hydraulic outlet on

mode

Hydraulic outlet

valve ON

Main conveyor enable

Main conveyor hydraulic

valve ON

Process

stopping

Process start continue

Process

stopping

Fault

Yes

Yes

Yes

Yes

Yes

No

No




20

Crusher enable Process stopping

Side conveyor present

Side conveyor enable

Process stopping

Side conveyor

hydraulic valve ON

Start crusher

Process running

Crusher enable Process stopping

Start feeder

Crusher pressure risetoo fast at start

Process start continue

Process stop Process stopping

YesYes

Yes

Yes

Yes

No

No

No

Yes

No

No




21

Process stopping

procedure

Feeder running ? Stop feeder

Side conveyor present

Stop side

conveyor

Crusher running ? Stop crusher

Stop main

conveyor

Hydraulic outlet on

mode ?

Stop hydraulic

outlet

Magnetic separator

present ?

Stop magnetic

separator

Screen moduleconnected ?

Stop screen and

conveyor

Engine to min

rpm

Process stopped

Yes

Yes

Yes

Yes

Yes

Yes




22

Process control in running

mode

Engine control

Crusher enable

Screen module

connected

Main conv.enable

Screen enable

Side conveyor connected

Process stop

Process running Process stopping

Side conveyor enable

Fault

Yes

Yes

Yes

Yes

Yes

No

No




23

Track drive from radio

Radio selected

Yes

Yes

Radio or process

Radio left track

Radio left track

Radio right track

Radio righttrack

No

No

No

No

Engine control

Hand valve on

Screen connected

Track

control

Track drive

not enabled

Process running

Yes Yes

Fault

No

Yes




24

Track drive from drivebox

Radio selected

No

Yes

Drivebox connected

Drivebox left track

Drivebox left track backward

Drivebox right track

Drivebox righttrack

No

No

No

No

Engine control

Hand valve on

Screen connected

Track

control

Track drive

not enabled

Process running

Yes Yes

Fault

No

Yes




25

Track drive from display

Radio selected

No

Radio process or

Display left track

Display left track

Display right track

Display righttrack

No

No

No

No

Engine control

Hand valve on

Screen connected

Track control

Track drive

not enabled

Yes

No

Process running

Yes Yes

Yes

Fault

No




26

Track control

Process running

YesYes

Normal driving:

Track speed

according to

engine RPM.

Driving with

slow speed.



07/00 APPENDA

-1

Symbol Identification APPENDIX A

1.General symbols

1. On/Start 2. Off/Stop 3. Connecting 4. Disconnecting

5. Increase 6. Decrease7. Stepless adjustable

movement8. Warning

9. Warning: pressurized10. Warning: electric

danger 11. Grease lubrication

point12. Oil lubrication point

13. Running hours 14. Lifting point 15. Horn 16. Level



-2 APPENDA 07/00

APPENDIX A - SYMBOL IDENTIFICATION

17. Belt conveyor 18. Feeding 20. Check 21. Max. temperature

1.General symbols

2. Electric symbols

1. Remote control2. Battery charging

indicator

3. Lights

1. Work light 2. Driving lights

4. Engine

1. Engine emergencystop

2. Stopping of engine 3. Engine running speed 4. Combustion engine



07/00 APPENDA

-3


5. Starting of engine

4. Engine

5. Fuel

1. Fuel volume 2. Fuel pressure 3. Fuel filter 4. Fuel shut-off

5. Fuel refill



-4 APPENDA 07/00


6. Engine oil

1. Oil level 2. Oil refill 3. Oil pressure 4. Oil temperature

5. Oil filter

7. Cooler system

1. Coolant refill 2. Coolant level indicator 3. Coolant pressure 4. Coolant temperature



07/00 APPENDA

-5


8. Transmission oil

1. Oil refill 2. Oil level indicator 3. Oil pressure 4. Oil temperature

5. Oil filter 6. Testing point: oil

pressure

9. Hydraulic oil

1. Hydraulic oil refill 2. Hydraulic oil level 3. Hydraulic oil pressure4. Hydraulic oil

temperature



-6 APPENDA 07/00


5. Hydraulic oil filter 6. Pressure testing 7. Shut-off valve

9. Hydraulic oil

10. Air

1. Air intake 2. Air pressure 3. Air filter

11. Symbols not included in the ISO standard

1. Tensioning of powertransmission belt

2. Tightening of nuts andbolts

3. Remove / installtransport locking



1/95 12-00-EN A-1

ADDITIONAL INFORMATION CHAPTER 6

GUARDS AND PROTECTION DEVICES

– Belt drives are guarded.

– The feed opening to the crusher is

guarded.

– Conveyor head and tail drum nip pointsare guarded.

– Conveyors are equipped with emergencystop cables and safety switches or valves.

– Emergency stop buttons are provided onthe remote control box and service

platform and in the electrical centre andcabin.

EMERGENCY STOP

If a dangerous situation occurs, pull the nearestemergency stop cable or push an emergency stop

button. After pulling an emergency stop cable, thetrip switch will remain engaged and a signal lightwill 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 themachine ensure the area is clear around the unit andthat no one will be endangered by your action. Startthe machine according to the instruction manual.

DISPOSAL OF WASTE

Waste materials, such as oil, battery acids andcleaning fluids etc. must be removed carefullyusing suitable containers to prevent any hazard to

people, animals or environment. The hazardousmaterial must be removed to a suitable wastecollection plant for disposal or recycling.

FIRE

The Manufacturer has not provided this machinewith a fire extinguisher, and recommends that theuser equips the machine with an extinguisher of atype approved by his local authorities. Inflammable

materials used in the construction and use of thismachine include: diesel and lubricating oils,conveyor belting and skirts, electrical cables andfittings, etc.

STORAGE OF THE MACHINES

The machine must be stored in a dry and coveredarea.

DISPOSAL OF THE MACHINE

Whenever a machine is taken out of use, beingdismantled or disposed of, all hazardous materials,such as oils, battery acids, fuels etc. must becarefully removed first to eliminate any danger tolife and the environment. The hazardous materialsmust be removed to a suitable waste collection

plant for disposal or recycling. Dispose of themachine so that there is no danger to life or theenvironment.



6-2 A-1 12-02-EN 1/95




03/03 NORDBERG LT INSTRUCTION MANUAL

0-1

NOISE LEVELS OF LT95/95S SECTION 0

Noise levels in excess of 85 dBA around the Lokotrack while running are shown in the diagram below. Earprotection must be worn in this area.



0-2 NORDBERG LT INSTRUCTION MANUAL 03/03

SECTION 0 - NOISE LEVELS OF LT95/95S

Noise levels

Noise levels in excess of 85 dBA around theLokotrack while running are shown in the tablebelow. Ear protection must be worn in this area.

Vibration

Property Measured value Standard Notes

A-weighted soundpower level LWA

125 dB ISO 3746

(1995) during crushing

A-weighted soundpower level LWA

115 dB ISO 3746

(1995) during idling

Equivalent A-weightedsound pressure level

LAeq

107 dB ISO 11202

(1995)at service platformduring crushing


LAeq

89 dB ISO 11202

(1995)at service platformduring idling

Equivalent C-weightedpeak sound pressure

level LCpeak

131 dB ISO 11202

(1995)at service platformduring crushing


level LCpeak

110 dB ISO 11202

(1995)at service platformduring idling


LAeq

87 .. 107 dB ISO 11202

(1995)

at the distance of 1 m and height of 1,6 maround the LTduring crushing (maximumlevel by the crusher)


LAeq

79 .. 100 dB ISO 11202

(1995)

at the distance of 1 m and height of 1,6 maround the LTduring idling (maximum levelby the crusher)


level LCpeak

116 .. 131 dB ISO 11202

(1995)

at the distance of 1 m and height of 1,6 maround the LT during crushing (maximumlevel by the crusher)


level LCpeak

100 .. 115 dB ISO 11202

(1995)

at the distance of 1 m and height of 1,6 maround the LT during idling (maximum levelby the crusher)

Property Measured value

during crushingMeasured value

during idling Standard Notes

Weighted r.m.s.acceleration aw

1,9 m/s2 0,75 ISO/DIS

2631-1 (1994) vertical direction


0,45 m/s2 0,19 /s2 ISO/DIS2631-1 (1994)

transversal direction


0,22 m/s2 0,21 m/s2 ISO/DIS2631-1 (1994)

longitudinal direction

Vibration total valueav of weighted r.m.s.

acceleration1,9 m/s2 0,79 m/s2 ISO/DIS

2631-1 (1994)calculated according tochapter 8.2 of the standard



If the machine is used for recycling, pay attention to the following:

Break the feed material small enough and cut the metal bars to 0.5 - 1 metres long depending on themachine. Too long bars may damage the conveyor belt.

Remove the metal objects from the feed, if possible. At least remove the loose metal. The metal objectslarger than the crusher setting must not enter the crusher. When removing the metal objects be verycareful. Never go to the feeder when the machine is running. Observe the feed material. Never let theuncrushable objects enter the crusher.

Be very careful when clearing the blocking. Stop the machine and use safety valve or switch duringclearing.



0-2




07/04 EN SAFETY PLATES 0-1

SAFETY PLATES APPENDIX 0

Do not stand in the vicinity of the crusher when theengine is running.Item: N11904845

Do not stand in the vicinity of the crusher when theengine is running.Item: N11904846

Do not stand on the machine.Item: N11904847

There are moving parts behind the protecting cover.Do not open the cover when the engine is running.

Item: N11904848



0-2 SAFETY PLATES EN 07/04

APPENDIX 0 - SAFETY PLATES

Do not go near the feeder when the engine isrunning.

Item: N11904849

Do not go under the machine when the engine isrunning.

Item: N11904850

Mind the hot surface.

Item: N11904851

Mind the high-pressure liquid.

Item: N11904852





Stay away from the powerful magnet.Item: N11904853

Read the user instructions.Item: N11904863

Do not open the hatch when the rotor is moving.Item: N11904855 Lock the rotor before entering the crusher.Item: N11904856





Watch out for material dropping from the conveyor.Item: N11905034

Watch out for material dropping from the bucket.Item: N11904865

Rotation direction of the vibrator.Item: N11904938

Switch off the radio control before blasting.Item: N11904944





Emergency stop.Item: N11904932

Conveyor emergency stop.Item: N11904933

Conveyor emergency stop wire.Item: N11904934

Do not open the main current switch when the engineis running.

Item: N11904936





Close the hatch before lowering the conveyor.Item: N11904939

Stay away from the crusher cavity.Item: N11905009

Do not step under the conveyor.Item: N11905035 Use a safety rod to prevent the crusher from closing.Item: N11905011





Do not insert tools in the crusher cavity when theengine is running.Item: N11905012

Pressure accumulator.Item: 945457

Do not open the hatch when the engine is running.

Item: N11905036





Do not attach or detach hydraulic connection whenthe engine is running.

Item: N11904858

Keep the door closed when the engine is running.Item: N11904857

Tighten the wheel nuts to the specified torque whenchanging tires.

Check the tightness of the nuts after 50km and150km.

Item: 11904927

Use the pin to lock the conveyor before moving themachine.

Item: N11904930





Use the pin to lock the conveyor before starting thecrushing.

Item: N11904931

Oil.Item: N11904941

Oil recommendation.Item: N11904940

Use of respirators required.Item: N11904862





Inspect every 8 hours and tighten every 40 hours.Item: 945454

Lock the catch.Item: 923896

Use of hearing protectors required.Item: 803720

Use of a helmet required.Item: 803721





Greasing point.Item: N11904928

Check every 8 hours.Item: 945394

Fuel tank.Item: 319008

Use of eye shields required.Item: N11903275





Engine oil.Item: 942688

Coolant.Item: 942686

Hydraulic oil.Item: 319009

Valve.Item: 319010





Oil recommendation.Item: N11904929





DANGER! Electric shock.Item: 319001

People using pacemakers must not go near themagnet.

Item: N11904854

Fastening flat bar.Item: 945452

CE mark.Item: 803814





Conveyor safety switch.Item: N11904937



NORDBERG C SERIES JAW CRUSHERS

INSTRUCTION MANUAL

140588-EN



Nordberg C Series Jaw Crushers

Table of Contents

PREFACE

1.1FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

SAFETY

GENERAL CRUSHER INFORMATION

3.1CRUSHER TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2CRUSHER COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.3SPARE PARTS BOOK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.4ORDERING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.5ESTIMATING CRUSHER CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.6ESTIMATING CRUSHER PRODUCT GRADATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.7CRUSHER SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3.8CRUSHER SETTING LIMITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3.9OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

OPERATING INSTRUCTIONS

4.1PREPARATIONS BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2STARTING THE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.3STOPPING THE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.4OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.5RE-STARTING A CRUSHER STALLED UNDER LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.6CRUSHER SETTING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.7TOGGLE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.8SPACER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.9TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10



Nordberg C Series Jaw Crushers

Table of Contents

MAINTENANCE

5.1SPACER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2TOGGLE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.3LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.4PERIODICAL MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

5.5MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5.6OTHER BOLT TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

REPLACEMENT OF WEAR PARTS

6.1GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16.2JAW SELECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.3JAW HARDENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.4CHANGING OF CHEEK PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.5CHANGING/TURNING OF JAW PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6.6PITMAN EYE PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

6.7FEEDING CHUTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

6.8TOGGLE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

APPENDIXNORDBERG C SERIES JAW CRUSHER’S JAW-LIFTING TOOL



EN 140587-0H NORDBERG C SERIES JAW CRUSHERS 0-1

NORDBERG C SERIES JAW CRUSHERS CHAPTER 0

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

Because of the continuous development of the products, the manufacturer reserves a right to alter thetechnical specifications written in this manual, without any advance information.

This is the first edition published in April 2003 in Tampere, Finland .

Metso Minerals (Tampere) Oy

P.O. Box 306

FIN-33101 Tampere

Finland

Tel. +358 (0)20 484 142

Fax +358 (0)20 484 143



0-2 NORDBERG C SERIES JAW CRUSHERS 140587-0H EN

CHAPTER 0 - NORDBERG C SERIES JAW CRUSHERS




EN 140588-1H NORDBERG C SERIES INSTRUCTION MANUAL 1-1

PREFACE CHAPTER 1

1.1 FOREWORD

This instruction manual provides guidance for first

time operators of the crusher as well as technical procedures as a reference for the experiencedcrusher operator. Read, study, and keep it for futurereference.

The instructions given are for the operation and basic maintenance procedures only, as thisinstruction book is not a repair manual. Shouldmaintenance procedures not covered in this manual

be required, contact Metso Minerals.

Illustrations and instructions guide the operator

through correct procedures for checking, operatingand maintaining the crusher and its accessories.

Operating techniques outlined in this manual are basic. Operating skills and additional techniqueswill develop through experience as the operator gains knowledge of the crusher and its capabilities.

Continuing improvement and advancement of product design may result in changes to your newmachine that may not be included in this

publication. As required, each publication isreviewed and revised to update and includeappropriate changes in the later editions.

The descriptions and specifications in this manualwere in effect at the time this manual was approvedfor printing. Metso Minerals reserves the right todiscontinue models at any time and to changespecifications and designs, without notice andwithout incurring obligation.

Whenever a question arises concerning your

crusher, or this publication, please consult your Metso Minerals representative for the latestavailable information.

1.2 SAFETY

BASIC RULES REGARDING SAFETY IN AND

AROUND A CRUSHING PLANT AREOUTLINED IN THE SECTION ENTITLED"SAFETY."

OPERATOR SAFETY AND THE SAFETY OFOTHERS DEPEND UPON REASONABLECARE AND JUDGEMENT IN THE OPERATIONOF THIS CRUSHER. A CAREFUL OPERATOR IS GOOD INSURANCE AGAINST ANACCIDENT.

MOST ACCIDENTS, NO MATTER WHERE

THEY OCCUR, ARE CAUSED BY FAILURETO OBSERVE AND FOLLOW SIMPLEFUNDAMENTAL RULES OR PRECAUTIONS.FOR THIS REASON RECOGNIZING HAZARDSAND TAKING STEPS TO AVOID THEM CANPREVENT MOST ACCIDENTS.

REGARDLESS OF THE CARE USED IN THEDESIGN AND CONSTRUCTION OF THISTYPE OF EQUIPMENT, THERE ARECONDITIONS THAT CANNOT BECOMPLETELY SAFEGUARDED AGAINSTWITHOUT INTERFERING WITHREASONABLE ACCESSIBILITY ANDEFFICIENT OPERATION. WARNINGS AREINCLUDED IN THIS INSTRUCTION MANUALTO HIGHLIGHT THESE CONDITIONS.



1-2 NORDBERG C-SERIES INSTRUCTION MANUAL 140588-1H EN

CHAPTER 1 - PREFACE




EN 140587-2 SAFETY 2-1

SAFETY CHAPTER 2

Please refer to the general SafetyInstructions supplied together withthis Manual.



2-2 SAFETY 140587-2 02/05

CHAPTER 2 - SAFETY





GENERAL CRUSHER INFORMATION CHAPTER 3

3.1 CRUSHER TERMINOLOGY

Throughout this instruction manual, technical terms

are used to describe the crusher, its components andits operation. These terms are defined herein with

the intent of avoiding any confusion or misunderstanding.

Figure 3.1 Jaw crusher terminology

Feed: The raw material to be crushed, such as therock type (limestone, basalt, granite, etc.) or man-made materials such as concrete and asphalt.

The feed size is typically denoted in terms of a sizedistribution or based on an average top (maximum)size.

Product size: The size of the material after it has been crushed. Similarly to the feed size, the productsize is typically denoted in terms of a sizedistribution or based on an average top (maximum)size.

Capacity: The output of the crusher in tons per hour.

Feed Opening: The opening where the feed

material is fed into the crusher. The feed openinghas two dimensions: a width and a depth. The feedopening depth is a critical dimension because itdictates the maximum feed size a given jaw crusher model can accept.

Maximum Recommended Feed Size: As ageneral guideline, the maximum average


1 Feed opening depth 5 Stroke

2 Moving jaw 6 Nip angle

3 Stationary jaw 7 Feed opening width

4 Closed side setting (c.s.s)



3-2 NORDBERG C SERIES INSTRUCTION MANUAL 140588-3H EN

CHAPTER 3 - GENERAL CRUSHER INFORMATION

recommended feed size should be about 80% of thefeed opening depth. Such measures will ensure thatany bridging events resulting from oversized feed

are kept to a minimum. A rock hammer isrecommended for applications where the maximumfeed size is regularly close to the feed openingdepth.

Table 3-1 Maximum recommended feed sizes

Nip Angle: The angle between the fixed andmoving jaws. The nip angle is often referred to asthe "bite" angle as well.

Jaws: The members that perform the crushing arecommonly referred to as jaws. The jaws consist of astationary and moving jaw, and depending on themodel each one of these may consist of either 1 or 2

pieces. Different jaw profiles are available for different applications.

Discharge Setting: The shortest distance betweenthe bottom of the fixed and moving jaws as

measured at the point where the jaws are at their closest relationship during their work cycle (i.e. theclosed side setting, or c.s.s.). The method in whichthe setting is measured varies depending on the jaw

profile. These differences are explained in detail inthe CRUSHER SETTING section.

Stroke: The difference between the maximum andminimum distances at the bottom of the fixed and

moving jaws during one revolution of the eccentricshaft.

Feed Opening

MaximumRec. Feed

Size

mm inch mm inch

C63 630 X 440 17 X 25 352 14

C80 800 X 510 20 X 32 408 16

C95 930 X 600 24 X 37 480 19C100 1000 X 760 30 X 40 608 24

C105 1060 X 700 28 X 42 560 22

C110 1100 X 850 34 X 44 680 27

C125 1250 X 950 37 X 49 760 30

C140 1400 X 1070 42 X 55 856 34

C145 1400 X 1100 43 X 55 880 35

C160 1600 X 1200 47 X 63 960 38

C200 2000 X 1500 59 X 79 1200 47

C3054 1380 X 760 30 X 54 608 24




CHAPTER 3 - GENERAL CRUSHER INFORMA TION

3.2 CRUSHER COMPONENTS

Figure 3.2 Jaw crusher main components

Callout Description Callout Description1 Front frame 16 Pitman bearing

2 Upper wedge 17 Pitman

3 Filling wedge 18 Frame connecting rods

4 Jaw bolt 19 Side plate

5 Disc spring package 20 Frame bolt

6 Cheek plate, upper 21 Rear frame

7 Fixed jaw, upper 22 Adjustment wedges

8 Moving jaw, upper 23 Spacer

9 Cheek plate, lower 24 Toggle seat plate

10 Fixed jaw, lower 25 Toggle seat

11 Moving jaw, lower 26 Locking nuts with thrust bearing

12 Fixed wedge 27 Tension spring

13 Pitman eye protection plate 28 Toggle seat

14 Flywheel 29 Toggle plate

15 Eccentric shaft 30 Tension rod

31 Center wedges





3.3 SPARE PARTS BOOK

A Spare Parts Book containing various assemblydrawings pertaining to your crusher will be sentimmediately after the crusher has been shipped.This book illustrates each and every part used in theassembly of the machine and is to be used whenordering spare or replacement parts.

3.4 ORDERING PARTS

Metso Minerals endeavors to carry an ample supplyof parts in stock to provide prompt and efficientservice on all orders for repairs and replacements.

To avoid delay and the possibility of incorrect parts being furnished, the following information should be given:

1. Crusher size.

2. The serial number of the crusher which isstamped on the crusher nameplate. Theserial number is also on the cover of thespare parts books.

3. Complete name and part code number asshown in the Spare Parts Book.

4. Exact quantity of each part ordered.

5. Complete shipping instructions.

If your crusher Spare Parts Books have been lost,destroyed or misplaced, an additional set can beordered.

For proper operation, only genuine factory partsshould be installed. These are guaranteed as toaccuracy, workmanship and material. Using pirate

parts may put your safety and that of your crusher at risk. Make sure you completely understand your

crusher's Warranty conditions at all times.

3.5 ESTIMATING CRUSHER CAPACITY

The capacity of the crusher depends on factors suchas the type of feed (material type, size distribution,

fracture characteristics, moisture content, etc.), typeof operation (feed availability, feed arrangement)and discharge setting. To obtain an estimate of thecapacity, refer to the following capacity table.These capacities are based on results obtained inactual practice with hard granite that has a bulk density of 1.6 t/m3 (100 lb/ft3), and are where thefeed has been properly graded so that bridging doesnot take place.

To obtain more accurate capacity estimates specificto your actual crushing application, contact your local Metso Minerals sales representative to requesta computer simulation of your circuit's operating

condition





Table 3-2 Nominal jaw crusher capacities

c.s.s. C63 C80 C95 C100 C105 C110 C125 C140 C145 C160 C200 C3054Mtph Mtph Mtph Mtph Mtph Mtph Mtph Mtph Mtph Mtph Mtph Mtph

mm in Stph Stph Stph Stph Stph Stph Stph Stph Stph Stph Stph Stph

40 40 65

1-5/8" 45 70

50 55 80

2" 60 90

60 65 95 120

2-3/8" 70 105 135

70 80 115 140 150 155 190 240

2-3/4" 90 125 155 165 170 210 265

80 95 130 160 170 175 210 270

3-1/8" 105 145 175 190 195 235 295

90 110 150 180 190 200 235 295

3-1/2" 120 165 200 210 220 260 325

100 120 165 200 215 220 255 290 3254" 135 180 220 235 245 285 320 355

125 210 250 265 280 310 250 385 400 390

5" 230 275 290 305 345 385 425 440 430

150 250 300 315 335 370 410 455 470 520 460

6" 275 330 350 370 405 455 500 520 575 510

175 290 350 370 390 425 470 520 540 595 760 530

7" 320 385 405 430 470 520 575 595 655 840 585

200 420 445 480 530 590 610 675 855 600

8" 465 490 530 585 650 670 740 940 660

225 590 655 680 750 945

9" 650 725 750 825 1045

250 650 725 750 825 1040

10" 720 800 825 910 1145

275 820 900 1130

11" 900 995 1250

300 980 1225

12" 1080 1350





3.6 ESTIMATING CRUSHER PRODUCTGRADATION

The crusher's product gradation depends on thesame factors that affect capacity. The followingfigure gives an indication of the product gradationas a function of the closed side setting (c.s.s.).

These product gradations are based on resultsobtained in actual practice with hard granite.

To obtain more accurate product gradation

estimates, contact your local Metso Minerals salesrepresentative to request a computer simulation of your circuit's operating conditions.

Figure 3.3 Crusher product gradation

0

10

20

30

40

50

60

70

80

90

100

1 10 100 1000

Product size

P e r c e n t a g e p a s s i n g , w e i g h t %

40 50 70 100 130 160 200 250 300

4" 16"2" 8"1"

css





3.7 CRUSHER SETTING

The Crusher setting is the most important Crusher parameter since it determines the Crusher's capacityas well as the top size of the Crusher product. It istherefore indispensable for everyone to understandhow the Crusher setting is measured.

The discharge setting is the shortest distance between the bottoms of the fixed and moving jawsduring their work cycle. This distance is referred toas the closed side setting (c.s.s.), and it is acalculated distance as the Crusher setting istypically measured when the Crusher is at rest. Thelargest distance between the bottoms of the fixed

and moving jaws is referred to as the open sidesetting (o.s.s.), and it is typically a distance that isdirectly measured when the Crusher is at rest.

The Crusher setting is measured in three differentways, first referring to the tooth groove (bottom) or crown (top) of the stationary jaw and then to the

tooth groove (bottom) or crown (top) of themovable jaw. Thus, the setting is always measuredfrom the Stationary (bottom or top) to the Movable

jaw (bottom or top). The three alternatives areshown in Table 3-3.

The measurement type depends on the profile aswell as on the Crusher model. This information isalso found in the Crusher Spare Parts Book.

Table 3-3 Measurement types

Figure 3.4 Crusher setting measurement

MeasurementType

Reading Sequence (Jaws)

Stationary to Movable

1 Bottom to Top2 Top to Top

3 Top to Bottom





For example, the setting of the C125, equipped withQuarry jaws, is measured from Top to Top (Type2). However, with Standard jaws, the setting is

measured from Bottom to Top (Type 1).

It is easiest to measure the setting when the Crusher is at rest with a device such as a block of wood of known dimensions (several blocks should beavailable if more than one setting is typically used).The distance measured this way is larger than theclosed side setting (c.s.s.) because the pitmanalways stops at its lowest point. This value is close(±2mm/±0.08") to the open side setting (o.s.s.). As

previously mentioned, the closed side setting iscalculated by deducting the stroke from the openside setting (Table 3-4).

Table 3-4 Dimension (stroke) to be deductedfrom the open side setting (o.s.s.) to calculatethe closed side setting (c.s.s.).

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

IMPORTANT!

The Crusher setting must always be

measured in a straight line at the bottom

of the crushing cavity. Measure the set-

ting always from the least worn area.

Model Stroke

mm Inch

C63 22 7/8

C80 24 1

C95 32 1¼

C100 32 1¼

C105 32 1¼

C110 36 13/8

C125 39 1½

C140 42 15/8

C145 36 13/8

C160 39 1½

C200 50 2

C3054 32 1¼

Example

Crusher: C140

Stroke: 42 mm (15/8” ) (Table 3-4)

Jaw Profile: Quarry (top to top)

O.S.S.: 230 mm (9")

C.S.S.: 230 – 42 = 188 mm (9" – 1 5/8" = 7 3/8")





Figure 3.5 Measuring the setting

NOTE: The C.S.S does not have to be calculated if the user knows the Crusher setting limits in termsof the O.S.S. The C.S.S. is typically calculated

because Crusher capacity is always denoted interms of the C.S.S. only.

3.8 CRUSHER SETTING LIMITS

All C-Series Crusher models have a maximum possible setting as well as a minimum allowedsetting, and it is very important that the user understands why these are important to keep thesein mind at all times.

The maximum possible setting is simply themaximum setting that the Crusher is physically ableto accommodate. Typically, such setting isindicated with new jaws, and the setting actuallydepends on the jaw profile as well as on whether aspacer is being used or not. This information isalways found in the Crusher Spare Parts Book.

The minimum allowed setting (c.s.s. or o.s.s.) is theminimum setting at which the Crusher can be usedwhen the Crusher is operated according to MetsoMinerals' recommendations. The minimum allowedsetting is very important as it takes into account thedesign and operation limits of the Crusher. Notrespecting these recommendations can lead to a

poor utilization of the jaws (high scrap rate) as wellas a shortened Crusher life.

The minimum allowed setting varies depending onwhether the application is a normal rock application(Normal), or a recycling application (Special),when materials such as concrete, asphalt and bricksare being crushed. Note that the minimum allowedsetting does not depend on the jaw profile (it isalways the same for a specific Crusher model). SeeTable 3-6.





Table 3-5 Minimum allowed settings for hardrock, soft rock and recycling applications.

Crusher model

CSS OSS

Hard rock(>150 Mpa)(> 22 000 psi)

Soft Rock(<150 MPa)(<22 000 psi)

Recycling Strokemm

Hard rock(>150 Mpa)(> 22 000 psi)

Soft Rock(<150 MPa)(<22 000 psi)

Recycling

mm mm mm mm mm mm

C63 40 20 20 22 62 42 42

C80 40 30 20 24 64 54 44

C95 60 45 25 32 92 77 57

C100 70 60 45 32 102 92 77

C105 70 50 25 32 102 82 57

C110 70 60 45 36 106 96 81

C3054 70 60 45 32 102 92 77

C125 100 N.A N.A 39 139 N.A N.A

C140 130 N.A N.A 42 172 N.A N.AC145 125 N.A N.A 36 161 N.A N.A

C160 150 N.A N.A 39 189 N.A N.A

C200 175 N.A N.A 50 225 N.A N.A

Crusher model

CSS

Strokein

OSS

Hard rock(>150 Mpa)

(> 22 000 psi)

Soft Rock(<150 MPa)

(<22 000 psi)Recycling

Hard rock(>150 Mpa)

(> 22 000 psi)

Soft Rock(<150 MPa)

(<22 000 psi)Recycling

in in in in in in

C63 1 5/8 7/8 7/8 7/8 2 4/8 1 6/8 1 6/8

C80 1 5/8 1 2/8 7/8 1 2 5/8 2 2/8 1 6/8

C95 2 4/8 1 7/8 1 1 2/8 3 6/8 3 1/8 2 3/8

C100 2 7/8 2 4/8 1 7/8 1 2/8 4 1/8 3 6/8 3 1/8

C105 2 7/8 2 1 1 2/8 4 1/8 3 3/8 2 3/8

C110 2 7/8 2 4/8 1 7/8 1 4/8 4 3/8 3 7/8 3 2/8

C3054 2 7/8 2 4/8 1 7/8 1 2/8 4 1/8 3 6/8 3 1/8

C125 4 1/8 N.A N.A 1 5/8 5 5/8 N.A N.A

C140 5 2/8 N.A N.A 1 6/8 7 N.A N.A

C145 5 1/8 N.A N.A 1 4/8 6 5/8 N.A N.A

C160 6 1/8 N.A N.A 1 5/8 7 6/8 N.A N.A

C200 7 1/8 N.A N.A 2 9 1/8 N.A N.A





3.9 OPTIONS

Following options can be installed on Crusher after start-up.

3.9.1 Intermediate Plate

Fitting an intermediate (backing) plate behind thefixed jaw reduces the nip angle of the crusher. Theintermediate plate reduces the feed opening and thesetting range by approximately the same amount asits thickness. However the intermediate plate

does not, under normal circumstances, allow theuser to use a smaller setting than the minimum

recommended setting.

If available with the specific C-Series jaw crusher

model, an intermediate plate may be used for thefollowing reasons:

To improve the nip angle (by decreasing the nipangle) when crushing slippery material (materialthat is difficult to bite).

To increase the length of the crushing zone (andthus increase the life of the jaw dies) when the feed

material is consistently smaller than the crusher'sinput capacity.

The intermediate plate is not available for all

models. Moreover, multiple plate thicknesses areavailable with certain models. Before orderingintermediate plate consult Metso Minerals if it fitsto your application.

3.9.2 Protection Plates

Protection plates are designed for additional protection of the crusher's front frame and pitman.They are recommended when using small settings

(always greater than or equal than the minimumrecommended setting) and/or when the rock to becrushed is very hard (very low crushability). Of course, these can be used at any time for added

protection.

NOTE: The front frame protection plate is notused when an intermediate plate is used.

Protection plates are not available options with allC-Series crusher models.

NOTE: Excessive replacement of the protection plates indicated a feed problem. Contact MetsoMinerals if such is the case with your Crusher.

WARNING!

The minimum allowed setting of a Crusher must be respected at all times unless otherwiseindicated by Metso Minerals. Not respectingthese recommendations can lead to a poor utilization of the jaws (high scrap rate) as well asto a shortened Crusher life. Moreover, operatingthe Crusher at settings smaller than allowed willvoid the Crusher's warranty.

WARNING!

The maximum size of tramp iron (rebars,excavator teeth, etc.) must be smaller than theCrusher closed side setting (c.s.s.).

IMPORTANT!

When using protection plates, different bottomretaining wedges must be used.





Figure 3.6 Protection plates

3.9.3 Conveyor Belt Protector

Conveyor belt protector prolongs lifetime of conveyor belt under Crusher. Angle of the protector can be adjusted.

Especially in recycling applications, rebars candamage the belt.


1 Front frame protection plate 2 Pitman protection plate





Figure 3.7 Conveyor belt protector

3.9.4 Hydraulic Setting Adjustment

A Crusher equipped with mechanical settingadjustment can be retrofitted with the hydraulicsetting adjustment.

Refer to Chapter 4.6.2.

3.9.5 Automatic Lubrication Unit

The lubrication system automatically lubricates thefour (4) eccentric shaft bearings in accordance withthe recommendations provided by the factory.

Refer to Chapter 5.3 and Installation ManualChapter 6.5.

Callout Description

1 Protector plate

2 Support holder 3 Eye screw

4 Split pin

5 Washer

6 Washer

7 Hex screw

8 Hex nut

9 Joint pin




OPERATING INSTRUCTIONS CHAPTER 4

4.1 PREPARATIONS BEFORE STARTING

Good inspection habits will do much to insure years

of successful operation of the Crusher. Do not relyon memory alone to regulate required periodicmaintenance, keep an accurate written record.Regularly performing pre-start and maintenanceinspections will pay off in the way of eliminatingcostly down time and prolonging the life of theCrusher. Before starting the Crusher, perform thefollowing operations:

1. Make a final inspection of the Crusher to becertain that no tools or mechanicalobstructions are on the Crusher, that all

joints and fasteners are properly tightened,

that no leaks are apparent and that there isno other reason why the Crusher should not

be started.

2. Ensure that the Crusher cavity is empty.

3. Ensure also that there are no persons in thearea whose safety may be endangered. Walk around the Crusher and ensure that there isnobody on, by or below the Crusher. Warneverybody in the vicinity before starting.

4.2 STARTING THE CRUSHER

An electric motor or diesel engine drives theCrusher. Starting the Crusher merely amounts tostarting the motor or engine according to themanufacturers' instructions. Do not introduce anyfeed to the Crusher during starting. To start theCrusher, proceed as follows:

1. Start the discharge conveyor.

2. Start the electric motor or diesel engine. If aslip ring motor is used, wait until its starting

resistor reaches the operating stage. If a pounding or thumping sound is heard, refer to the TROUBLESHOOTING section of this chapter (chapter 4.9).

3. Start the feeder.

This is a brief outline of the control logic sequencethat is required to start the Crusher. Other measuresmay be taken in accordance with local conditions.

Figure 4.1 Starting and stopping sequence

4.3 STOPPING THE CRUSHER

To stop the Crusher, proceed as follows:

1. Stop the feeder.

2. Wait until the Crusher cavity is empty.

3. Stop the electric motor or diesel engine.

4. Stop the discharge conveyor.

IMPORTANT!

After stopping the Crusher motor or diesel engine,the Crusher will coast down for about five minutes




CHAPTER 4 - OPERATING INSTRUCTIONS

4.4 OPERATION

Feed the material to the Crusher evenly inaccordance with the feed arrangementrecommendations. Note that the Crusher operatesmost efficiently when the crushing cavity istwo-thirds (2/3) full. An ultrasonic level sensor may be integrated into the Crusher control in order to optimize the feed level of the Crusher.

Figure 4.2 Recommended filling ratio

Refer to the WEAR PARTS section for operatinginstructions pertaining to wear parts.

4.4.1 Oversized Feed

Avoid trying to crush oversized feed (feed too large

for the cavity). Having to reposition rock wastestime, reduces capacity and imposes unnecessaryloads on the Crusher. Therefore attention must be

paid to the size of feed. A stationary grizzly is asuitable alternative for limiting oversized feed. Ahydraulic hammer can be used for breakingoversized material and is recommended if such

problems are foreseen.

The oversized rock can be lifted out of the cavitywith a "clamp" and crane or it can be turned to a

better position.

When the Crusher is running a hydraulic hammer can be used for breaking the oversized or blockedfeed.

4.4.2 Tramp Iron/Uncrushables

Uncrushable ("tramp iron") material larger than theCrusher's c.s.s., such as excavator teeth, should be

prevented from entering the Crusher by installing amagnetic separator. Uncrushable material larger than the c.s.s will cause the toggle plate to buckle,and will impose unnecessary stresses on theCrusher.

If tramp iron enters and stays in the Crusher, stopthe feeder and Crusher immediately. Empty thecavity and remove the tramp iron. If necessaryincrease the Crusher setting to remove the trampiron.

WARNING!Lift or turn the rocks in the cavity only when theCrusher is stopped. Do not try to clear the blockedcrushing cavity when the Crusher is running. Bealways very careful when clearing the cavity.

Never use a crowbar to turn oversized feed.

WARNING!

Never use explosives to clear a blocked crushingcavity. Make sure no explosives enter the Crusher

WARNING!

Always inspect the toggle plate, tension rod andspring (or hydraulic cylinder) for possible damage.





4.4.3 Packing

The Crusher should never be operated when thefeed is packing in the crushing cavity (i.e. when thefeed packs in such a way that it cannot be reducedin size), as this results in a drastic reduction of theCrusher lifetime.

When packing occurs, the:

1. Crusher speed slows down.

2. Engine speed slows down.

3. Load of the Crusher rises.

4. The Crusher is overloaded.

Packing can occur due to the following reasons:

1. There is too much fines in the feed material.2. The maximum feed size relative to the feed

opening is very small (less than 50 % of thefeed opening width).

3. The material is very brittle and readily breaks into fines (material characteristics).

4. Wet feed material.

5. Incorrect jaws.

To prevent packing, all possible causes must beaddressed. If, however, the causes cannot be

eliminated, the material level in the Crusher cavitymust be lowered and/or the Crusher setting must beincreased.

4.5 RE-STARTING A CRUSHER STALLEDUNDER LOAD

A stalled Crusher MUST be treated as possibly being jammed and therefore a potential hazard.Clear the plant area of all personnel. Notify themanager or his deputy of a stalled Crusher situationimmediately.

Find out why the Crusher stalled. If, after carefulexamination, there appears to be no electrical or mechanical reason why the Crusher has stalled, itwould indicate that the Crusher is jammed by theingress of foreign matter and is in a hazardous state.

If a Crusher stalls under load any stored energywithin a mechanism due to tramp material can bereduced to insignificant level by ensuring that the

jaws are moved to the open position. After that startthe Crusher. If the Crusher won't start, repeat this

procedure. When the jaws are fully open, don't start

the Crusher anymore. In this case stones and trampmetal must be removed from the Crusher manually.

WARNING!

Never operate the Crusher when the feed is packing in the cavity. This will result in a drasticreduction of the Crusher lifetime.

WARNING!

Any inspection of the crushing cavity must becarried out from underneath the Crusher, not fromabove. Tramp iron could be ejected from thecrushing cavity. Serious personal injury can result.

WARNING!

Always note the position of the gib keys todetermine if the crusher is "at rest" or if there is

potential energy remaining in the flywheels.





4.6 CRUSHER SETTING ADJUSTMENT

The setting adjustment of C Series Jaw Crushers isdone by means of moving two wedges against or away from each other. Such movement changes theeffective thickness "s" of the wedge pair, which inturn increases or decreases the Crusher setting,respectively.

For all Crusher models, the setting adjustment may be done mechanically by turning cap nut(s)manually, or alternatively hydraulically (option)through the use of an electrical control panel. For instructions concerning the hydraulic settingadjustment (option), refer to the HYDRAULICSETTING ADJUSTMENT section.

4.6.1 Mechanical Setting Adjustment

The main components of the device are theadjusting wedges, cap nut(s) (2) and locking pipe(s)

(3). Changing the setting requires the use of theratchet delivered with the Crusher (special tool) toturn the cap nuts.

Figure 4.3 Mechanical setting adjustment

Callout Description

1 Adjusting wedges

2 Cap nut

3 Locking pipe

WARNING!

Turning the cap nuts should be made with theratchet provided with the Crusher. NOHYDRAULIC OR PNEUMATIC WRENCHMAY BE USED

WARNING!

The wedges are self-restraining and their surfacesmust not be lubricated. It may overload theadjusting mechanism.





To change the setting, the locking nuts of thetension rod must be loosened, and then the cap nutsmust be turned clockwise or counterclockwise to

increase or decrease the Crusher setting,respectively. A single complete rotation of one capnut has a net effect on the Crusher setting asindicated in Table 4-1. Turning both cup nuts onecomplete rotation in the same relative direction willthus change the Crusher setting by twice as what isindicated in Table 4-1.

Table 4-1 Average change in setting per cap nutrotation

To calculate how many rotations the cap nuts must be turned to change the Crusher setting, simplydivide the desired setting change amount by theappropriate value in Table 4-1 and the quantity of cap nuts.

Required Rotations = (Desired SettingChange)/(Crusher Change in Setting)

Round the result to the nearest higher number.

4.6.1.1 Decreasing the Crusher Setting

The Crusher setting can only be adjusted while thecrusher is at rest.

1. Stop crushing, then stop the Crusher.

2. Determine how much the setting must bedecreased and calculate how many rotationsthe cap nuts must be turned.

3. Loosen the locking nuts of the tensionspring (Figure 4.4). Be careful not to dropthe toggle plate as the spring gets loose.

4. Remove the locking pin from the locking pipe and push the pipe towards the Crusher.

5. Turn the cap nuts COUNTERCLOCKWISE.Make sure that both wedges are adjustedequally so that their position in relation tothe Crusher remains the same. If you have tochange the setting remarkably, turn the capnuts for a while and loosen the springlocking nuts again if necessary. There arewashers fastened to the rear end of theadjusting wedges. When decreasing thesetting, push the wedges only until thesewashers are against the guide plates.

6. Lock the pipes with the pin.

7. Adjust the spring length according to Table

4-2 (see Figure 4.4).

8. Start the Crusher and listen if the toggle plate knocks. If it knocks, contact MetsoMinerals.

9. Start crushing.

ModelChange in Setting

mm (in)

C63 1.9 (0,07)

C80 2.3 (0.09)C95 2.2 (0.09)

C100 2.3 (0.09)

C105 4.0 (0.16)

C110 2.0 (0.08)

C125 1.7 (0.07)

C140 2.3 (0.09)

C145 2.5 (0.10)

C160 2.2 (0.09)

C200 3.2 (0.12)

C3054 2.3 (0.09)

Example:

To change the setting of a C125 by 10 mm(3/8"), turn the cap nuts as follows:

10 mm / 1.7 mm / rotation = 5.88 => 6 totalrotations => 3 rotations per cap nut

3/8" / 0.07" / rotation = 5.35 => 6 total rotations=> 3 rotations per cap nut





Figure 4.4

Table 4-2 Tension Spring Operating Length

4.6.1.2 Increasing the Crusher Setting

The Crusher setting can only be adjusted while thecrusher is at rest.

1. Stop crushing, then stop the Crusher.

2. Determine how much the setting must beincreased and calculate how many rotations

the cap nuts must be turned.

3. Loosen the locking nuts of the tensionspring (Figure 4.4).

4. Remove the locking pin from the locking pipe and push the pipe towards the Crusher.

5. Turn the cap nuts CLOCKWISE. Make surethat both wedges are adjusted equally so thattheir position in relation to the Crusher remains the same. Be careful not to drop thetoggle plate as the spring gets loose.

6. Lock the pipes with the pin.

7. Adjust the spring length according to Table4-2 (Figure 4.4).

8. Start the Crusher and listen if the toggle plate knocks. If it knocks, contact MetsoMinerals.

9. Start crushing.

WARNING!

Always tighten and loosen the spring from theside. Never remove the protection plate

ModelTension Spring Length

L mm (in.)

C63 310 (12 ¼")

C80 310 (12 ¼")

C95 385 (15 ¼”)

C100 370 (14 ½")C105 365 (14 ¼")

C110 365 (14 ¼")

C125 425 (16 ¾")

C140 540 (21 ¼")

C145 540 (21 ¼")

C160 540 (21 ¼")

C200 540 (21 ¼")

C3054 440 (17 1/3")

WARNING!

Always tighten and loosen the spring from theside. Never remove the protection plate.





4.6.2 HYDRAULIC SETTING ADJUSTMENT(OPTION)

Hydraulic setting adjustment enables remote settingadjustments that are much quicker and simpler assetting adjustments are made remotely by operatinga control panel.

Figure 4.5 Setting adjustment

The system is powered with an independenthydraulic unit, or it can be connected to a largehydraulic system, as in the Lokotrack. Thehydraulic oil pressure forces the wedges either towards or apart from each other, thereforedecreasing or increasing the setting, respectively.

Setting can be adjusted while the Crusher is at restor idling. If adjustment of setting is done during

crushing lifetime of crusher components is shorter.For detailed information, refer to the InstallationManual, Chp. 4.7 Installing the Hydraulic Unit.

4.6.2.1 Decreasing the setting

Turn the setting adjustment switch 6 (located in thecontrol panel) to the "decrease" position. Observethe wedge movement.

NOTE: Do not let the jaws hit each other.

Adjust the setting in several stages. Check thesetting between adjustments, see the minimum

setting in chapter General Crusher Information.

After adjustment, check the pressure values in the jacking cylinder.

Callout Description

A Mechanical setting adjustment

B Hydraulic setting adjustment

Callout Description

1 Main switch

2 ON

3 Running

4 ON

5 Hydraulic pump

6 Setting (1 Decrease, 2 Increase)

7 Oil heating





Figure 4.6 Setting adjustment control panel

4.6.2.2 Increasing the setting

Turn the setting adjustment switch 6 (located in thecontrol panel) to the "increase" position. Observethe wedge movement.

When the setting is increased, the pressure in the jacking cylinder will rise automatically and thewedges will stop for a moment.

After adjustment, check the pressure values in the jacking cylinder.

4.7 TOGGLE PLATE

For spontaneous overloading or uncrushableobjects that are larger than the Crusher setting, suchas excavator bucket teeth, the Crusher is equippedwith a toggle plate that serves as a safety device. Inthe event of overloading, the toggle plate collapsesthrough elastic buckling, frequently preventingdamage to more costly parts.

The function of the toggle seats is based upon arolling concept against the roll-shaped surfaceswith different radii against each other. Thereforethe toggle seats should be kept dry and must not belubricated.

Check the condition of the seats and protectionrubber regularly during weekly maintenance. Theymust be kept clear of dust and dirt. If dust hasentered the seat surfaces, flush with running water.If there is no water available, compressed air may

be used. It is important that dust doesn't enter theseareas and contaminate seat surfaces.

Toggle plate and seat installation and removaldescribed in Maintenance chapter.

IMPORTANT!

Note that the toggle plate is designed to buckle whenoverload events occur in the lower half of thecrushing cavity. The toggle plate will not buckle if the crusher is overloaded due to oversized feed or aninadequate feed arrangement. Thus, in these cases,certain crusher components such as the eccentricshaft, flywheels, bearings and bearing housings will

be unnecessarily loaded.

IMPORTANT!

Although the toggle plate is designed to protect themore expensive Crusher components, certainoverload events are often so violent in nature that itis possible for other components such as the tensionspring, tension rod and tension spring bracket to failwhen the toggle plate buckles

IMPORTANT!Toggle plate is not protecting crusher components of fatigue damages when crusher is continuouslyoverloaded with smaller setting than allowed byMetso Minerals

WARNING!

Do not lubricate the toggle seats, toggle plate or toggle plate ends. This area of the crusher isdesigned to operate without lubrication.

WARNING!

Always use original Metso Minerals toggle plates.Toggle plate design and manufacturing is morecomplicated than most people think. Using atoggle plate that is not manufactured by MetsoMinerals will put the Crusher at risk and will voidthe Crusher's warranty.





4.8 SPACER

A spacer may be placed between the adjustingwedges and the toggle plate assembly (notapplicable to all models). The use of the spacer makes it possible to use two different Crusher setting ranges, but its use does not permit that theCrusher is used with settings smaller than theminimum allowed settings (see the Crusher Settingsection).

Qualitatively, the use of the spacer reduces both theCrusher's minimum and maximum setting. Refer tothe Crusher parts book for details concerning theeffect of the spacer on the Crusher setting range for a specific jaw profile. The spacer is not available

for all Crusher models.Spacer installation and removal instructions can befound in Maintenance chapter.





4.9 TROUBLESHOOTING

PROBLEM CAUSE REMEDYToggle plate falls out of seat.

Feed material is too large. Feed the Crusher with proper size material. Make surethe feed hopper's rear wall is properly designed.

Tension spring too loose. Tighten the tension spring.

Material fed directly ontothe upper pitman cover.

Material must be fed into the crushing chamber without hitting the upper pitman cover. Make sure thefeed hopper's rear wall is properly designed.

Toggle plate breaks(buckles).


Feed material is too small. Feed the Crusher with proper size material.

Tramp iron or other uncrushable materialcaught near the bottom of

the crushing chamber.

Empty the crushing chamber to remove tramp iron or other uncrushable material.

Toggle plate not installedcorrectly.

When installing the toggle plate, inspect the toggleseats for good condition and smooth, even surfaces.

Feed hopper hasloosening or breakingbolts.

Feed material is beingcrushed too high in thechamber.

RESTRICT FEED! Feed to keep the chamber 2/3 fullwith proper size material for greatest efficiency.

Loctite not applied to thefeed hopper bolts.

Apply Loctite.

Jaw bolts looseing or breaking.

Incorrect jaws installed. Use Metso Minerals jaws.

Insufficient capacity. Feed too large. Check for proper feed size.

Wrong direction of flywheelrotation.

Make sure the flywheels turn in the correct direction.

Incorrect speed. Check for proper speed.Discharge setting toosmall.

Increase the discharge setting.

Jaws worn excessively. Replace the jaws.

Loose jaws. Tighten the jaw bolts.

Stalled Crusher. Large rock or tramp iron jammed in the crushingchamber.

Remove stuck material. DO NOT USE EXPLOSIVESTO CLEAR A STALLED CRUSHER!

Discharge setting is toosmall.

Each Crusher has a minimum recommended setting.DO NOT use a smaller setting unless authorized byMetso Minerals.

Power failure. Check all fuses in the motor electrical control panel.

Motor failure. Check the motor.

Damaged and/or looseV-belts.

Check the condition of the V-belts.

Excessive vibration. Wrong speed. Operate the Crusher at the recommended speed.

Flywheels loose. Tighten the flywheels properly. Weld the bolts together with plates to prevent them from coming loose.





Flywheel aligned with thewrong keyway (gibkey)

during assembly.

Remount the flywheel with the appropriate keyway(gibkey).

Bearing too hot. Toggle plate improperlyseated.

Check the toggle plate and seats for wear.

Too much or insufficientgrease.

Use correct quantity of grease for each bearing. Seata schedule for greasing of the bearings.

Opearting too fast. Check the Crusher's speed.

Crusher operating at lessthan minimumrecommended setting.

Each Crusher has a minimum recommended setting.DO NOT use a smaller setting unless authorized byMetso Minerals.

Crusher not level. Check or re-level the Crusher.

Feeding the Crusher withvery fine material.

Feed the Crusher with proper size material.

Crusher speed varies. Damaged and/or loose

V-belts.

Check the condition of the V-belts.

Inadequate plant voltagelevel.

Check the plant's voltage level.

A "knocking" is heardwhile operating.


Toggle plate improperlyseated.

Check the toggle plate and seats for wear.

Loose jaws. Tighten the jaw bolts.

Jaws hitting each other. Check the Crusher's discharge setting.

Movement of the jaws. Loose jaws. Tighten the jaw bolts.

Inadequate clearance. Check that the clearance between the upper andlower jaws is between 5-8 mm (3/16-5/16").

Adjusting wedges don´tmove Wedge surfaces worn. Drop couple of small stones to cavity to decreasefriction between wedges.

PROBLEM CAUSE REMEDY




MAINTENANCE CHAPTER 5

5.1 SPACER

A spacer may be placed between the lower adjusting wedge and toggle seat plate (figure 5.1).Use of the spacer makes it possible to use two

different crusher setting ranges. Never use a settingsmaller than the minimum allowed setting evenusing the spacer.

After installing or removing the spacer the crusher setting must be adjusted (also when using hydraulicsetting adjustment).

Before you operate the machine make sure thatthere is no clearance between the upper and lower wedge. When using the spacer make sure there isno clearance between the spacer and adjustingwedges.

The spacer is available in the crushers: C80, C95,

C100, C110, C125, C140, C145 and C160

There is no spacer available in these crushers: C63,C200

Figure 5.1 Spacer makes it possible to use twodifferent crusher setting ranges

5.1.1 Spacer Installation

1. Open the crusher’s setting to maximum

2. a. Hydraulic setting:

In the valve unit, release the hydraulic pressurefrom the return cylinder by turning the knob of the shut-off valve (1) counter-clockwise. Youcan check the pressure level from the pressuregauge (2).

IMPORTANT!

After installing or removing the spacer the Crusher setting and the spring tension must be adjusted.





2b. Mechanical setting:Loosen the tension spring in order to be able tomove the pitman.

3. Use a come-along in order to retract the pitman. Attach on shackle to the bottom of the front frame and another shackle to the

back of the pitman. Use these shackles tosupport the ends or hooks of thecome-along. Make sure that both ends (or hooks) are properly secured.

4. Inch the come-along until the lower adjustment wedge touches the washers (or the jaws contact each other).

5. Insert the spacer between the front wedgeand toggle seat plate by inserting the spacer through the side plate hole.

6. Release the pitman and remove thecome-along and shackles.

7. a. Hydraulic setting:Pressurize the return cylinder by turning theknob of the shut-off valve clockwise in thevalve unit (check the pressure level from the

pressure gauge).

7 b. Mechanical setting:Fasten the locking nuts of the tension spring.Adjust the tension spring length.

IMPORTANT!

Be careful not to drop the toggle plate.

IMPORTANT!

After installing or removing the spacer the Crusher setting and the spring tension must be adjusted





5.1.2 Spacer Removal

1. When removing the spacer pull the settingadjustment wedges as far out as possible.

Secure the wedges so that they do not slidedown when spacer is being removed.

2. Make sure that the toggle plate does not falldown.

3. Loosen the tension rod spring to make it possible to move the pitman.

4. Pull the pitman forward with a winch.Remove the flange from the end of thespacer. Then pull the spacer out.





5.2 TOGGLE PLATE

5.2.1 Replacing the Toggle Plate AndToggle Seats

If the toggle plate has to be replaced, it isrecommended that the following steps be followed:

1. Open the crusher's setting to maximum.

2. Remove all necessary covers.

3. Attach and tighten lifting hooks (3, fig below) to the toggle plate on both sides.

4. Attach the chain of a come-along to thetoggle plate lifting tool (3, fig below) andupper end for example to the eyebolt of the

pitman (4, fig below).

5. Tension the come-along so that the toggle plate does not drop.

6. Support the lower setting adjustment wedgeto its position by using a proper sling. Makesure that the sling is properly tensioned.


In the valve unit, release the hydraulic pressurefrom the return cylinder by turning the knob of the shut-off valve (1, fig below)counterclockwise. You can check the pressurelevel from the pressure gauge (2, fig below).





7 b. Mechanical setting:

Remove the locking nuts of the tension spring(fig below).


Unfasten the return cylinder from the pitman.


Unfasten the tension rod from the pitman.

9. Use the come-along in order to retract the pitman. Attach one shackle to the bottom of the front frame and another shackle to the

back of the pitman. Use these shacles tosupport the ends or hooks of thecome-along. Make sure that both ends (or hooks) are properly secured (fig below).

10. Inch the come-along until the toggle plate isloose.

11. Lower the toggle plate on to the dischargeconveyor belt and take it out.

12. Check the condition of the toggle seats andother related components.

13. Replace the toggle seats if they aredamaged.

14. Install the new toggle plate and release the pitman.

15. Remove lower adjusting wedge support.


Attach the return cylinder to the pitman and pressurize the hydraulic return cylinder


Attach the tension rod to the pitman and fastenthe locking nuts of the tension spring.

Adjust the tension spring length according tothe table 5.1.

17. Remove the toggle plate lifting tool.

Figure 5.2

Callout Description

1 Lifting tool

2 Chain block

3 Protection rubber

4 Chain block





Table 5-1 Tension spring operating length

5.3 LUBRICATION

5.3.1 GENERAL

The appropriate lubrication of your crusher is of outmost important. To ensure that your crusher is

appropriately lubricated at all times, follow theinstructions provided in this chapter diligently.

5.3.2 Grease Specifications

For lubrication points, lithium-based multi-purposegrease with the following characteristics isrequired:

• NLGI-class of 2

• Minimum viscosity of the base oil must be 160mm2/s (cSt) in +40ºC/104ºF with a minimumviscosity-index 80.

• Appropriate for cold temperatures(-30ºC/-22ºF) and hot temperatures(continuous operating temperatures of +100ºC/212ºF).

• Good resistance to water

• The grease must not oxidize easily and it mustcontain EP-additives.

Some of the recommended lithium based grease brands are as follows. Other grease brands withsimilar characteristics may be used as well.

Table 5-2 Recommended grease brands

Metso Minerals does not recommend that different brands of grease are mixed. When in doubt, pleasecontact Metso Minerals.

Model Tension Spring Length Lmm inch

C63 310 12 ¼

C80 310 12 ¼

C95 385 15 ¼

C100 370 14 ½

C105 365 14 ¼

C110 365 14 ¼

C125 425 16 ¾

C140 540 21 ¼

C145 540 21 ¼

C160 540 21 ¼

C200 540 21 ¼

C3054 440 17 1/3

Brand Type

CASTROL APS 2

BP Energrease LS-EP 2

ESSO Beacon EP 2

GULF Gulfcrown Grease EP 2

MOBIL Mobilux EP 2SHELL Alvania Grease EP 2

SKF LG EP 2

WARNING!

Do not use grease types containing molybdenumor calcium as their solid components causeadditional wear in the bearings and thus decrease

bearing lifetime.

WARNING!

C Series crushers are not designed to operate attemperatures lower than -30ºC/-22ºF. Shouldoperating temperatures be lower than-30ºC/-22ºF, contact Metso Minerals.





5.3.3 Eccentric Shaft Bearings

Lubrication of the jaw crusher spherical roller bearings is accomplished by using a manual typegrease gun or an automatic lubricating system

through four grease fittings. Refer to Figures 5.4and 5.5.

Figure 5.3 Lubrication of jaw crusher spherical roller bearings with grease gun





Figure 5.4 Lubrication of jaw crusher spherical roller bearings using automatic lubricating system

During operation there is always a very slightworking of the grease out through the pitman andframe bearings and adjacent labyrinth seals.Movement of the grease out of the bearing and theadhering of grease outside the seal, protects the

bearing and seal from foreign particles. Byobservation of this grease working action, theoperator will soon be able to estimate the amount

and frequency of bearing grease requirements. Theamount of grease required and the length of time

between greasings will vary in accordance withoperating conditions.

Before greasing the bearings, thoroughly clean thearea around each grease fitting before removing thecover from the fitting. If the grease gun method of


1 Pump unit 2 Distributor unit





lubrication is used, add the grease immediatelyafter shut down while the bearings are still warm.Refer to the Lubrication Schedule in table 5-3.

Table 5-3 Lubrication schedule of eccentricshaft bearings

5.3.4 Eccentric Shaft BearingTemperatures

Bearing temperature should be checked frequentlyand greasing accomplished immediately if anunusual temperature rise is noted. Duringoperation, bearings will feel warm to the touch but

it should always be possible to touch them for a fewseconds without discomfort to the hand. Normal bearing operating temperature is 40-70°C(104-158°F). Should operating temperature reach75°C (167°F) or in very warm conditions 90°C(194°F) a check should be made to determine thecause. A check should also be made, if one bearingis over 10-15°C (18-27°F) warmer than the other

bearings.

Model

Manual Lubrication Automatic Lubrication

Normal Conditions(every 80 hours)

Very Dusty Conditions(every 40 hours)

All Conditions(continous)

Grease Amount/Nipplegrams (oz.)

Grease Amount/ Nipplegrams (oz.)

Grease Amount g/h(oz./h)

C63 60 (2.1) 30 (1.1) 1.1 - 1.8 (.04 - .06)

C80 60 (2.1) 30 (1.1) 1.1 - 1.8 (.04 - .06)

C95 125 (4.4) 63 (2.2) 2.0 - 3.4 (.07 - .11)

C100 175 (6.1) 88 (3.1) 2.9 - 4.8 (.1 - .17)

C105 125 (4.4) 63 (2.2) 2.0 - 3.4 (.07 - .11)

C110 175 (6.1) 88 (3.1) 2.9 - 4.8 (.1 - .17)

C125 250 (8.8) 125 (4.4) 3.9 - 6.5 (.14 - .23)

C140 300 (10.5) 150 (5.3) 4.7 - 7.8 (.16 - .27)

C145 300 (10.5) 150 (5.3) 4.7 - 7.8 (.16 - .27)

C160 400 (14) 200 (7) 5.9 - 9.8 (.2 - .34)

C200 500 (17.5) 250 (8.8) 7.7 - 12.9 (.27 - .45)

C3054 175 6.1) 88 (3.1) 2.9 - 4.8 (.1-.17)

WARNING!

Avoid using too much grease as excessivegrease will cause overheating and shorten the

bearing life.

WARNING!

C Series crushers are not designed to operate attemperatures lower than -30ºC/-22ºF. Shouldoperating temperatures be lower than-30ºC/-22ºF, contact Metso Minerals.

WARNING!

If temperature sensors are not installed on thecrusher, temperature reading must be done whenthe crusher is at rest.





5.3.5 Jack-shaft Bearings

When applicable, the jack-shaft bearings must belubricated manually with a grease gun. Before

greasing the bearings, thoroughly clean the areaaround each grease fitting before removing thecover from the fitting. If the grease gun method of

lubrication is used, add the grease immediatelyafter shut down while the bearings are still warm.Refer to the Lubrication Schedule in table 5-4.

Figure 5.5 Jack-shaft bearings lubrication





Table 5-4 Lubrication schedule of jack-shaftbearings

5.3.6 Jack-shaft Bearing Temperatures

Bearing temperature should be checked frequentlyand greasing accomplished immediately if anunusual temperature rise is noted. Duringoperation, bearings will feel warm to the touch butit should always be possible to touch them for a fewseconds without discomfort to the hand. Normal

bearing operating temperature is 40-70°C(104-158°F). Should operating temperature reach

75°C (167°F) or in very warm conditions 90°C(194°F) a check should be made to determine thecause.

5.3.7 Thrust Bearing And Cap Nut Bearings

This only applies to crushers equipped withmechanical setting adjustment. The turning capnut(s) and the thrust bearing must be manuallylubricated in accordance with the followingLubrication Schedule (table 5-5).

Table 5-5 Lubrication schedule of thrustbearings

5.3.8 Electric Drive Motor

For instructions, refer to the motor documentationthat has been provided with the crusher.

Model

NormalConditions

(every 80 hours)

Very DustyConditions

(every 40 hours)

GreaseAmount/Nipple

grams (oz.)

Grease Amount/Nipple

grams (oz.)

C80 40 (1.4) 20 (0.7)

C95 40 (1.4) 20 (0.7)

C105 40 (1.4) 20 (0.7)

C110 70 (2.5) 35 (1.2)

C125 70 (2.5) 35 (1.2)

C140 70 (2.5) 35 (1.2)

C145 70 (2.5) 35 (1.2)

C160 80 (2.8) 40 (1.4)

C200 80 (2.8) 40 (1.4)

C3055 55 (2) 28 (1)

WARNING!

Avoid using too much grease as excessivegrease will cause overheating and shorten the

bearing life.

WARNING!

If temperature sensors are not installed on thecrusher, temperature reading must be done whenthe crusher is at rest.

Model

Thrust Bearings Cap Nut(s)

GreaseAmount/Nipple

grams (oz.)

Grease Amount/Nipple

grams (oz.)

C63 n/a 20 (0.7)

C80 n/a 20 (0.7)

C95 20 (0.7) 20 (0.7)

C105 20 (0.7) 20 (0.7)

C110 20 (0.7) 20 (0.7)

C115 20 (0,7) 20 (0,7)

C125 20 (0.7) 20 (0.7)

C140 20 (0.7) 20 (0.7)

C145 20 (0.7) 20 (0.7)

C160 20 (0.7) 20 (0.7)

C200 20 (0.7) 20 (0.7)

C3055 20 (0.7) 20 (0.7)





5.3.9 Toggle Seats And Toggle Plate

Figure 5.6 Do not lubricate the toggle seats, toggle plate or toggle plate ends

WARNING!

Do not lubricate the toggle seats, toggle plate or toggle plate ends. This area of the crusher isdesigned to operate without lubrication





5.3.10 Setting Adjustment Wedges

5.4 PERIODICAL MAINTENANCE

5.4.1 Daily maintenance

• BEFORE STARTING

See figure 5.7 for reference.

1. Check the tension of the V-belts. Seechapter 3.8.2 Installation Manual.

2. Check the tightness of the jaw bolt nuts (A).

The washers must be in the level with thedisc spring housing 0-0,5mm (0-0.02")

3. Check the tightness of the cheek plate bolts(B), see the tightening torque in chapter 6.1.

4. Check that the protection rubber of thetoggle plate (C) is in good condition and in

place.

5. Check the tightness of tightening rod nuts(D). The washers must be in the levelwith the disc spring housing 0-0,5mm(0-0.02").

Figure 5.7 C63, C80, C95, C100, C110, C125, C140, C145, C160, C200

WARNING!

Do not lubricate the setting adjustment wedges.This area of the crusher is designed to operatewithout lubrication. Water or dust suppressionspray mists must be kept away from this area of the Crusher.





Figure 5.8 C105, C3055

• DURING OPERATION

Listen to the sound of the bearings and check their temperature (max. 75°C/167°F). Check for the

proper outflow of grease.

Check the tension and operation of the return rod,see chapter 4.4 - 4.7 Installation Manual.

5.4.2 Weekly

If an automatic lubrication device is not used,lubricate the eccentric shaft bearings (figure 5.9).Before lubrication, the grease nipples must becleaned. Under normal operating conditions addgrease every 80 operating hours. Under dustycondition the frequency must be doubled (to every

40 hours). See the required grease quantity inchapter 5.3.3.

Lubricate the cap nut bearings of the settingadjustment device and check their rubber covers(mechanical setting adjustment), see chapter 5.3.7.

Check the wear on the cheek plates. Change if necessary.

Check the toggle plate for alignment, straightnessand cracks.

Check the toggle seats and the rubber protection.Clean the seat surfaces if necessary.

Check the tightness of the frame tie bolts.

Check the mounting and condition of the flywheel.





Check the rubber dampers under the crusher'smounting brackets. If any damper is damaged, itshould be changed.

5.4.3 Monthly

Check the tightness of the frame mounting bolts onthe side plates.

5.4.4 Twice a Year

Check the condition of the eccentric shaft bearings,using e.g. a hearing device.

Check for any wear on the seating surfaces of the pitman as well as the front frame.

Check for any wear on the seating surfaces between

the side plates and cheek plates.

5.4.5 Regularly

Change oil and the filter in the hydraulic unit firsttime after 100 operating hours. After that the oiland the filter must be changed at 1000 hoursintervals or at least twice a year.

Replace oil tank breather twice a year.

5.4.6 Oil recommendation

Oil amount in the hydraulic unit is 40 litres (10½gal).

Use only high quality hydraulic oil with goodresistance to corrosion, water, air and foam. The oilmust not oxidize easily. The minimum viscosityindex is 100.

Suitable brands listed in Table 5-6:

Table 5-6

Figure 5.9 Lubricate eccentric shaft bearings weekly

Ambienttemperature-30...+25°C(-22...+77°F)

Ambienttemperature-10...+60°C

(+14...+140°F)

BP Bartran HV 32 Bartran HV 46

ESSO Univis N 32 Univis N 46SHELL Tellus oil T 32 Tellus oil TX 46

TEBOILTebo hydraulic lift

32Tebo hydraulic lift

46

MOBIL DTE 24 DTE 25

CASTROL Rando HD 32 Rando HD 46





5.5 MAINTENANCE INTERVALS

ITEM Daily Weekly MonthlyEvery 6months

Check V-belt tension. X

Check the tightness of jaw bolts. X

Check the tightness of cheek plate bolts. X

Check the side guide plates and the protection rubber of thetoggle plate.

X

Check wear on the jaw plates X

Check the sound, temperature (max. 75°C/167°F) and grease flowin the eccentric bearings.

X

Check tension and operation of tension rod spring. X

Lubricate eccentric shaft bearings. X

Check wear on the cheek plates. X

Check toggle plate for alignment, straightness and cracks X

Check toggle seats, clean as necessary X

Check the tightness of the mounting bolts of the labyrinth covers. X

Check the tightness of the frame tie rods X

Check the mounting and condition of the flywheel. X

Check the tightness of the gib keys X

Check the rubber dampers under the crusher's mounting brackets. X

Check the tightness of the frame mounting bolts on the sideplates.

X

Check the bearings on the eccentric shaft. X

Check for any wear on the contact surfaces of the pitman andfront frame.

X

Check for any wear on the contact surfaces between the sideplates and cheek plates. X

Lubricate crusher drive jackshaft X

Check the mounting of the crusher X

Mechanical setting adjustment

Lubricate the cap nuts of the setting adjustment device X

Check the rubber covers X

Lubricate thrust bearing. X

Hydraulic setting adjustment

Change oil, breather and filter. X

Check operation and oil amount (add oil if necessary). X

Automatic lubricating device

Check operation and grease amount (add grease if necessary). X





5.6 OTHER BOLT TORQUE VALUES

All other bolts must be tightened according to thetable below. Correct pretightening is possible only

with clean , unlubricated screw threads that are notsurface treated. The table applies to bolts with

property class 8.8.

Table 5-7

BoltTorque

Nm kpm ft lbs

M10 47 4.8 35

M12 81 8.3 60

M16 196 20 145

M20 382 39 285

M24 662 67 490

M30 1320 135 975

M36 2310 236 1705

M42 3700 378 2730

M48 5590 570 4125

M52 7180 733 5295

M56 8960 914 6610

M64 13460 1370 9930

M72 19350 1970 14275

M80 26850 2740 19805

M100 53340 5440 39280




REPLACEMENT OF WEAR PARTS CHAPTER 6

6.1 GENERAL

Nordberg C Series crusher jaw plates are made of

manganese steel which work hardens. For differentmaterials and applications there are different jaw

profiles to obtain the best possible capacity to jawcost ratio.

Before lifting any wear parts check the weights of the parts and ensure that lifting equipment is strongenough. Also, familiarize yourself with all of thespecial tools provided specifically for replacing thewear parts of your Crusher.

6.2 JAW SELECTION

There are several different types of jaw platesavailable for Nordberg C Series jaw crushers. For

profile details and application guidelines, contactMetso Minerals.

The type of jaw plates must be selected accordingto the feed material and the required end product.Because of the many different applications andvariables, exact instructions are almost impossibleto provide.

If you are experiencing problems with your existingapplication or would just like to improve it, contactyour Metso Minerals representative. Wheninquiring about the right jaw type the following

information must be provided:

1. Feed size and gradation

2. Feed type and characteristics

3. End product gradation

4. Capacity required

5. Options; intermediate plate, spacer

6. Used setting

6.3 JAW HARDENING

Because hardening and wearing of the jaw platesdoes not occur evenly in the crushing cavity, it isrecommended that the following measures be takento maximize the useful life of the jaw plates:

– When using 2-piece jaw plates, exchangethe upper and lower jaw plates after first50 to 200 operating hours, depending on

the hardness of the feed material.

– Exchange the upper and lower jaw platesafter every 400 to 500 operating hours(200 hours if the feed material is veryabrasive).

For more detailed information on lifting

accessories, see appendix A.

WARNING!

DO NOT wear the cheek plates through or jaw plates through. This will damage the surfaces inthe crusher frame and pitman. These surfaces

can only be repaired by welding and machining.

WARNING!

Lifting tools provided with the crusher aredesigned to be used only with Metso Mineralsgenuine wear parts.




CHAPTER 6 - REPLACEMENT OF WEAR PARTS

6.4 CHANGING OF CHEEK PLATES

The lower cheek plates usually will wear before theupper ones. By replacing the lower cheek platesonly, a shelf may be created between the upper andlower cheek plates, and this may slow some of thematerial flow into the crushing chamber.

6.4.1 Cheek Plate Removal

To remove a cheek plate, refer to Figure 6.1 and proceed as follows:

1. Hold the upper cheek plate(s) (1) up with a

hoist and the lifting hooks provided with theCrusher.

2. Remove the nuts (5), washers (4) and bolts(3).

3. Lift out the upper cheek plate (1).

4. Follow the above procedure for removal of lower cheek plates (2).

WARNING!

Do not use an alternative component handlingmethod or tool without first consulting MetsoMinerals.





Figure 6.1 Cheek plate removal


1 Cheek plate, upper 4 Washer

2 Cheek plate, lower 5 Nut

3 Bolt





6.4.2 Cheek Plate Assembly

To assemble a cheek plate, refer to Figure 6.2 and proceed as follows:

1. Replace the lower cheek plate (2). Fasten the bolts (3), washers (4) and nuts (5). Make

sure that the nuts are on the outside of thecrusher!

2. Follow the above procedure for the

replacement of upper cheek plates.

Figure 6.2 Cheek plate assembly


1 Cheek plate, upper 2 Cheek plate, lower





The cheek plate bolts must be tightened accordingto Table 6-1.

Table 6-1 Cheek plate bolt torques.

6.4.3 Flipping the Cheek Plates

Depending on the amount of wear the cheek platescan be flipped if needed

– Make sure that there is enough material inthe cheek plate fixing areas to tighten allfixing bolts according to the torque table

– Make sure that cheek plates have enoughmaterial to face the side plate properly.

6.5 CHANGING/TURNING OF JAW PLATES

6.5.1 One-Piece Jaws: C63, C80, C95, C100,C3054, (C110)

6.5.1.1 Removal: C63, C80, C95, C100,C3054, (C110)

To remove a jaw plate, refer to Figures 6.3, 6.4 and6.5 and proceed as follows:

1. Fixed Jaw

– Clean the jaw plate lifting holes (1).Remove stones and sand from the jaws.Remove also material packed between the

jaw and side plates (Fig. 6.3, a).

– Hold the jaw plate (1) up with a hoist andthe lifting hooks provided with theCrusher.

– Remove the nuts (10) and the spring packages (8).

– Remove the T-head bolts (6), tighteningwedge (4) and upper wedge (3).

– Lift out the jaw plate (1) with care (Fig.6.3, b).

BoltSize

Torque

Nm kpm ftlbs

C63 M24 216 22 160

C80 M24 216 22 160

C95 M24 216 22 160

C100 M30 437 445 325

C105 M24 216 22 160

C110 M36 760 77.5 560

C125 M36 760 77.5 560

C140 M42 1216 124 900

C145 M42 1216 124 900C160 M48 1834 187 1355

C200 M42 1216 124 900

C3054 M24 216 22 160





Figure 6.3





– Slowly place the jaw on safe ground,seating surface downwards. Note that if you are turning the jaw, make sure that the

ground is clean and dry. Blocking may beused if the ground cannot be readilycleaned (Fig. 6.4).

Figure 6.4

2. Moving Jaw

– Clean the jaw plate lifting points (1).Remove stones and sand from the jaws.Remove also material packed between the

jaw and side plates (Fig. 6.5, c)

– Hold the jaw plate (2) up with a hoist andlifting the lifting hooks provided with theCrusher.


– Remove the T-head bolts (7), tighteningwedge (5) and upper wedge (3).

– Lift out the jaw plate (2) (Fig. 6.5, d).

– Slowly place the jaw on safe ground,seating surface downwards. Note that if

you are turning the jaw, make sure that theground is clean and dry. Blocking may beused if the ground cannot be readilycleaned (Fig. 6.4).

WARNING!

Handle the jaw with care. A swinging jaw may

cause damage to the front frame and is a serioushazard for all maintenance personnel. Droppingthe jaw in the cavity will cause damage to theunderlying structures.





Figure 6.5

WARNING!

Handle the jaw with care. A swinging jaw maycause damage to the front frame and is a serioushazard for all maintenance personnel. Droppingthe jaw in the cavity will cause damage to the

underlying structures





6.5.1.2 Assembly: C63, C80, C95, C100,C3054, (C110)

Before assembling new or partially worn jaws,make sure that the jaw and crusher (front frame and

pitman) seating surfaces are clean. The jaws should be in continuous contact with the seating surfaces(ref Fig. 6.6).

Figure 6.6 Checking the straightness of a jaw

NOTE: If the ends of the jaws are distorted or bent, the original dimensions must be achieved bytorch cutting before their assembly

IMPORTANT!

When turning jaws, it is always good practice toconfirm that the seating surface of the jaw is straight.This can be easily done with a straight edge, and ishighly recommended. Jaws can occasionally bend if

they are not properly tightened during operation, or in cases when they are worn excessively.

WARNING!

DO NOT install jaws on the Crusher if the jawseating surfaces are not straight. Bent jaws cancause severe damage to your Crusher. Contactyour Metso Minerals representative for adviceimmediately.





Figure 6.7 Jaw seating surfaces

1. Fixed Jaw

– Clean the seating surfaces (ref. Fig. 6.7).

– Place the jaw plate (2) with care, makingsure that the bottom of the jaw seats on thelower wedge properly.

– Place the upper wedge (3), tighteningwedge (4) and T-head bolts (6).

– Install the spring packages (8) accordingto Figure 6.11.

– Tighten the spring packages according toChapter 5.4. Use double nuts (10) tosecure the T-head bolts.

– Remove the jaw lifting hooks.

IMPORTANT!

Check the tension (compression) of the spring packages after 8 hours of operation. Retighten thespring packages if necessary.





2. Moving Jaw

– Clean the seating surfaces (ref. Fig. 6.7). – Place the jaw plate (2) with care, making

sure that the bottom of the jaw seats on thelower wedge properly. Place the upper wedge (3), tightening wedge (5) andT-head bolts (7).

– Install the spring packages (8).

– Tighten the spring packages according toChapter 5.4. Use double nuts (10) tosecure the T-head bolts.

IMPORTANT!

Check the tension (compression) of the spring packages after 1 hour of operation. Retighten thespring packages if necessary.

IMPORTANT!

The correct tension of the bolts is indicated by thethickness of the spring packages. See detail inChapter 5.4. Tighten or loosen the nuts as required.

IMPORTANT!

The Crusher's setting must be adjusted every timeafter changing or turning the jaws.

IMPORTANT!

These procedures can be used also with C3054excluding it has no tightening wedge.





6.5.2 One-Piece Jaws: C105

6.5.2.1 Removal: C105

To remove a jaw plate, refer to Figures 6.8, 6.9 and6.10 and proceed as follows:

1. Fixed Jaw

– Clean the jaw plate lifting holes. Removestones and sand from the jaws. Removealso material packed between the jaw andside plates.

– Hold the jaw plate up with a hoist and thelifting hooks provided with the Crusher.

– Remove the nuts (2) bushing (3), thespring packages (8) and the tightening rod(5).

– Loosen the wedges (4) by hitting themwith an iron bar (ref. Figure 6.9). In casethe wedges still do not move, pull them

out by the threads in the wedges – Be careful not to drop the jaw in the gap

and cause damage

– Lift out the jaw plate (1) with care (ref.Figure 6.10).

– Slowly place the jaw on safe ground,seating surface downwards. Note that if you are turning the jaw, make sure that theground is clean and dry. Blocking may beused if the ground cannot be readilycleaned.

Figure 6.8 Changing of jaw plates C105


1 Fixed jaw 7 Nuts2 Nuts 8 Spring package

3 Bushing 9 T-head bolts

4 Wedge 10 Tightening wedge

5 Tightening rod 11 Moving jaw

6 Spring package





Figure 6.9

Figure 6.10

2. Moving Jaw

– Clean the jaw plate lifting holes. Removestones and sand from the jaws. Removealso material packed between the jaw andside plates.

– Hold the jaw plate (11) up with a hoist andlifting the lifting hooks provided with theCrusher.


– Remove the T-head bolts (9) andtightening wedge (10).

– Lift out the jaw plate (11).

6.5.2.2 Assembly: C105


pitman) seating surfaces are clean. The jaws should be in continuous contact with the seating surfaces.

To assemble a jaw plate, refer to Figures 6.8, 6.9and 6.10 and proceed as follows:WARNING!

Handle the jaw with care. A swinging jaw maycause damage to the front frame and is a serioushazard for all maintenance personnel. Droppingthe jaw in the cavity will cause damage to theunderlying structures

WARNING!

Handle the jaw with care. A swinging jaw maycause damage to the front frame and is a serioushazard for all maintenance personnel. Droppingthe jaw in the cavity will cause damage to theunderlying structures

IMPORTANT!





1. Fixed Jaw

– Re-install the tightening rod (5) and thetightening wedges (4) so that the wedgestouch the side plates

– Install the jaw plate (1). Replace the bushings (3).


– Tighten the spring packages according toChapter 5.4. Use double nuts (2) to securethe bolts.

– Check the setting of the crusher and adjustif necessary.

– Remove the jaw lifting hooks.

2. Moving Jaw

– Place the jaw plate (11) with care, makingsure that the bottom of the jaw seats on thelower wedge properly. Place the upper

wedge (10) and T-head bolts (9). – Install the spring packages (8).

– Check the setting of the crusher and adjustif necessary.

– Tighten the spring packages according toChapter 5.4. Use double nuts (7) to securethe T-head bolts

When turning jaws, it is always good practice toconfirm that the seating surface of the jaw is straight(Ref. Figure 6.4). This can be easily done with a

straight edge, and is highly recommended. Jaws canoccasionally bend if they are not properly tightenedduring operation, or in cases when they are wornexcessively.

WARNING!


IMPORTANT!

Check the tension (compression) of the spring packages after one hour of operation. Retighten thespring packages if necessary.

IMPORTANT!

Check the tension (compression) of the spring

packages after onehour of operation. Retighten thespring packages if necessary.

IMPORTANT!

The correct tension of the bolts is indicated by thethickness of the spring packages. Tighten or loosenthe nuts as required (See Chapter 5.4).

IMPORTANT!






6.5.3 TWO-PIECE JAWS C110, C125, C140,C145, C160, C200

6.5.3.1 Removal: C110, C125, C140, C145,C160, C200

To remove a jaw plate, refer to Figure 6.11 and proceed as follows:

1. Fixed Jaws

– Clean the jaw plate lifting holes. Removestones and sand from the jaws. Remove

also material packed between the jaw andside plates.

– Hold the upper jaw plate (1) up with ahoist and the lifting hooks provided withthe Crusher.

– Remove the upper nuts (13) and the spring packages (11).

– Remove the T-head bolts (8), tighteningwedge (6) and fill wedge (4).

– Lift out the upper jaw (1).

– Remove the center nuts (13) and thespring packages (11)

– Remove the T-head bolts (7) andtightening wedges (3).

– Lift out the lower jaw (1).

WARNING!

Handle the jaw with care. A swinging jaw maycause damage to the front frame and is a serioushazard for all maintenance personnel. Droppingthe jaw in the cavity will cause damage to the

underlying structures.





Figure 6.11 Removal of a fixed jaw


1 Fixed jaw 7 T-head bolt

3 Tightening wedge 8 T-head bolt

4 Fill wedge 11 Spring package

6 Tightening wedge 13 Hex nut





2. Moving Jaws (ref. Fig. 6.12)

– Clean the jaw plate lifting holes. Removestones and sand from the jaws. Remove

also material packed between the jaw andside plates.

– Hold the jaw plate (2) up with a hoist andlifting hooks.

– Remove the upper nuts (13) and the spring packages (11).

– Remove the T-head bolts (10), tighteningwedge (5) and fill wedge (4).

– Remove the lower nuts (13) and the spring packages (11).

– Lift out the upper jaw (2)

– Remove the T-head bolts (9) andtightening wedges (3).

– Lift out the lower jaw (2).

Figure 6.12


2 Moving jaw 9 T-head bolt

3 Tightening wedge 10 T-head bolt

4 Fill wedge 11 Spring package

5 Tightening wedge 13 Hex nut

WARNING!

Handle the jaw with care. A swinging jaw maycause damage to the front frame and is a serioushazard for all maintenance personnel. Droppingthe jaw in the cavity will cause damage to theunderlying structures.





6.5.3.2 Assembly: C110, C125, C140, C145,C160, C200


pitman) seating surfaces are clean. The jaws should be in continuous contact with the seating surfaces.

NOTE: If the ends of the jaws are distorted or bent, the original dimensions must be achieved bytorch cutting before their assembly.

To assemble a jaw plate refer to Figures 6.11, 6.13,6.14 and 6.15 and proceed as follows:

Figure 6.13 Jaw seating surfaces

IMPORTANT!

When turning jaws, it is always good practice toconfirm that the seating surface of the jaw is straight(Ref. Figure 6.4). This can be easily done with astraight edge, and is highly recommended. Jaws canoccasionally bend if they are not properly tightened

during operation, or in cases when they are wornexcessively.

WARNING!






1. Fixed Jaws

– Install the lower jaw (1). Install thetightening wedge (3) and T-head bolt (7).


– Screw in lower nut (13) lightly.

– Install the upper jaw (1).

– Install the fill wedge (4), tightening wedge(6) and T-head bolt (8).


– Make sure that there is a clearance of 5-8mm (3/16"-5/16") between the upper andlower jaw plate and that the tighteningwedge (3) has not bottomed out.

– Tighten the spring packages according toChapter 5.4. Use the nut (13) and securewith a "double" nut (13).

– Check the tension of all spring packagesafter one operating hour, and correct themas required (Fig. 6.15)

2. Moving Jaws

– Install the lower jaw (2) and the tighteningwedge (3) and T-head bolt (7).


– Screw in the lower nut (13) lightly.

– Install the upper jaw (2).

– Install the upper wedge (4), tighteningwedge (5) and T-head bolt (10).


– Make sure that there is a clearance of 5-8mm (3/16"-5/16") between the upper andlower jaw plate and that the tighteningwedge (3) has not bottomed out.

– Tighten the spring packages according toChapter 5.4. Use the nut (13) and securewith a "double" nut (13).

– Check the setting of the crusher and adjustas necessary.

– Check the tension of all spring packagesafter one operating hour, and correct themas required (Fig. 6.15).

Figure 6.14





Figure 6.15

Figure 6.16 Assembly order

Callout Description

1 Washer

2 Cup spring

3 Spring casing

4 Rubber plate

IMPORTANT!

Follow the recommended tightening sequence: First pre-tighten the lower bolts and adjust the clearance between the upper and lower jaw plate 5-8 mm(3/16"-5/16"). Tighten the upper bolts and then lower ones. If the tightening wedge has bottomed out andthere is no clearance, torch cut a piece from the jaw

plates or add the flat iron onto the wedge.

WARNING!

The correct tension of the jaw bolts is indicated by the thickness of the spring package. Refer tofigure 6.11. Tighten or loosen as required.Inadequate tensions will allow the jaws to move,

and may cause costly damages.

IMPORTANT!






6.6 PITMAN EYE PROTECTION

Replace protection plate before worn through.

6.7 FEEDING CHUTE

Replace wear plates before worn through.

6.8 TOGGLE SEATS

Toggle plate and bearings in both ends of it have

hardened sliding surface. The wearing of thesecomponents accelerates when the hardened surfacewears out. Replace these parts when they are wornabout 3 mm ( 1/8 ").



EN N11450704_H JAW LIFTING TOOL -1

APPENDIX A

NORDBERG C-SERIES JAW CRUSHER'S

JAW-LIFTING TOOL

SAFETY, OPERATING AND MAINTENANCEINSTRUCTIONS

1. Purpose of the jaw-lifting tool

The jaw-lifting tool that is provided with NordbergC Series jaw crushers is intended for the lifting of genuine Metso Minerals Nordberg C Series wear

parts (jaws) only. The jaw-lifting tool is notdesigned nor tested for the lifting of other types of

jaws (including copies of the Nordberg C Series jaws).

2. Storage of the jaw-lifting tool

When not in use the jaw-lifting tool shouldnormally be kept on a properly designed rack. Theyshould not be left lying on the ground where theymay be damaged.

If it is likely that the jaw-lifting tool will be out of use for some time they should be cleaned, dried and

protected from corrosion, e.g. lightly oiled.

3. Safe use

Read carefully all instructions concerning the jaw-lifting tool and make sure that the tool isinspected regularly. Prior to lifting, make sure thatthe jaw-lifting tool is locked and does not come out

of the lifting hole. The jaw-lifting tool is onlymeant for the lifting of genuine Metso Minerals

Nordberg C Series jaws. It is neither designed nor tested for unfastening used jaws that may notreadily come loose prior to lifting.

Do not overload the jaw-lifting tool. The maximumlifting load is found on the tag of the jaw-liftingtool (see Table 1). Stop the lifting procedureimmediately if the jaw is stuck to its location.

Load the lifting tool evenly and carry out lifting anddisplacement of the jaw carefully. Keep the liftingzone free of people during lifting. Do not use the

jaw-lifting tool in a hurry.

4. Commissioning and operatingconditions

The jaw-lifting tool is supplied fully assembled andit is ready for immediate use.

The jaw-lifting tool can be used in the sameoperating conditions as the jaw crusher.

5. Technical data

The maximum lifting load is mentioned on theattached tag of the jaw-lifting tool. Table 1 showsavailable lifting tools.

Table 1

6. The jaw-lifting tool verification beforefirst use and in service

Before first use

Before first use of the jaw-lifting tool it should beensured that:

a. the jaw-lifting tool is precisely asordered;

b. the manufacturer's certificate is to hand;

c. the identification and working load limitmarking on the jaw-lifting toolcorrespond to the information on thecertificate;

d. full details of the jaw-lifting tool arerecorded.

Liftingtool

Maximum lifting load(Working load limit, WLL)

582133 1500 kg (3307 lbs)

582151 2800 kg (6173 lbs)

585042 5000 kg (11023 lbs)



-2 JAW LIFTING TOOL N11450704_H EN

APPENDIX A

Before each use

Before each use the jaw-lifting tool should beinspected for obvious damage or deterioration (see

8 Maintenance / Inspection). If faults are foundduring this inspection, the procedure given in 8Maintenance should be followed.

The jaw-lifting tool must be inspected visually before every lift and more precisely at least once ayear. See detailed instructions below. Inspectionsmust be documented for own as well as authorityaudits.

A damaged jaw-lifting tool must be replaced or repaired immediately. Special attention should be

paid to the condition of the threads, welds andfasteners.

The jaw-lifting tool should be clean enough toobserve possible damages.

Adequate lighting should be provided and the jaw-lifting tool should be examined throughout itslength to detect any evidence of wear, distortion or external damage.

7. Handling the load

Preparation

Attention should be given to any specificinstructions provided for the handling of the load.

Before starting the lift, it should be ensured that theload is free to move and is not bolted down or otherwise obstructed.

Mass of the load

It is essential that the mass of the load to be lifted isknown. If the mass is not marked the informationshould be obtained from the consignment notes,manuals, plans etc. If such information is notavailable the mass should be assessed bycalculation.

Centre of gravity

The position of the centre of gravity of the loadshould be established in relation to the possible

points of attachment of the chain sling. To lift theload without it tilting or toppling the followingconditions should be met:

a. For two leg chain slings the attachment points should be either side of and abovethe centre of gravity.

b. The hook to which the jaw-lifting tool isattached should be directly above thecentre of gravity.

Method of connection

The jaw-lifting tool is attached to the load and thelifting machine by means of terminal fittings suchas hooks and links. Chains should be without twistsor knots. The lifting point should be seated welldown in a hook and the hook should be free toincline in any direction so as to avoid bending. For the same reason, the master link should be free toincline in any direction on the hook to which it isfitted.

Straight leg

In this case lower terminals are connected directly

to the attachment points. Selection of hooks andattachment points should be such that the load iscarried in the seat of the hook and tip loading of thehook is avoided.

In order to prevent dangerous swaying of the loadand to position it for loading, a tag line isrecommended.

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

Safety of lift

Hands and other parts of the body should be keptaway from the chain to prevent injury as the slack istaken up. When ready to lift, the slack should betaken up until the chain is taut. The load should beraised slightly and a check made that it is secureand assumes the position intended. This isespecially important with basket or other loosehitches where friction retains the load.

Landing the load

The landing site should be prepared. It should beensured that the ground or floor is of adequatestrength to take the weight taking account of anyvoids, ducts, pipes etc. which may be damaged or collapse. It should also be ensured that there isadequate access to the site and that it is clear of anyunnecessary obstacles and people. It may benecessary to provide timber bearers or similar




APPENDIX A

material to avoid trapping the chain sling or to protect the floor or load or to ensure the stability of the load when landed.

8. Maintenance

Inspection

During service, the jaw-lifting tool is subjected toconditions which affect their safety. It is necessarytherefore to ensure, as far as is reasonably

practicable, that the chain sling should be safe for continued use.

If the tag or label identifying the chain sling and itsworking load limit becomes detached and thenecessary information is not marked on the master link itself, or by some other means, the jaw-liftingtool should be withdrawn from service.

The chain sling should be withdrawn from serviceand referred to a competent person for thoroughexamination if any of the following are observed:

a. The chain sling markings are illegible,i.e. information on the chain slingidentification and/or the working loadlimit.

b. Distortion of the upper or lower terminals.

c. Chain stretch.

If the chain links are elongated or if there is

any lack of free articulation between thelinks or noticeable difference in the leglength of multi-leg chain slings, the chainmay have been stretched.

d. Wear by contact with other objectsusually occurs on the outside of thestraight portions of the links where it iseasily seen and measured. Wear betweenadjoining links is hidden. The chainshould be slack and adjoining linksrotated to expose the inner end of eachlink. Inter-link wear, as measured bytaking the diameter indicated ( d1) and

one at right angles, (d2) may be tolerateduntil the mean of these diameters has

been reduced to 90 % of the nominaldiameter (dn) (see Figure 1) provided

Figure 1

e. Cuts, nicks, gouges, cracks, excessivecorrosion, heat discoloration, bent or distorted links or any other defects.

f. Check the condition of the pin in

posit ion 1 (see Figure 2) below. If the pin is worn by 10% (or more) of itsoriginal dimension (10 mm, 0.39"), itmust be replaced immediately.

Figure 2

d d d

n9.02

21>

+




APPENDIX A

Dimension L (4), measured between positions 2and 3, must not exceed 10% of the value given inTable 2 below. If dimension L (4) exceeds 10% of

the original value, the jaw-lifting tool must bereplaced immediately.

Table 2

g. Check the condition of the lockingmechanism (5).

h. Lubricate the mechanism (6) with sprayvaseline oil and turning the lever.

i. Check the surfaces of the centre pin (7)and shoulder (8) visually.

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

Thorough examination

A thorough examination should be carried out by acompetent person at intervals not exceeding twelvemonths. This interval should be less where deemed

necessary in the light of service conditions.Records of such examinations should bemaintained.

Chains slings should be thoroughly cleaned so as to be free from oil, dirt and rust prior to examination.Any cleaning method which does not damage the

parent metal is acceptable. Methods to avoid arethose using acids, overheating, removal of metal or movement of metal which may cover cracks or surface defects.

Adequate lighting should be provided and the chainsling should be examined throughout its length to

detect any evidence of wear, distortion or externaldamage.

Repair

Any replacement component or part of the chainsling should be in accordance with the appropriateEuropean Standard for that component or part.

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

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

process.

Components that are cracked, visibly distorted or twisted, severely corroded or have deposits whichcannot be removed should be discarded andreplaced. Minor damage such as nicks and gougesmay be removed by careful grinding or filing. Thesurface should blend smoothly into the adjacentmaterial without abrupt change of section. Thecomplete removal of the damage should not reducethe thickness of the section at that point to less than

the manufacturers specified minimum dimensionsor by more than 10 % of nominal thickness of thesection.

In the case of the jaw-lifting tool on which repair work has involved welding, each repaired chainsling should be proof tested following heattreatment using a force equivalent to twice theworking load limit and thoroughly examined beforeit is returned to use. However, where repair iscarried out by inserting a mechanically assembledcomponent, proof-testing is not required providingthat the component has already been tested by themanufacturer in accordance with the relevant

European standard.

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

3. Operating instructions

a. Clean the lifting hole of jaw in order toinsert the jaw-lifting tool in. Make surethat there is not any material in the

jaw-lifting hole, as it may prevent jaw-lifting tool 's locking mechanism tofunction properly.

b. Jaw-lifting holes can be kept clean bycovering them with polyurethane. The

polyurethane must withstand ambienttemperatures and must be melted awaywith a torch prior to inserting the

jaw-lifting tool.

c. Turn the lever to the installation positionso that the hinged tip of centre pin and

Liftingtool

Check dimension L

582133 382 +38 mm (15.04" +1.50")

582151 367 +37 mm (14.45" +1.47")

585042 395 +40 mm (15.55” +1.57”)




APPENDIX A

the stationary part of the pin form a flushshape (Ref. Figure 2). The lever mustremain locked in this position.

d. Insert both hooks into the lifting holesand turn the levers 180 degrees in order to lock the pins to the jaw. The leverslock themselves to this position but as anadditional safety precaution the lockingmechanisms are secured by means of screwing in butterfly screws.

e. Before beginning the hoist make surethat jaw is loose.

f. Start the hoist slowly. If the jaw jams,stop lifting and unfasten jaw.

g. Keep the hoisting zone free of people at

all times.

h. Never stand underneath a suspendedload.

Figure 3 Lifting tool usage:A) Locked

B) Unlocked




APPENDIX A




Instruction manual

140401



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 alterthe 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) OYPL 30633101 TampereFinland

Tel. +358-204 84 142Fax. +358-204 84 143

Instruction manual Vibrating chutes

6/99



TABLE OF CONTENTS

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

2. SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.1 WARNING SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.2 INTENDED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.3 INSTRUCTION MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.4 PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22.5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32.6 MAINTENANCE AND REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.7 OTHER SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42.8 TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

3. GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.1 Used terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.2 Nordberg vibrating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.3 Uses of Nordberg vibrating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23.4 Principle of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23.5 Spare and ware parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33.6 Optional equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

4. INSTALLATION, OPERATION AND TRANSPORT. . . . . . . . . . . . . . . . . . . . 4-14.1 Foundation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14.2 Service level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24.3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24.4 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24.5 Electrification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34.6 Connecting a hydraulic drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

5. OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15.1 Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15.2 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.3 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15.4 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15.5 Measuring the stroke and the stroke angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

6. LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16.1 Vibrating motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

7. PERIODICAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17.1 Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17.2 Monthly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17.3 Every three months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Instruction manual Vibrating Chutes

6/99 140401



8. OTHER MAINTENANCE ACTIVITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18.1 Pre-tightening of screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18.2 Changing of grizzly cassettes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

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

Vibrating Chutes Instruction manual

140401 6/99



This instruction manual is intended to assistowners and users of Nordberg products in theproper use of the equipment.

It includes important references to safe,proper and economical operation of theequipment. Following these instructions willhelp to avoid possible danger, reduce repaircosts and breakdowns and to increase thereliability and life of the equipment.

This manual must be complemented by those

instructions necessary because of existingnational mandatory rules relating to accidentprevention and environmental protection.

A copy of this manual must be kept at theequipment’s location and made available tothe operators as required.

In addition to this manual and accidentprevention regulations mandatory in thecountry of use and at the equipment’s place of operation, generally recognized rules for safe

and professional operation must be observed.

This instruction manual must be read and usedby each person who works with theequipment, typically:

— operations, including installation, startup,operation, application engineering,materials handling, site labour,environmental engineering and safetydepartments.

— maintenance, including inspection andrepair.

— transport, materials handling and rigging.

Note that this instruction manual containsinformation and instructions on alternativeand optional equipment. Normally themachines have only some of them. Beforemaintaining and servicing, find out whichalternative and optional equipment yourmachine has.

See separate instruction manuals for moredetailed instructions when servicing the maincomponents.

There may be optional equipment which haveseparate instruction manuals. Those manualsmust be read and used by each person whoworks with the equipment.

Preface

1/95 1-00-B 1-1



2.1 WARNING SYMBOLS

The following symbols for particularly impor-tant instructions are being used in the instruc-tion manual:

Reference

Refers to economical operation of the equip-ment.

Attention

Particular attention must be given to preventpossible incorrect or dangerous operating si-tuations from occurring.

Danger

Particular attention must be given to preventaccidents or damage to personnel and/or pro-perty.

2.2 INTENDED USE

Metso Minerals’ products are designed withsafety as a major criteria and also manufactu-red according to the state of art principals inengineering and safety. Nevertheless, impro-per or careless operation can be dangerous.Operating personnel and others must be madeaware of the inherent dangers in operating thistype of equipment.

The equipment shall be used only when inproper mechanical condition, according to its"intended use", and careful consideration gi-ven to safe operation and possible danger.Strict attention must be paid to this instructionmanual. Poor mechanical or site conditionsthat would prejudice safety must be correctedimmediately.

The equipment is intended to be used in ore,rock or rock-based materials handling exclu-sively. Any application different from above

or exceeding the design limitations of theequipment will not be considered as intended.The manufacturer will not be liable for anyconsequential or inconsequential damages re-sulting from the product’s misuse. The useronly, shall incur these risks.

The "intended use" must also include: adhe-rence to all instructions in this manual, properand safe operation, and the observing of re-sponsible inspection and maintenance proce-dures.

2.3 INSTRUCTION MANUAL

Keep the instruction manual permanently ac-cessible at the equipment’s location.

In addition to the following advise provided inthe instruction manual, observe and provideinstruction regarding all general legal andmandatory regulations relating to safety, acci-

dental prevention and environmental protec-tion.

Safety

5/95 2-00-B 2-1



Such responsibilities also include: handlingand disposal of dangerous materials or consu-mables, wearing of personal protection appa-

rel and other protective equipment, and obser-ving of materials handling and transport regu-lations.

Read the instruction manual completely. Ini-tiate and institute proper training proceduresfor; operator instruction and education, repor-ting and control procedures, supervision gui-delines and procedures, personnel supervi-sion, etc.

Before starting assembly or site preparation,

personnel in charge must read the instructionmanual and in particular the chapter on safety.This is imperative. Particular attention must bepaid to the activities or safety of personnel notfamiliar with the equipment and its applica-tion, for example those involved in assembly,startup or maintenance.

Control must be exerted over work performedon or near the equipment to ensure that strictadherence to this manual is maintained.

The personnel must not wear long hair, looseclothing or jewelry, because of possible dang-er or injury.

Use personal protection suits and other protec-tive equipment where mandatory.

Observe and follow any safety, danger or war-ning signs on the equipment.

Keep all safety, danger and warning signs onthe equipment in legible condition.

If safety-related modifications to the equip-ment or its performance are required, stop theplant immediately and before beginning anywork notify the person responsible.

Do not make any modifications or repairs tothe equipment which would prejudice safety,without the supplier’s written approval. Thisincludes work on attached or remote safetydevices, control valves, as well as the weldingof supporting structures, brackets, etc.

Spare and wear parts must meet the manufac-turer’s technical specifications. Conformity

can only be fully guaranteed when originalmanufacturer’s parts are used.

Replace hydraulic hoses and pipes at the indi-cated or appropriate time intervals, even if nosafety-related defects are perceptible! Alwaysreplace them immediately when there is anyindication of unsafe, worn, damaged or faultyparts.

Always follow the time period guidelines spe-cified in the instruction manual for inspectionand maintenance.

Always use tools and suitable for the work tobe performed.

Always know the location and proper use of fire extinguishers.

Always observe the proper procedures for firealarms and fire fighting.

2.4 PERSONNEL

Any work on the equipment must be perfor-

med by skilled and trained personnel only.Observe the minimum legal age requirements.

Clearly state and follow guidelines for person-nel skills and requirements necessary for thesafe operation, installation, service, mainte-nance and repair of the equipment.

Ensure that only personnel with these skillsand that meet these requirements work on theequipment.

State clearly the responsibilities of the machi-ne operator. Authorize him to refuse any un-safe instructions by third parties.

Let personnel in training, in training on the jobor in general education work with the equip-ment only under permanent supervision of anexperienced person.

Work on electrical controls and equipmentmust only be performed by a licenced electri-cian or under the guidance and supervision of an electrician, always according to applicableregulations.

Safety

2-2 2-00-B 5/95



Only trained and experienced hydraulics tech-nicians should perform work on any hydraulicsystem.

2.5 OPERATION

Refrain from any work that would endangersafety.

Before starting work, familiarize with the sur-roundings of the work place, e.g. any possiblehindrances (barriers/obstructions/ obstacles)in the reach of work and traffic, soil bearingcapacity and necessary site protection towardsthe public road traffic area.

Take any necessary measures to ensure that theequipment is operated in a safe manner andwhen in good mechanical condition.

If the equipment is used alone, it must beequipped with main switch and emergencyswitch.

Only operate when all safety devices and safe-ty-related equipment, e.g. removable guards,

emergency stops, sound insulation, dust col-lector are in proper position and operative.

Check the equipment at least once a shift forvisible damage and defects. Notify the respon-sible person immediately of any problems inc-luding any deviations in normal operating per-formance. In every case stop equipment imme-diately and resolve the problem!

In the case of any malfunction, stop and safe-guard the equipment immediately. Have the

problem immediately corrected.

Observe starting and stopping procedures,control devices and signals as specified in theinstruction manual.

Before starting the equipment inspect the ge-neral area to ensure that there are no personnelthat may be endangered from starting. Walk around the equipment and make sure that thereis nobody on, by or below the equipment.Warn all persons in the area before starting.

Do not climb on the equipment during opera-

tion or touch the moving parts.

All the moving parts relating to power trans-mission ie. flywheels, shafts, couplings, V-belt pulleys and V-belts must be covered gu-arded properly to eliminate danger to person-nel.

Make sure that all the persons operating ormaintaining the equipment know the locationof the emergency stop buttons or controls.

Do not try to clear any blockings when theequipment is running.

Rock or other objects may fall from the machi-

ne. Always wear a helmet in the dangerousarea.

Be very careful near sharp corners, edges orrough surfaces.

2.6 MAINTENANCE AND REPAIR

Observe all guidelines outlined in the instruc-tion manual regarding adjustment, maintenan-

ce and inspection schedules, as well as replace-ment of parts or equipment. Only trained tech-nicians should perform this work.

Inform the maintenance staff of any mainte-nance or service work required. Ensure propersupervision.

In any work related to the operation, modifi-cation, conversion or adjustment of the equip-ment and its safety devices including inspec-tion, maintenance and repair, observe all star-

ting, stopping and maintenance procedures asoutlined in the instruction manual.

Ensure as extensively as possible that the im-mediate area is safe and secure.

When installing or replacing parts, incorrectmounting may be hazardous. Always ensurethat the parts are properly installed.

When the equipment is switched off duringmaintenance and repair, the motor controlsmust be locked out/off. Secure the lock keysand attach a hazard notice at the main discon-nect switch. Make sure that the equipment can

Safety

5/95 2-00-B 2-3



not be started during maintenance and repair.

During replacement of parts or heavy structu-ral components careful handling and hoistingprocedures must be followed to eliminate anypossible danger. Only use appropriate, proper-ly designed lifting and handling equipmentwith sufficient capacity. Place the parts onground with sufficient bearing capacity. Neverstand or work underneath a suspended load.

Use only approved lifting equipment andslings when lifting components. Tighten anylifting eyebolts before lifting.

Allow only skilled personnel to sling loads anddirect the crane operators. The hoisting personin charge must keep in visual or voice contactwith the crane operator.

For any work above grade level, use approp-riate stairs and working platforms. Do not usemachine parts as platforms. For maintenancework involving any height other than gradelevel use appropriate safety equipment andprocedures.

Due to small size and mobility of the machine,the accesses may be different from the requi-rements of the standards. Always be verycareful when walking on the machine.

Keep all handles, steps, railings, platforms,stages and ladders free from dirt, snow, ice andother hazards.

When cleaning hoppers or other hazardousplaces be very careful to prevent falling andinjuries.

Prior to maintenance and repair work, cleanthe machine. In particularly clean all connec-tions and leads to remove oil, fuel or otherfluids. Do not use harsh cleansers. Use fibre-free cleaning rags.

Before cleaning the machine with water, steamor high-pressure cleaning methods, cover andprotect all openings where water, steam orcleanser must not penetrate, particularlyelectrical motors and controls.

After cleaning remove any temporary coversor protection completely.

Check all fuel, motor oil and hydraulic oilhoses for leaks, loose screws, fasteners, bolts,fittings, cuts, shearing or damage. Repair all of

these immediately.

After maintenance and/or repair work, tightenany loose fittings, bolts, fasteners, etc.

If any maintenance and repair procedures re-quire the dismantling of safety controls, theymust be re-assembled and checked immedi-ately upon completion of the work.

Care must be taken for the safe and environ-mentally correct disposal of process materials,parts and other consumables.

Always attach a hazard notice to the mainelectrical disconnect switch and lock it out,when starting the equipment may be hazardousor when maintaining or repairing the equip-ment.

Always attach a hazard notice to the powersupply of electrical components and lock themout, when starting the equipment/componentmay be hazardous or when maintaining orrepairing the equipment/component.

2.7 OTHER SAFETYCONSIDERATIONS

Electricity

Only use fuses of proper and recommendedcapacity. Never use fuses of higher capacitythan indicated in the electrical drawings.

In case of electrical problems, shut down theequipment immediately.

Any work on electrical equipment must onlybe performed by a licenced electrician or underthe guidance and supervision of a licencedelectrician, providing all codes and regulationsare followed.

Prior to any inspection, maintenance and repa-ir being performed, the equipment must, if required, be secured electrically and switched

voltage free. Follow all required safety proce-dures and regulations.

Safety

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The electrical equipment must be inspected atregular intervals. Defects such as loose con-nections, damaged wiring must be repaired

immediately. The work must be performed bya licenced electrician or equivalent as specifiedby law.

Should work be required on live electricalapparatus, a second person must be assignedto actuate the emergency stop or disconnect themain switch in case of emergency. Safeguardthe working area with a red and white safetychain and "danger" sign. Use voltage isolatedtools only.

Where work is required on high voltage com-ponents, connect the supply cable after voltageclearance to mass, and short-circuit compo-nents, e.g. capacitors, by an ground rod.

Use only proper parts in electrical appliances.Electric cables should be properly sized andprotected, for example from falling rocks.Wiring should be long enough to provide forcomponents requiring adjustment.

Hydraulic, pneumatic

Only persons with special knowledge and ex-perience in hydraulics shall perform work onthe hydraulic equipment.

Check at specified intervals that all conduits,hoses, lines and fittings are free of leaks orvisible defects. Repair any defects immedi-ately. Spurting oil may cause injury and fire.

Prior to any repair work, depressurize any airor hydraulic system, including hoses, lines andfittings to be opened. This must be done in asafe, approved manner.

Assemble hydraulics and compressed-air pi-ping carefully according to all proper proce-dures. Take precautions to not mix up anyconnections. Fittings, length and quality of thehoses and pipes must satisfy any requirementsset.

When replacing or repairing hydraulic parts,make sure that only parts designed for theoperating pressures of the system are used.This also relates to any pressure hoses.

Never search for leaks from the pressurizedhoses with hand. High pressure fluid jet maypenetrate the skin and cause injury. Search for

leaks with paper, etc.

Gas, dust, steam, smoke

Perform welding, cutting and grinding work atthe equipment only where allowed. Fire haz-ard may exist and explosion hazard may occur.

Before welding, cutting and grinding clean theequipment and site to remove dust and com-

bustible materials. Take the necessary precau-tions in providing for sufficient ventilation.

Dust protection must be fitted to the machinewhere necessary to prevent injury to personnelor contamination of the environment. Airbor-ne dust must be minimized while feeding,moving or discharging the product. Recom-mended methods for dust prevention are:

1. Dust covers and dust extraction2. Dust enclosures3. Water suppression

Noise

During operation, sound insulation, if avai-lable, must be in its proper and safe location.

Wear ear protection.

Oil, grease and other chemical materials

When using oil, grease and other chemicalmaterials, observe the product safety guideli-nes and warnings.

Be careful when using any hot materials toprotect personnel from burning or scalding.

Hot surfaces

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5/95 2-00-B 2-5



During operation some surfaces become veryhot (for example exhaust pipes and turbo-char-gers). The wear parts of the crusher and metal-

lic object which go through the crusher canalso become hot.

Fire

In case of fire near the equipment:

— 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.

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.

Blasting

The use of the radio control device is strictlyforbidden during blasting operations, as it maycause a premature explosion.

The equipment must be moved far enoughaway from the dangerous area when blasting.

Explosives must be prevented from enteringthe equipment.

2.8 TRANSPORTATION

Only use appropriate transportation and liftingequipment with adequate capacity.

Provide a supervisor to direct lifting opera-tions.

Transport or hoist components, and handle anyparts in accordance with the instructions and

advice provided herein.

Fasten the lifting equipment only to the pointsmeant for lifting.

Use only proper means of transport with ade-quate transporting capacity!

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

Secure all component parts of the equipmentimmediately after loading to avoid any acci-dental shifting. Attach required warning signsto the load.

Remove all temporary supporting structures orbrackets before re-starting the equipment.

Carefully assemble all of the parts previouslydisassembled.

Disconnect all external power supply beforemoving any part of the equipment and recon-nect it properly before re-starting.

Perform any start-up in accordance with theinstruction manual.

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The operation manual deals with vibrating TKfeeders and screens. Henceforth these will begenerally called vibrating devices.

3.1 Used terms

— Capacity = Transport ability of vibrator intons per hour.

— Sorting capacity = Sorting ability of vib-rator in tons per hour.

— Feeding end (F) = The end of the vibrator,where material is fed into.

— Discharge end (D) = The end of the vibra-tor, where material is discharged from.

— Vibrator = The mechanism in the vibratingdevice that makes the device vibrate.

— Grizzly (G) = Grating structure in the vib-rating device that separates the fine matterfrom the fed material.

— Screen deck = Cloth structure in vibratingdevice that sorts the fed material into frac-

tions.— Stroke length = Distance between vibrati-

on motion extreme positions of vibratingdevice.

— Stroke angle = Direction of stroke move-ment in relation to horizontal.

3.2 Nordberg vibrating devices

The Nordberg vibrating devices have either aclosed bottom, or a screen deck and one ormore grizzlies. There are different sizes of vibrating devices for various uses.

The vibrating devices have either a directsquirrel-cage motor drive or a regulating drivewith a frequency converter, some vibratingdevice types have a hydraulic drive.

Grizzlies and screen cloths are available fordifferent uses and they can be changed.

FIGURE 3.1.1 Terms used in the operation manual

General Vibrating Chutes

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3.3 Uses of Nordberg vibrating devi-ces

The vibrating devices manufactured by MetsoMinerals are used for feeding, transport andsorting 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 thevibrating device and it is discharged from its

discharge end.

Two identical rotating mechanisms revolvingin opposite directions provide a rectilinearstroke movement.

The material on the vibrating device movesdue to the fact that the vertical movement of the base is quicker than that produced by thegravitational pull. Therefor the material comesoff the bottom, continuing its movement in thedirection of the movement of the moment of

the base.

The stroke angle of free synchronizing shaftsis defined by the center of gravity and theposition of the vibrator.

The stroke angle of interconnected shafts is

defined by the reciprocal position of the shaftsand the position of the vibrator.

The vibrating device can have a grizzly or ascreen deck that lets the fine grain sizesthrough.

The capacity (feeding efficiency) is regulatedby altering the eccentric masses of the vibra-tor. The capacity can also be regulated bychanging the speed of rotation of the vibratorby means of an optional frequency converter

or a hydraulic drive, if needed.

TYPE MARKING

TK 13 - 20 - 3V

Vibrator

Body width (dm)

Body length (dm)

No marks = closed bottomS = with screen deck2V = two stage grizzly3V = three stage grizzly

FIGURE 3.2.1 Type marking of vibrating chutes

Vibrating Chutes General

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3.5 Spare and ware parts

Nordberg produces, with the same type mar-

king, vibrating devices that differ from eachother. In order to secure the right informationconcerning each vibrating device, the partnumber related to the device in questionshould always be quoted.

The original Nordberg parts have precise mea-sures and they are made out of the most appro-priate material. Original parts make certainthat your device works impeccably and theymaintain the guarantee.

The original Nordberg parts signify savings inyour 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 mustinclude the following information:

— Device type, part number and productionnumber

— Order number, title and amount of parts tobe ordered

— Official name and complete address of firm that pays the invoice

— Precise delivery instructions, way of deli-very and address

If the original spare parts book has been lost,you can order a new one from Nordberg.

General Vibrating Chutes

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3.6 Optional equipment

Grizzlies

The grizzlies can be changed and there is achoice of different types of grizzlies with dif-ferent grizzly openings.

There are three different types of grizzlies infigure 3.6.1. On the left is a plate grizzly, in themiddle a rod grizzly and on the right a bargrizzly. Measure G is the grizzly opening atthe end, which is mainly used to identify thegrizzlies.

The choice of the grizzly depends on the feedto be used and the required sorting limit,among others. Contact a Nordberg specialistwhen you want to choose a grizzly.

Screen cloths

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

The choice of the cloth depends on the feed tobe used, the required sorting limit and thepurity requirements of the fractions, amongothers. Contact a Nordberg specialist whenyou want to choose a screen cloth.

The tightening of the screen cloth is done withtightening bars, hook screws and wedges. Thetension of the screen cloth always depends onthe cloth properties.

The biggest recommended cloth screen holesize is 50-60 mm.

Figure 3.6.1 Different kinds of grizzlies.

Vibrating Chutes General

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4.1 Foundation

The vibrating device is mounted on springs,and the spring fixing plates are installed ontoa firm foundation. The mounting surfaces forthe fixing plates have to be horizontal. Verticalsprings have to be in vertical position. If theupper spring support is adjustable, verify thatit is parallel to the lower fixing plate. See if thesprings on both sides are compressed an equalamount, you will notice the distortion of thebase from the compression. Spacer plates canbe used underneath the fixing plates, if nee-ded.

Figure 4.1.1 shows the straightness require-ments for the foundation.

The spring bases of the vibrating device haveto be on the same level with each other up toa precision of 10 mm.

The supporting structures have to be placeddirectly below the springs. Verify that the

lower structures of the vibrating device are notelastic. If the lower structure is elastic, the

stroke movement of the vibrating device be-comes vague decreasing the output. Observethat you also have to pay attention to thehorizontal rigidity of the base.

The support forces of the vibrating device canbe found in the information related to eachtype.

No undue parts may be fixed onto the bodyof the vibrating device, e.g. feeding funnels,chutes, etc. These have to be fixed onto theirown support structures, apart from the vib-rating device.

If extra masses are fixed onto the body, thecenter of gravity moves downward and thebody movement becomes uneven. Besides,feeding output decreases due to the increase inweight.

Figure 4.1.1 Straightness requirements of the vibrating device foundation

— sideways15 mm— lengthwise30 mm— vertical direction50 mm

Installation Vibrating Chutes

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The vibrating device should be installed insuch a way that the distances between thevibrating device and other structures (e.g. sup-

porting structures, funnels, chutes, silos),when loaded, are at least as follows.

This relatively large free space between thebody and other structures is needed for themomentary irregular swinging motion whenstarting and stopping the device.

Eventual beams under the body have to beinstalled in such a way that the material thatgathers on top of them does not touch the body.Correspondingly, the fixing points of the

springs have to be such that there is no possi-bility for sufficient material to gather near tothem as to cover the springs and damage them.If the body hits the funnel, or another fixedstructure, when the vibrating device is run-ning, loading increases to a multiple of thedesigned loading, leading to a device failure.

The discharge opening of the funnel that feedsmaterial onto the vibrating feeder may not beessentially smaller than the body width. Thisway the whole transversal area of the body can

be utilized. Nevertheless, movement gaps of the previously mentioned size have to be leftbetween the body side plate and the side of thefunnel.

The sides may not extend too far down into thebody in order for fed material not to get squ-eezed between the lower edge of the funneland the bottom of the vibrating device. Thesides have to reach, however, to at least 70 mmbelow the top edge of the vibrating device

body.Chains or a hatch may be used to conduct thematerial flow discharging from the feedingfunnel onto the vibrating device. The hatchmay not extend too near to the bottom of thevibrating device. Especially in connectionwith vibrating devices with a closed bottom,the feeding funnel discharge opening has to bedesigned and placed in such a way that mate-rial cannot have a free flow over the dischargeend when the vibrating device is not running.

When designing feeding funnels, it has to beobserved that the pressure caused by material

does not exceed the maximum allowable valueof the vibrating device (see specifications,chapter ASupport loads and AMinimum mea-

sure of springs, loaded).

The design of the feeding funnel has to be suchthat it carries part of the feed mass.

When installing funnels, channels or otherstructures near to the feeder body, the gapsbetween the structures have to be guardedaccording to safety regulations of the countryof operation (e.g. EN 294).

4.2 Service level

There has to be a service level around thevibrating device in order to make maintenanceand operation easy. If the service level has notbeen ordered and delivered together with thedevice, it has to be built by the user.

The service platform of crushing equipmenthas to comply with the safety regulations validin the country of operation.

All instructions on crushing equipment servicelevels in force in the country of operation of the vibrating device must observed.

4.3 Transport

During transport, the vibrating device must befirmly fixed onto the trailer. Most vibratingchute types have transport supports designedfor this purpose.

Turn the device into the most appropriate po-sition according to the way of transport (e.g.vibrators upwards and the body downwards).

4.4 Welding

The body and other parts of the vibratingdevice may not be welded without the consentof the manufacturer.

Vibrating Chutes Installation

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4.5 Electrification

It has to be noted that the separate vibrators of

electrically driven vibrating devices have to beconnected to turn in opposite directions.

Safety regulations of the country of operationof the vibrating device have to be observed inelectrification.

When the operation frequency of the devicechanges, the vibrators’ regulating valueshave to be set to correspond to the newfrequency. Especially when connecting aspare part vibrator, the regulating values

have to be checked. The regulating valuescan be found in the specification annex.

4.6 Connecting a hydraulic drive

It has to be observed that the separate vibratorsin hydraulically operated vibrating feedersmust be connected to turn in opposite direc-tions.

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5.1 Before starting

NOTE! Remove eventual transport supportsand inspect the device as indicated in point7.1.

Make sure that the electric con-nections are properly done andthat the cables etc. are in conditi-on of operation.

Operate the device only when all necessary

safety devices are installed (e.g. covers, emer-gency stop devices, etc.) and they are in con-dition of operation.

Make sure before starting the device that star-tup puts nobody in danger. Walk around thedevice and make sure that nobody is on top of,beside or under it. Warn those in the vicinitybefore starting.

5.2 Starting

When starting the process, the devices remo-ving material from the vibrating feeder haveto be started before starting the vibrating de-vice, and the feeding devices after the vibra-ting device.

Make sure that in a vibrating device withtwo vibrators, both vibrators start. Usingthe 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 devi-ces are stopped in the opposite sequence inrespect to starting.

5.4 Operation

Do not drop big stones into an empty vibratingdevice, the bottom might get damaged. Try tokeep material on the bottom of the device inorder to soften the blows of falling big stones.Stones may not be dropped onto the grizzly of the vibrating device. Stones stuck into grizzlyopenings must be removed in order not todamage the grizzly.

Material should be fed correctly onto the vib-rating device, this conserves the device andgives it a longer service life.

Check at least once during a shift, as indicatedin point 7.1, that the device works properlyand for possible failures. Report changes (alsoin the operation of the device) immediately tothe person responsible at the job-site. Thedevice has to be stopped and safety measureshave to be taken, if needed.

Do not climb onto the devicewhen it is running. Also, do nottouch moving parts on the devicewhen it is running. When the de-vice is running, do not approachit so much that feed material may pose a risk.

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5.5 Measuring the stroke and the stro-ke angle

There are stickers on the device, where thestroke and stroke angle can be read on duringoperation.

There are black circles of a diameter of 1...20mm on the sticker. The difference between thediameters is one millimeter. When the bodyvibrates, the eye perceives two circle rowsunderneath each other. The stroke is indicatedby the circles below each other that are tangentto each other. The diameter of the circle con-cerned is the stroke. In order to help the deter-

mination of the diameter, there is a circularring in the circles of 5, 10, 15 and 20 mm.

In order to determine the stroke angle, there isa dot in the sticker and lines at 15° intervals.The line, the direction of which the dot seemsto move, determines the stroke angle. If the dotmoves between the lines, the stroke angle canbe 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°

Vibrating Chutes Operation

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6.1 Vibrating motor

The instructions for vibrator lubrication are ina separate vibrator operation instruction.

NOTE! Excessive lubrication may damagethe bearings and other parts of the device.

Lubrication Vibrating Chutes

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7.1 Daily

Check all safety devices and that they work properly. Repair revealed faults at once.

Check the state and fixing of wearing parts,change or tighten them if needed.

If there is a screen cloth in the device, itstension has to be regularly checked.

Check the electric devices, especially the con-

nection and condition of the cables leadinginto the vibrators.

Listen to the sound of the vibrating device. Thecause of all extraordinary sounds has to bedetermined.

7.2 Monthly

7.3 Every three months

Check the condition of the vibrating device.

All screws, nuts and connections have to bechecked and tightened, if needed, in order toavoid damages. See pretightening torque of screws in chapter 8.1 "Pretightening of screws".

Check the springs (wear, corrosion, breaks,protections).

Check that nothing touches the movingbody (sufficient free space around)

Periodical maintenance Vibrating Chutes

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8.1 Pre-tightening of screws

The torques in the table have to be used totighten all screws. In order to achieve the rightpre-tightening tension in the screws, thethreads have to be clean, dry and zink-plated.

The tightening instructions of the vibrator fi-

xing screws are in the vibrator operator’s ma-nual.

8.2 Changing of grizzly cassettes

When ordering a grizzly, make sure that it suitsthe vibrating feeder and the application inquestion.

The tightening torques of the screws are ex-plained in the previous point.

Special attention has to be paid to safety at

work when changing the grizzly (see chapter2).

The working levels have to be sturdy and thelifting devices appropriate for the purpose.The lifting ropes have to be fixed properly.When lifting, nobody may be underneath theload to be lifted or too near to it.

The grizzlies are described more in detail inthe Specifiactions annex.

Screw Torque

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

Other maintenance Vibrating Chutes

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In spite of careful operation of the vibrating device according to instructions, as well as of carefulquality control in the production of the vibrating device, different failures may turn up in thevibrating device and the process associated with it.

The following presents some possible failures and their corrective procedures.

FAILURE CAUSE PROCEDURE

Small feeding capacity. Feeding funnel or discharge openingtoo small and they vault.

Body touches fixed structure or material.

Change structures so that body hassufficient swinging room. (point4.1)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 besuitable, e.g. by mixing.

Grain size of feed is too big and itvaults.

Reduce grain size of feed.

Wrong vibrator speed of rotation. Check vibrator control circuit and speedof rotation.

Uneven vibration See following point.

Uneven vibration. Material in feeding funnel weighs toomuch on the vibrating device.

Change structure of funnel.

The strokes at the different ends of thebody are remarkably unequal in size. Contact Nordberg specialist.

Wrong stroke angle. Contact Nordberg specialist.

Lower structure of vibrating device orground gives in.

Reinforce structure and place betterfoundation under support structures.

Extra structures have been fixed ontothe body.

Remove extra structures from body andfix them on other structures.

Material has stuck onto the body. Remove stuck material.

Broken springs. Replace them with new springs.

Troubleshooting Vibrating Chutes

2/99 140401 9-1



FAILURE CAUSE PROCEDURE

Vibrating device vibratessideways Only one vibrator works.

Device may not be operated with only

one of the vibrators working. ContactNordberg specialist.

Both vibrators turn in same direction. Check vibrator control circuit.

Operation base gives in. Make better foundations according tomanufacturer’s instructions.

The body clatters. Loose screws in body. Tighten screws.

Body touches other structures. Verify that spacings are according tochapter 4. point 1.

Vibrator becomes too hot. Air does not circulate enough aroundvibrator. Improve air circulation.

Insufficient lubrication in bearings. Lubricate bearings.

Too much grease in bearings. Stop device, let it cool down and startagain.

Vibrators will not start. Grease has become stiff due to coldweather.

Warm the vibrator.

Fault in vibrator control circuit. Check vibrator control circuit.

Too high speed of rotation ofhydraulic driven vibrator. Only one vibrator is working.

Device may not be operated with onlyone of the vibrators working. Contact

Nordberg specialist.

Hydraulic oil leaks from

hydraulic vibrator.Shaft packing of hydraulic motor leaks. Contact Nordberg specialist.

Vibrating Chutes Troubleshooting

9-2 140401 2/99



I n s t r u c t i o n m a n u a l ,

V 15 0 h y d r a u l i c d r i v e

Terms used

Fixed side = the side of the fixed bearing, Aside

Free side = the side of the moving bearing, Bside

Drive axle = the axle containing the drivemotor

Driven axle = the axle being rotated via thegear assembly

Half = the frame is made of two, identicalhalves

General instruct ions

The cooling openings on the sides of the vib-rator must not be covered. Covering theopenings prevents air from circulating and cancause the bearings to overheat. The coolingopenings are shown in the figure 930640 (mar-ked with number 1). Also, avoid covering theslots on the circle of the vibrator.

The tightness of the fixation screws of thevibrator (shown in the figure 930640, marked with number 2) must be checked in connectionwith other maintenance operations of the de-vice. One indication of loose screws is a rustystreak coming from the screw joints. The loosescrews must be re-tightened at the torque of 662 Nm.

The frame of the vibrator is made of ballgraphite cast iron which must not be subjected

to physical force. This is especially importantin cold weather.

V150 Hydraulic drive Instruction manual

5/00 B-1



Checking the oil level and changingthe oil

The oil level is checked by opening the capshown in figure 930461 (7) while themachinery is in the angle of 45 degrees. Someoil should drip from the cap. The oil levelindication is reliable when the machinery has

been stopped for at least 30 minutes. The oilis changed for the first time at 200 runninghours. In the future, oil must be changed every1,000 running hours and at least twice a year.For oil change, drain the machinery of oil byopening the cap (2) in figure 930461 while themachinery is in operational position. Oil isfilled through either of the two caps (3). Therecommended oil volume is 4 litres (allowablerange is 3.5 to 4.5 litres, this corresponds to oillevel of the cap (1) with the angle of 42.5º to47.5º). Absolute cleanliness is imperativewhen changing the oil.

Recommended oil qualities:

For summer use (temperature above -10 ºC):

Manufacturer Oil

BP Energol GR-XP 150ESSO Spartan EP 150FINA Giran 150MOBIL Mobilgear 629

NESTE Vaihteisto 150 EPSHELL Omala Oil 150

TEBOIL Pressure Oil 150TEXACO Meropa Lubricant 150

For winter use and for cold conditions (temperature below -10$C):

Manufacturer Oil

BP Energol GR-XP 100ESSO Spartan EP 100FINA Giran 100MOBIL Mobilgear 627

NESTE Vaihteisto 100 EPSHELL Omala Oil 100TEBOIL Pressure Oil 100TEXACO Meropa Lubricant 100

The recommended temperature of use with oilis -30 to 95 ºC.

Note! The above recommendations are for reference only. To ensure the optimal lubrica-tion efficiency for the bearings, the viscosityof the oil has to be 30 to 40 cST in thetemperature of use.

An adhesive label with more details is attached on the side of the machinery. The label hasspace for the first few oil change dates.

Instruction manual V150 Hydraulic drive

B-2 5/00



Breather

A blocked breather causes the internal pressu-

re of the machinery to rise which causes inc-reased wear of the seals and leads to oil leaks.

If the feeder is turned (during transportation)so that oil can travel to the breather, the breat-her should be removed and the connectionshould be closed using the cap in the alu-minium cover. The breather is screwed in toreplace the cap. Make sure no dust or dirtenters the connection threads and the oil cavi-ty. When the machinery is taken into use, the

breather is reinstalled in the operational posi-

tion and the cap is reinstalled in the cover. The breather MUST be in operational positionwhenever the device is in use. Pay specialattention to making sure that the cup spacer (shown with number 1 in figure 930461) isalways installed correctly.

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


5/00 B-3



Adjusting the angle of stroke

Adjusting the angle of stroke influences theflow speed of material and the accuracy of thegrizzling operation. See the table below

The angle of stroke is adjusted as indicated infigure 930722. Both the aluminium coversmust 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 dri-ven axle. Consequently, loosen the screw (2)at the end of the axle. Beware of rotating axles

when loosening the weights.2. Position the weight as desired using theretaining screw (1). Both sides must be posi-tioned the same way, and symmetrically inrelation 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 thescrew.

4. Tighten the tightening screw (3, 4) of theweight, and use Loctite 270 to lock.

5. Finally, check that the tightness of the re-taining screw is 24 Nm (2.4 kpm). Use Loctite270 to lock.

6. Install the aluminium covers and the hyd-raulic motor.

NOTE! The vibrator must not be used withoutthe aluminium covers due to risk of accidents!

Instead of Loctite 270, the screws can belocked using similar products from other ma-nufacturers.

Change in the angle of stroke Flow speed of material

Accuracy of the grizzlingoperation

Raising Faster Worse

Lowering Slower Better


B-4 5/00




5/00 B-5



Replacing the seal

Instructions for changing the seal in the fixed

side (the side indicated in the figure) of thedrive axle (the axle with the drive motor):

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 theweight.

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 re-moval.

4. Remove the weight (6) and pull the sleeveoff together with the O rings (7).

5. Replace the seal (8). The detailed picturesT and U indicate the correct position of the sealand the sleeve. Make sure that the spacer ring(17) is placed in between the bearing and thesleeve (7) on the fixed side.

6. Reinstall the sleeve (7).

7. Reposition the weight (6) using the re-taining 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 thescrew.

10. Tighten the tightening screw of the weight(2). Use Loctite 270 to lock.

11. Finally, check that the tightness of theretaining screw is 24 Nm (2.4 kpm). Use Loc-tite 270 to lock.

12. Reinstall the vibrator cover (1).

The seal on the free side of the drive axle ischanged similarly. The procedure with thedriven axle (the axle being rotated by the drive

axle via the gear assembly):

1. Open the vibrator cover (1).

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 picturesT and U indicate the correct position of theseal.

7. Reinstall the sleeves (14 and 13).

8. Reposition the weight (12) using the re-taining screw.

9. Reinstall the flange (10).

10. Tighten axially using the screw (9) at theend of the axle at the torque of 196 Nm (20.0kpm). 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 theretaining screw is 24 Nm (2.4 kpm). Use Loc-tite 270 to lock.

13. Reinstall the vibrator cover (1).

Fluorocarbon seals (e.g. VITON etc.) mayleak when cold. This is a normal phenomenonand does not necessitate any corrective ac-tions.

If the axle is corroded at the location of the Oring (7) of the sleeve or in the countersurfaceof the lip seal, the sleeve can be turned so thatthe O ring meets a non-corroded spot of the

axle and the lip surface gets a new countersur-face.


B-6 5/00




5/00 B-7



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 thecoupling 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 driveaxle and remove the flange (4).

3. Remove the coupling half (5) from the driveaxle. The half can be heated up to max. 100ºCto facilitate removal.

Coupling half of the motor

Open the retaining screw (6) and remove thecoupling (7) from the motor axle. The half can

be heated to max. 100ºC to facilitate removal.Beware of overheating and damaging the mo-tor seals.

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 axleand lock with Loctite 270.

3. Reinstall the cover (2) of the machinery.Make sure that the guiding surface of thehydraulic motor is aligned with the couplinghalf of the vibrator. Make sure the guide pinsof the cover are properly in place.

4. Install the spacer (8) of the coupler at theend of the coupler in the axle side.

5. Install the coupling half (7) in the axle of the hydraulic motor. The coupling half can beheated to max. 100ºC.

6. Fix the coupling half with the retainingscrew (6) and lock with Loctite 270. Makesure the axial position of the coupling is withinthe allowable range given by the manufactu-

rer.7. Install the hydraulic motor. Note the positi-on according to the operational position


B-8 5/00




5/00 B-9



Additional weights

Many additional weight options are available

for the vibrator:

Identification Mass torque N11897099 5.34 kgm N11897100 6.10 kgm N11897101 6.87 kgm N11897103 7.58 kgm N11897106 8.35 kgm N11897111 9.12 kgm N11897557 9.12 kgm

The procedure for installing additional

weights is device specific. Installing addi-tional weights is agreed on separately. Installthe additional weights according to the inst-ructions in the document 926418.


B-10 5/00



D 58455 Witten - Germany

Ident.-Nr. / ident.-no. NO5638525Type / product GFT 36 T3 3216

Serial-Nr. / serial-no. Imprint on Rating Plate

Auftrag Nr. / order no. 367594.010

Baujahr / produced in 2004

Abtriebsmoment / output torque max. 40318 Nm

Antriebsdrehzahl / input speed max. 3800 min-1

Übersetzung / ratio 161

Schmiergruppe / lubr. group CLP 220

MobileHydraulics

Betriebsanleitung / Operating InstructionsPlanetengetriebe / Planetary Gearbox

HYDROTRAC GFT 36 T3 3216

The Drive & Control Company

GetriebetechnikGear Technology

4/6171/4216/0 14.04.2004 61712160.pdf



Inhaltsverzeichnis Table of Contents

4/6171/4216/0 00-2/28

1. Einleitung 1. Preliminary Notes1.1 Einführung 1.1 Introduction1.2 Sicherheitshinweise 1.2 Notes on Safety

2. Produktbeschreibung 2. Product Description

2.1 Einführung 2.1 Introduction2.2 Beschreibung 2.2 Description2.3 Beschreibung der Bremse 2.3 Description of brake2.4 Lieferumfang 2.4 Scope of Supply2.5 Technische Daten 2.5 Technical Data2.6 Zeichnungen und Listen 2.6 Drawings and Lists2.7 Betriebsmittel 2.7 Operating Media

3. Transport / Lagerung 3. Handling / Storage3.1 Einführung 3.1 Introduction3.2 Hinweise zu Transport und Lagerung 3.2 Notes on Handling and Storing3.3 Verpackung 3.3 Packing3.4 Konservierung 3.4 Preservation

3.4.1 Lagerung in gelüfteten Räumen 3.4.1 Storage in Ventilated Rooms3.4.2 Lagerung im Freien 3.4.2 Storage Outdoors3.4.3 Lagerung in klimatisierten Räumen 3.4.3 Storage in Air-Conditioned Rooms3.4.4 Lagerung von teilgeschlossenen Getrieben 3.4.4 Storage of part closed Gearboxes3.4.5 Langzeitkonservierung 3.4.5 Long-Term Preservation

4. Einbau 4. Mounting4.1 Einführung 4.1 Introduction4.2 Handlungsschritte zum Einbau 4.2 Mounting Work to be Performed

5. Inbetriebnahme 5. Commissioning5.1 Einführung 5.1 Introduction5.2 Handlungsschritte zur Inbetriebnahme 5.2 Commissioning Activities

6. (in diesem Handbuch nicht enthalten) 6. (does not form part of this manual)

7. Pflege / Wartung 7. Maintenance / Care7.1 Einführung 7.1 Introduction7.2 Handlungsschritte zu Pflege und Wartung 7.2 Maintenance and Care Activities7.3 Wartungsplan 7.3 Maintenance Schedule7.4 Wartungsplan Bremse 7.4 Maintenance Schedule Brake

8. Ausbau 8. Dismantling8.1 Einführung 8.1 Introduction8.2 Handlungsschritte zum Ausbau 8.2 Dismantling Work to be Performed

9. (in diesem Handbuch nicht enthalten) 9. (does not form part of this manual)

10. Ersatzteilbestellung 10. Spare Parts Ordering

Anhang Appendix

A. Anschriften A. AddressesB. Schmieröle B. Lube OilsC. Anbauteile C. Attachment PartsD. Zeichnungen D. DrawingsE. Teilelisten E. Parts lists



Einleitung Preliminary Notes 1.

4/6171/4216/0 01-3/28

1.1 Einführung 1.1 Introduction

In der vorliegenden Betriebsanleitung finden SieInformationen zum Einbau, zur Inbetriebnahme, zur Pflege und Wartung und zur Ersatzteilbestellung.

The present operating instructions contain informa-tion on installation, start-up, care and maintenanceas well as spare parts ordering.

Beachten Sie unbedingt die Sicherheitshinwei-se dieser Dokumentation.

Make sure the safety instructions in this docu-mentation are carefully observed.

- Allgemeine Sicherheitshinweise finden Sie indiesem ersten Kapitel.

- General notes on safety are listed in this firstchapter.

- Besondere Hinweise finden Sie jeweils am An-fang eines Kapitels.

- Special instructions are given at the beginningof the individual chapter.

- Auf eine Handlung bezogene Sicherheitshin-weise finden Sie vor der Beschreibung desHandlungsschrittes.

- Safety instructions referring to actions are givenbefore the action itself is described.

Die Seitenzahl finden Sie am äußeren Seitenrand.Die Angabe 01-1/24 z.B. bedeutet:Kapitel 1, Seite 1, die Betriebsanleitung umfaßt 24Seiten.

Page numbers are shown at the outer bottom mar-gin. For example, 01-1/24 means:chapter 1, page 1, the operating manual has 24pages.

Die Bereiche des Anhanges sind durch Zwi-schenblätter voneinander getrennt und ggf. ver-sehen mit Hinweisen auf den angesprochenenLeserkreis.

The various areas of the Appendix have been se-parated by sheets and, where considered ex-pedient, provided with notes on the relevant per-sons.

1.2 Sicherheitshinweise 1.2 Notes on Safety

Die Produkte von LOHMANN+STOLTERFOHTsind nach dem aktuellen Stand der Technik aus-gelegt und hergestellt. Dennoch können Gefahrenauftreten für:

The products of LOHMANN+STOLTERFOHT havebeen designed and manufactured so as to reflectthe technological state of the art. Nevertheless, itcannot be ruled out that danger may arise to:

- Körper und Gesundheit, - life and limb,- das Produkt und die Gesamtanlage, - the product and overall plant,- sonstige Werte. - other assets.

Mit diesem Symbol sind Gefahren für Körper und Gesundheit gekennzeich-net.

This symbol signifies danger to lifeand limb.

Mit diesem Symbol sind Gefahren für

das Produkt und die Gesamtanlagegekennzeichnet.

This symbol signifies danger to the

product and the overall plant.

Mit diesem Symbol sind Gefahren für sonstige Werte gekennzeichnet.

This symbol signifies danger to other assets.

Dieses Symbol kennzeichnet Hinwei-se.

This symbol calls attention to notes.




4/6171/4216/0 01-4/28

Gefahren können insbesondere dann auftreten: In particular, hazards may occur:- wenn unzureichend ausgebildetes Personal am

Produkt tätig ist,- if insufficiently trained personnel manipulates

the product,- wenn das Produkt unsachgemäß installiert,

bedient und instand gehalten wird,- if the product is inexpertly installed, operated

and serviced,

- wenn das Produkt zu nicht bestimmungsge-mäßem Gebrauch eingesetzt wird. - if the product is used for other than the intendedpurposes.

Alle Personen, die mit dem Betrieb der Anlage oder des Produktes befaßt sind, müssen:

All persons responsible for the operation of theplant or product must:

- unbedingt das Kapitel "Sicherheitshinweise"gelesen und verstanden haben,

- have definitely read and understood the chapter "Notes on Safety"

- diese Betriebsanleitung zumindest in den Teilenkennen, in denen die jeweilige Tätigkeit undzugehörige Gefahrenhinweise beschrieben sind.

- know these Operating Instructions or at least befamiliar with those parts where the respectiveactivity and associated dangers are described,

- mit Abschaltprozeduren, z.B. "NOT-AUS", der ganzen Anlage oder den für die jeweilige Tätig-keit wichtigen Teilen der Anlage vertraut sein,

- be familiar with shut-down procedures, e.g."Emergency-OFF", relating to the entire plant or to plant items important to the relevant activity,

- technisch ausreichend ausgebildet und zu der jeweiligen Tätigkeit befugt sein, - have adequate technical qualifications and beauthorized to perform the relevant activity,- ihre Aufgaben und Befugnisse kennen. - know their specific duties and authority.

Sie müssen unbedingt: Moreover, it is mandatory that these persons:- alle Handlungen unterlassen, die Gefahren für

Körper und Gesundheit, Gefahren für das Pro-dukt oder Gefahren für andere Werte bedeutenkönnten,

- refrain from doing anything that might causebodily harm or constitute a danger to health, theproduct or other assets,

- alle an dem Produkt vorgenommenen Verände-rungen dem zuständigen Vorgesetzten oder Betreiber mitteilen,

- inform their superiors in charge or the Operator of any modifications made to the product,

- alle Veränderungen beim Betrieb des Produkts,

z.B. unübliche Laufgeräusche, dem zuständigenVorgesetzten oder Betreiber mitteilen.

- inform their superiors in charge or the Operator

of any changes detected in the operational be-haviour of the product, e.g. unusual runningnoise.

An dem Produkt dürfen keine Veränderungenvorgenommen werden, die nicht zuvor vonLOHMANN+STOLTERFOHT genehmigt wordensind.

No modifications to the product are permittedunless the prior approval of LOHMANN+STOLTERFOHT has been obtained.

Der Anwender verpflichtet sich: The User shall undertake to:- am und um das Produkt für Sauberkeit und

Ordnung zu sorgen,- ensure that the product and its surroundings are

kept clean and in good order,- das Produkt nur in einwandfreiem Zustand zu

betreiben,

- operate the product only when in perfect condi-

tion,- das Produkt nur zum bestimmungsgemäßenGebrauch einzusetzen,

- use the product exclusively for the intendedpurpose,

- das Produkt nur im Rahmen der unter 2.5 auf-geführten technischen Daten einzusetzen,

- use the product only in the framework of thetechnical characteristics listed under 2.5,

- umlaufende Teile durch geeignete Schutzvor-richtungen abzusichern,

- safeguard rotating parts by means of suitableprotective systems,

- das Personal soweit wie nötig zum Tragen vonSchutzkleidung zu verpflichten,

- instruct the personnel to wear protective clo-thing, to the extent deemed necessary,

- dem zuständigen Personal diese Betriebsan-leitung auszuhändigen.

- distribute these operating instructions amongthe personnel in charge.




4/6171/4216/0 01-5/28

Zum bestimmungsgemäßen Gebrauch gehört auchdie Beachtung aller Angaben dieser Betriebsanlei-tung.Beachten Sie ergänzend zur Betriebsanleitung alleallgemein gültigen gesetzlichen und sonstigen Re-

gelungen zur Unfallverhütung.

Using the equipment for the intended purpose asset out above also includes observing the instructi-ons given in this operating manual.In addition to the procedures and instructions outli-ned in this operating manual all generally appli-

cable statutory and other accident prevention rulesand provisions must be observed.

Die Gewährleistung durchLOHMANN+STOLTERFOHT erlischt:

The warranty obligations of LOHMANN+STOLTERFOHT will become void:

- wenn das Produkt ohne unsere Zustimmunggeöffnet oder verändert wird,

- if the product is opened or modified without our consent,

- bei Nichtbeachtung der Instruktionen dieser Betriebsanleitung,

- in the event the instructions in this manual aredisregarded,

- bei Ein- und Anbau nicht von uns gelieferter oder genehmigter Ersatzteile und Zusatzgeräte,

- if spare parts and auxiliary items are built in or attached which have not been supplied or ap-proved by us,

- bei Überlastung des Produktes von besonderer

Art, wie z.B. Drehschwingungen, Drehmoment-stößen, Fundamentverwindungen oder sonsti-gen unzulässigen Einflüssen,

- if the product is subjected to overloads caused

for example by torsional vibrations, torque im-pacts, distorted or deformed foundations or other impermissible influences,

- wenn die in Kapitel 2.5 aufgeführten techni-schen Daten über- oder unterschritten werden,

- if the technical characteristics specified under pt. 2.5 are exceeded or fallen short of,

- bei unsachgemäßer Handhabung des Produk-tes.

- if the product is improperly handled or manipu-lated.

Technische Änderungen, die der Verbesserungdes Produktes dienen, behalten wir uns vor.

We reserve the right to implement technical chan-ges for product improvement purposes.

Die Abbildungen in dieser Betriebsanleitung kön-nen von der tatsächlichen Ausführung geringfügig

abweichen.

The photos and figures shown in this manual mayslightly deviate from the actual design.

Soweit vertraglich nichts anderes vereinbart ist,richten sich die Gewährleistungsansprüche nachden zum Zeitpunkt des Vertragsabschlusses gel-tenden "Allgemeinen Bedingungen für Lieferungenund Leistungen" vonLOHMANN+STOLTERFOHT.

Unless otherwise stipulated in the contract, anywarranty claims shall be dealt with in accordancewith LOHMANN+STOLTERFOHT`s "GeneralTerms and Conditions of Supplies and Services"applicable at the time the contract has been conc-luded.

UrheberrechtDas Urheberrecht an Zeichnungen verbleibt beiuns. Eine Zeichnung darf nur zu den Zweckenbenutzt werden, zu denen sie dem Empfänger

anvertraut ist. Ohne unsere ausdrückliche schriftli-che Genehmigung dürfen Zeichnungen nicht anDritte weitergegeben oder diesen zugänglich ge-macht werden.Jede Vervielfältigung - auch von Einzelheiten - istuntersagt.Zuwiderhandlungen werden gerichtlich verfolgt.

CopyrightThe copyright on drawings remains with us. A dra-wing must only be used for the purposes it hasbeen transferred to the recipient. Drawings must

not be handed over disclosed to third partieswithout our express consent in writing.

Any reproduction of a drawing in whole or part isprohibited.Contraventions will be prosecuted.

LOHMANN+STOLTERFOHT wird im folgenden mitL+S bezeichnet.

LOHMANN+STOLTERFOHT is referred to in thismanual as L+S.



Produktbeschreibung Product Description 2.

4/6171/4216/0 02-6/28


In diesem Kapitel finden Sie eine Beschreibungdes Getriebes GFT 36 T3 3216. Diese wird ergänztdurch Angaben zum Lieferumfang, durch eine Auf-

listung der technischen Daten und durch Angabenzu den Betriebsmitteln.

This chapter contains a description of the propelgear GFT 36 T3 3216. The description issupplemented by information on the scope of

supply, a list of technical data and details of ope-rating media.

2.2 Beschreibung 2.2 Description

Bei dem Getriebe HYDROTRAC GFT 36 T3 3216handelt es sich um eine Kombination einesREXROTH Axialkolben-Hydromotors mit integrier-ter, hydraulisch lüftbarer Lamellenhaltebremse undeinem dreistufigen Planetengetriebe.Um einen optimalen Lastausgleich zu gewähr-

leisten, enthält jede Planetenstufe satzweise sor-tierte Planetenräder. Die außenverzahnten Räder sind einsatzgehärtet.Das komplett wälzgelagerte Getriebe ist mit einer Öltauchschmierung ausgestattet.Eine spezielle Gleitringdichtung sorgt für den op-timalen Schmutz- und Staubschutz der Felgen-bzw. Turaslagerung.Das Getriebe ist ausschließlich zum Einsatz alsFahrgetriebe für einen fahrbaren Steinbrecher vorgesehen.

Für Schäden, die aus nicht bestimmungsgemäßem

Gebrauch entstehen, haftet L+S nicht. Das Risikoträgt in einem solchem Fall ausschließlich der An-wender.

The unit HYDROTRAC GFT 36 T3 3216 arecompromising an REXROTH axial piston-hydraulicmotor with integrated, hydraulically released multi-plate parking brake and an 3-stage planetary gear-box.To ensure an optimum balancing of loads, each

planetary stage comprises of planet gears in sets.The externally toothed wheels are case-hardened.

The gearbox runs in antifriction bearings exclusi-vely and has a splash lubrication system.

A special mechanical seal reliably protects the rim-resp. the tumbler bearing system against theingress of dirt and dust.The gearbox is exclusively intended for use as apropel drive in a rock crusher .

L+S shall not be liable for any damage arising as a

result of the gearbox being used for purposes other than originally intended. In such a case, the risk liessolely with the User.

2.3 Beschreibung der Bremse 2.3 Description of Brake

Die im Hydraulikmotor integrierte, naßlaufende,hydraulisch lüftbare Lamellenbremse ist eine Park-bremse. Sie ist durch Federkraft ständig geschlos-sen und wird durch Zufuhr von Drucköl geöffnet.

The hydraulically released, wet running, multi-platebrake, integrated in the hydraulic motor, is a par-king brake. It is normally closed by spring force andreleased when pressurized by hydraulic oil.

2.4 Lieferumfang 2.4 Scope of Supply

Zum Lieferumfang gehört: The supply scope includes:- Getriebe. - Gearbox.- REXROTH Axialkolben-Hydromotor mit hydrau-

lisch lüftbarer Lamellenhaltebremse.- REXROTH axial piston hydraulic motor with

multiple disk holding brake.- Technische Dokumentation. - Technical documentation.



Produktbeschreibung Product Description 2.

4/6171/4216/0 02-7/28

Der gesetzlich vorgeschriebene Berührungsschutzan umlaufenden Teilen gehört nicht zum Liefer-umfang.

Means of protection against accidental contact withrotating parts as prescribed by statutory provisionsdo not form part of the supply scope.

Überprüfen Sie alle Anlieferungen nach Erhalt un-

verzüglich auf Vollständigkeit. Teilen Sie Ab-weichungen und Transportschäden sofort L+S mit.

Bestätigen Sie die Mitteilung schriftlich.

Please check all equipment supplies for comple-

teness immediately upon receipt. Any deviationsand transit damage must be reported to L+S rightaway.

A written conformation of such a report is also re-quired.

2.5 Technische Daten 2.5 Technical Data

Antriebsdrehzahl max. 3800 min-1 Input speed max. 3800 rpm Antriebsdrehmoment max. 250 Nm Input torque max. 184 ft.lbsÜbersetzung 161 Transmission ratio 161

Abtriebsdrehzahl max. 23,6 min-1 Output speed max. 23,6 rpm

Abtriebsdrehmoment max. 40318 Nm Output torque max. 29735 ft.lbsBremsmoment statisch 215 Nm Static brake torque 159 ft.lbsmax. Lüftdruck Bremse 50 bar max. release pressure brake 725 psiBetriebstemperatur max. 90 oC Operating temperature max. 90 oCGewicht ca. 110 kg Weight approx. 243 lbsGetriebeölmenge ca. 3 Liter Gear lube oil volume approx. 0,8 gallSchmieröl CLP 220 Lube oil CLP 220Konservierung innen: SHELL S. 7294

SAE 30 / 50Preservation inside: SHELL S. 7294

SAE 30 / 50Konservierung außen: TECTYL 502 C Preservation outside: TECTYL 502 C

2.6 Zeichnungen und Listen 2.6 Drawings and Lists

Einbauzeichnung 1/6171/5216/1 Installation drawing 1/6171/5216/1Ersatzteilzeichnung 1/6171/1216/0 Spare parts drawing 1/6171/1216/0Teileliste 16573601 Parts list 16573601

2.7 Betriebsmittel 2.7 Operating Media

Beachten Sie die Auflistung der ausgewähltenSchmieröle im Anhang B.

The list of recommended lube oils given in Appen-dix B shall be observed.



Transport / Lagerung Handling / Storage 3.

4/6171/4216/0 03-8/28


Dieses Kapitel gibt Ihnen Hinweise auf die sichereVorbereitung und Durchführung von Transport undLagerung der Produkte von L+S.

This chapter describes how the handling and sto-ring of the products of L+S are safely prepared andcarried through.

3.2 Hinweise zu Transport undLagerung

3.2 Notes on Handling and Storing

Achten Sie beim Transport auf eineausreichende Tragkraft des Kranes.

When handling the equipment makesure the carrying capacity of the craneis adequate.

•Benutzen Sie nur zugelassene Trans-portelemente. •

Use exclusively approved handlingequipment.

•

Befestigen Sie das Getriebe sorgfältigam Kranhaken und benutzen Sie inAbhängigkeit von der Getriebegrößevorgesehene Anhängevorrichtungen.

•

Carefully attach the gearbox to thecrane hook, using the lifting pointsprovided.

Stellen Sie sicher, daß beim Anhebendes Getriebes Anbauteile durchTransportelemente nicht beschädigtwerden können.

When lifting the gearboxes make surethat the handling elements do notcause damage to attachment parts.

•Lagern Sie die Getriebe nur in trok-kenen und temperierten Räumen.

•Store the gearboxes in dry and mode-rately heated rooms only.

•Lagern Sie Getriebe nur in Einbaulage.

•Store the gearboxes only in their in-tended mounting position.

•Stellen Sie sicher, daß abgesetzte Ge-triebe ihre Lage nicht ändern können.

•Make sure that set down gearboxesrest immovably.

L+S entsorgt mitgeliefertes Verpa-ckungsmaterial, wenn dies kostenfreizurückgesandt wird.

L+S will dispose of any packing mate-rial supplied with the gearboxes whenthis is returned to the Factory free of charge.

3.3 Verpackung 3.3 Packing

Getriebe bis zur Größe 1200 x 1200 mm werdenauf einer Palette in Folie verschweißt.

Up to dimensions of 1200 x 1200 mm the gearbo-xes will be welded with foil on a pallet.

Überseetransporte erfolgen vorwiegend in ge-schlossenen, seemäßig verpackten Holzkistenbzw. in geschlossenen Containern.

For oversea transports seaworthy packed woodencases respectively closed containers are used.




4/6171/4216/0 03-9/28

3.4 Konservierung 3.4 Preservation

L+S liefert die Getriebe ohne Ölfüllung aus. The gearboxes supplied by L+S are not filled withoil.

Die Getriebe sind mit SHELL Öl S. 7294 SAE 30bzw. 50 innenkonserviert. The interior of the gearboxes has been protectedwith SHELL oil S. 7294 SAE 30 resp. 50. Außenliegende Flansche, Wellenenden und An-flanschflächen sind mit TECTYL 502 C flächen-konserviert.

The surfaces of external flanges, ends of shaftsand flange attachment faces are preserved withTECTYL 502 C.

3.4.1 Lagerung in gelüfteten Räu-men

3.4.1 Storage in Ventilated Rooms

Die Getriebe sind in gelüfteten Räumen bis zu 24Monate nach Lieferung ab unserem Werk gegen

Korrosion geschützt.

In ventilated localities the gearboxes are protectedagainst corrosion up to 24 month after delivery ex

works.

Wird die Verpackung entfernt, so ist die Außen-konservierung zu prüfen und bei Bedarf fach-gerecht zu erneuern.

If the packing material is removed the outer pre-servation must be checked and -if necessary-skillfully renewed.

3.4.2 Lagerung im Freien 3.4.2 Storage Outdoors

Bei einer Lagerung im Freien ist unbedingt sicher-zustellen, daß kein Spritzwasser o.ä. die äußereKonservierung beschädigen bzw. ins Getriebe ein-dringen kann (Getriebe abgeplant; Spritzwasser

geschützt unter Schleppdach).

If the gearboxes are stored outdoors it must bemade safe that no splash water can enter thegearbox or can do any harm to the outer preserva-tion (Gearboxes canvas covered or splash proofed

by a movable hood).

In diesen Fällen ist die Innen- und Außen-konservierung regelmäßig alle 6 Monate zu über-prüfen und evtl. zu erneuern. Unter diesen Bedin-gungen besteht Korrosionsschutz bis zu max. 24Monate nach Lieferung ab unserem Werk.

In such cases the inner and outer preservation hasto be checked every 6 months and -if necessary- tobe renewed. Under this condition the protectionagainst corrosion will last max. 24 months after delivery ex works.

3.4.3 Lagerung in klimatisiertenRäumen

3.4.3 Storage in Air-ConditionedRooms

Ein Korrosionsschutz für max. 36 Monate ist nur

möglich, wenn die Lagerung in geschlossenen,klimatisierten Lagerräumen erfolgt. Kondensationund hohe Luftfeuchtigkeit sind unbedingt auszu-schließen.

A protection against corrosion for max. 36 months

is only possible, if the storage is done in air-conditioned localities. Condensation and high at-mospheric humidity must be avoided.

Wird die Verpackung vorher entfernt, ist eine Kon-trolle der freiliegenden blanken Teile und eine evtl.Nachkonservierung mit TECTYL 502 C unerläßlich.

If the packing material will be removed all bareparts have to be checked and the preservation withTECTYL 502 C has to be renewed.




4/6171/4216/0 03-10/28

3.4.4 Lagerung von teilgeschlosse-nen Getrieben

3.4.4 Storage of part-closed Gear-boxes

Getriebe oder Getriebeöffnungen, die nur mit Öl-

papier und einem Holzdeckel oder mit einem ölbe-ständigen Kunststoffdeckel verschlossen sind,dürfen nur in geschlossenen Räumen, max. 3 Mo-nate gelagert werden.

Gearboxes or gearbox orifices that are protec-

ted/closed off only by oil paper and a wooden cover or by an oil resistant plastic cover, must exclusivelybe stored in enclosed rooms for a maximum periodof 3 months.

3.4.5 Langzeitkonservierung 3.4.5 Long-Term Preservation

Bei einer Zwischenlagerung von mehr als 36 Mo-naten bedarf es einer speziellen Nach-konservierung und die Einhaltung verschiedener

Auflagen.

In the event the gearboxes are stored for a periodexceeding 36 months, they must receive a specialpreservation treatment. Furthermore various speci-al directions have to be executed.

In solchen Fällen sind die Getriebe vor dem Ein-satz einer gründlichen Inspektion und einem Pro-belauf zu unterziehen.

In such cases the gearboxes have to undergo acomplete inspection and a new test run.

Einzelheiten hierzu erfragen Sie bitte bei unserer Service-Abteilung.

For details in this respect please contact our Servi-ce Department.



Einbau Mounting 4.

4/6171/4216/0 04-11/28


Das Kapitel beschreibt den Einbau des Fahrge-triebes in den Fahrwerksrahmen.Der Hydromotor ist am Getriebe angebaut.

This chapter describes the installation of the gear-box.The hydraulic motor has been mounted at the

gearbox housing.

Beachten Sie unbedingt die vorange-stellten Sicherheitshinweise.

The preceding safety notes must becarefully observed.

Beachten Sie die Hinweise in der Einbauzeich-nung: 1/6171/5216/1

Carefully follow the instructions given on the instal-lation drawing: 1/6171/5216/1

4.2 Handlungschritte zum Einbau 4.2 Mounting Work to be Performed

Befestigen Sie das Getriebe sicher amFahrwerksrahmen, bevor Sie die An-schlagmittel entfernen.

Secure the gearbox safely before re-moving the lifting straps or ropes.

•Vermeiden Sie beim Einbau unbedingtgrobe Schläge. •

Avoid heavy blows when mounting theequipment.

Vermeiden Sie unbedingt Axialkräfte. Make sure that axial forces are notexerted during mounting.

•Vermeiden Sie unbedingt hohe Druck-

kräfte auf das Getriebegehäuse. •

Make sure high compressive forces do

not act on the gearbox housing.

•Beachten Sie die Einbauzeichnungund die zugehörigen Daten.

•During this work observe installationdrawing as well as pertinent data.

Hängen Sie das Getriebe an den Kran. Attach the gearbox to a crane.

Heben Sie das Getriebe in den Fahrwerksrahmen. Lift the gear into the bogie frame.

Ziehen Sie die Befestigungsschrauben mit einemDrehmomentschlüssel an. Entnehmen Sie die An-zugsmomente der Rahmenzeichnung.

Tighten the screws using a torque wrench. Therelevant tightening torques shall be taken from theframe drawing.

Entfernen Sie die Transportmittel. Remove the lifting straps or ropes.

Entfernen Sie die Schutzstopfen vor dem An-schrauben der Hydraulikölleitungen.

Remove the plugs before connecting the hydraulicoil lines.

Achten Sie darauf, daß kein Schmutzoder Fremdkörper in die Hydrau-likanlage gelangen.

Make sure that no dirt or foreign bo-dies are allowed to enter the hydraulicsystem.



Einbau Mounting 4.

4/6171/4216/0 04-12/28

•Schließen Sie den Hydromotor an.

•Connect the hydraulic motor.

Beachten Sie unbedingt die Sicher-heitshinweise des Herstellers.

The preceding safety notes of cus-tomer must be carefully observed.

•Wird der Hydromotor mit Druck beauf-schlagt ist die integrierte Bremse ge-öffnet.Die Bremse dient als Parkbremse undwirkt automatisch, wenn der vorgege-bene Betriebsdruck unterschrittenwird.

•The integrated brake is open when thehydraulic motor is pressurised.

The brake serves as parking brake andis applied automatically if the presetworking pressure is fallen short of.

Überprüfen Sie noch einmal den ordnungsgemä-

ßen Sitz und die Festigkeit aller Verbindungsele-mente.

Check once again tight fit of all joining elements.



Inbetriebnahme Commissioning 5.

4/6171/4216/0 05-13/28


Dieses Kapitel beschreibt die Handlungsschrittezur Inbetriebnahme des Getriebes. Beachten Siedie entsprechenden Sicherheitshinweise.

This chapter describes the course of action to befollowed when taking the gearbox into service. Therespective notes on safety shall be duly observed.

5.2 Handlungsschritte zur Inbetriebnahme

5.2 Commissioning Activities

Betätigen Sie im Gefahrenfall NOT-AUS.

In cases of emergency actuateEMERGENCY-OFF.

•Berühren Sie keine umlaufenden Teile.

•Do not touch any rotating parts.

Bei der Befüllung dürfen keineSchmierstoffe in die Umwelt gelangen.

When filling the gearbox take care thatlubricants are not allowed to pollutethe environment.

Führen Sie die Ölwechsel nur im be-triebswarmen Zustand unmittelbar nach dem Stillstand des Getriebesdurch.Hierdurch ist sichergestellt, daß keinAbsetzen der Feststoffpartikel stattge-funden hat.

Make sure to perform oil changesimmediately after standstill with thegearbox still being warm, to avoid anysetting of solid particles.

Befüllen Sie gemäß der Schmierölangabe das Ge-

triebe mit sauberem Öl.Bei der Erstölbefüllung können Ölmenge und Öl-mengenangabe durch im Getriebe vorhandenesKonservierungsöl voneinander abweichen.

Fill the gearbox with clean oil as specified under

the heading lubrication. At first oil fill, actual oil volume and specified oilvolume may vary due to preservation oil remains inthe gearbox.

Vermeiden Sie Verunreinigungen desGetriebes.

Ensure that no dirt or other contamin-ants are allowed to enter the gearbox.

Eine Liste der von L+S zugelassenenÖle finden Sie im Anhang B.

A list of oils approved by L+S is givenin Appendix B.

Füllen Sie das Öl durch die in der Einbauzeichnunggekennzeichnete Schraube ein.

Fill in oil through the screw indicated in the installa-tion drawing.

Überprüfen Sie den Ölstand, bevor Sie das Ge-triebe anfahren.Den korrekten Ölstand erkennen Sie bei Stillstanddes Getriebes durch die Öffnung im Getriebege-häuse.

Check the oil level before starting up the gearbox.

The correct oil level can be ascertained through theopening in the gearbox housing, when the gearboxis not operating.

Die max. Betriebstemperatur beträgt 90°C. The maximum operating temperature is 90°C.



Inbetriebnahme Commissioning 5.

4/6171/4216/0 05-14/28

Überprüfen Sie nach Erreichen der Betriebstem-peratur das Getriebe auf Dichtigkeit.Diese Prüfung können Sie während des Betriebesdurchführen.

When the operating temperature has been re-ached, check the entire gearbox for tightness.This check can be performed while the gearbox isrunning.

Die folgenden Überprüfungen dürfenSie nur bei Stillstand des Getriebesdurchführen.

The following checks must only becarried out when the gearbox is at astandstill.

Überprüfen Sie nach ca. 10 Stunden Vollastbetriebsämtliche Befestigungsschrauben auf festen Sitz.

After 10 hours of full load operation check all faste-ning screws and boltings for tightness.

Überprüfen Sie den festen Sitz aller Schrauben desGetriebes.

Check whether all bolts of the gearbox are tight asrequired.

Führen Sie den ersten Ölwechsel nach ca. 150Motorbetriebsstunden durch.

The first oil change is to be made after approx. 150motor operating hours.

Weitere Ölwechsel sind entsprechend den imWartungsplan (Kapitel 7.3) angegebenen Interval-len durchzuführen.

Further oil changes are to be made at intervals asper the Maintenance Schedule given in Chapter 7.3.



Pflege/Wartung Maintenance 7.

4/6171/4216/0 07-15/28


Dieses Kapitel zeigt Wartungsschritte und die zu-gehörigen Sicherheitsmaßnahmen auf.

This chapter indicates maintenance routines andrelated safety measures.

Berühren Sie keine umlaufenden Teile. Do not touch rotating components.

•Setzen Sie zu Wartungsarbeiten dasGetriebe still. •

If you intend to perform maintenancework shut down the unit.

7.2 Handlungsschritte zu Pflegeund Wartung

7.2 Maintenance and CareActivities

Durch entsprechende Pflege und Wartung könnenSie die Lebensdauer von Maschinen und Anlagen

wesentlich verlängern.

The service life of machinery and equipment canbe considerably increased by taking appropriate

maintenance and care steps.

Führen Sie wöchentlich Sichtkontrollen durch. Ü-berprüfen Sie dabei insbesondere die Dichtigkeitdes Getriebes.

Perform visual inspections on a daily basis. In par-ticular, check the tightness of the gear.

Führen Sie regelmäßig Geräuschkontrollen durch. Check the equipment regularly for unusual noise.

Führen Sie regelmäßig Ölstandskontrollen durch(Ölstandskontrolleinrichtung, Markierungen, Öl-standskontrollschrauben).

Make oil level checks at regular intervals (oil levelmonitoring device, markers, oil level plug).

Führen Sie die Ölwechsel nur im be-

triebswarmen Zustand unmittelbar nach dem Stillstand des Getriebesdurch.Hierdurch ist sichergestellt, daß keinAbsetzen der Feststoffpartikel stattge-funden hat.

Make sure to perform oil changes

immediately after standstill with thegearbox still being warm, to avoid anysetting of solid particles.

Führen Sie nach Angaben des WartungsplanesÖlwechsel durch.

Make oil changes as prescribed in the MaintenanceSchedule.

Fangen Sie Altöl in geeigneten Behäl-tern auf und entsorgen Sie es unter

Beachtung der entsprechenden Vor-schriften.

Collect spent oil in suitable containersand dispose of the oil in line with the

respective regulations.

Alle Stundenangaben zu den Ölwech-seln beziehen sich auf Motorbetriebs-stunden.

All user specifications concerning oilchange intervals refer to motor opera-ting hours.



Pflege/Wartung Maintenance 7.

4/6171/4216/0 07-16/28

Führen Sie den ersten Ölwechsel nach ca. 150Motorbetriebsstunden durch.

Make the first oil change after approx. 150 motor operating hours.

Führen Sie weitere Ölwechsel nach jeweils 1500Motorbetriebsstunden durch, spätestens jedoch

nach 12 Monaten.

Change the oil every 1500 motor operating hoursor after 12 months wichever is earlier.

Überprüfen Sie mindestens einmal monatlich denfesten Sitz aller Schrauben.

Check the tightness of all screws and bolts at leastonce a month.

7.3 Wartungsplan Getriebe 7.3 Maintenance ScheduleGearbox

Nach 150

Motorbetriebsstun-

den

- erster Ölwechsel After 150

motor operating

hours

- First oil change

Wöchentlich: -

-

-

Sichtkontrolle

Geräuschkontrolle

Ölstandskontrolle

Weekly: -

-

-

Inspect visually

Check for unusual noise

Check oil level

Monatlich: - Schraubenverbindungen

kontrollieren*

Monthly: - Check the tightness of all

screws and bolts*

Halbjährlich: - Ölqualitätskontrolle Semi-annually: - Check oil quality

Jährlich:

(spätestens jedoch

nach jeweils 1500

Motorbetriebsstun-

den)

- Ölwechsel Annually:

(or after 1500 motor

operating hours

whichever is earlier)

- Change oil

* Beachten Sie unbedingt die in der Ein-bauzeichnung angegebenen Anzugs-drehmomente.

* Observe the tightening torques indicated inthe installation drawing.

7.4 Wartungsplan Bremse 7.4 Maintenance Schedule Brake

Die Bremse ist wartungsfrei. The brake is maintenance-free.

Bei Funktionsstörungen, thermischer Überlastung und bei sämtlichen Repa-raturarbeiten an der Lamellenhal-tebremse müssen immer:

- Lamellen- Federn- Dichtelemente

ausgetauscht werden.

In case of malfunctions, excessivethermal stress and all repair works onthe multi-plate parking brake, makesure to always replace:

- disks- springs- seals.



Ausbau Dismantling 8.

4/6171/4216/0 08-17/28


Dieses Kapitel beschreibt den Ausbau des Ge-triebes aus dem Fahrwerksrahmen. Beachten Sieunbedingt die Sicherheitshinweise. Der Einbau ist

im Kapitel 4 beschrieben.

In this chapter the procedure of dismantling thegearbox is described. It is mandatory to observethe safety notes. A gearbox mounting description is

given in Chapter 4.

Die Anlage ist nicht in Betrieb. The plant has been taken out of servi-ce.

•Sichern Sie die Anlage zuverlässiggegen unbeabsichtigtes Einschalten. •

Make sure reliable measures are takento prevent the plant from being activa-ted inadvertently.

•Stellen Sie sicher, daß die Tragkraftdes Kranes zur Aufnahme des Getrie-bes ausreicht.

•Make sure the crane carrying capacityis adequate for gearbox lifting.

Sichern Sie das Getriebe gegen un-kontrollierte Bewegungen, z.B. Verrut-schen.

Safeguard the gearbox against un-controlled movements, e.g. sliding.

•Vermeiden Sie beim Ausbau grobeSchläge. •

Avoid heavy blows when dismantlingthe equipment.

•Vermeiden Sie Axialkräfte.

•Make sure that axial forces are notexerted.

8.2 Handlungsschritte zum Ausbau 8.2 Dismantling Work to bePerformed

Lassen Sie das Öl ab.Verwenden Sie dabei geeignete Auffanggefäße.

Drain the oil from the gearbox.For this purpose use suitable containers.

Fangen Sie evtl. auslaufendes Öl ingeeigneten Gefäßen auf.

Any oil spillage must be collected insuitable containers.

Achten Sie beim Transport auf eineausreichende Tragkraft des Kranes.

For gearbox handling make sure thatthe carrying capacity of the crane issufficient.

•Benutzen Sie nur zugelassene Trans-portelemente.

•Use approved handling elements only.

•Befestigen Sie das Getriebe sorgfältigam Kranhaken. •

Attach the gearbox carefully to thelifting hook.

Straffen Sie die Anschlagmittel, ohne jedoch dasGetriebe anzuheben.

Tighten the lifting straps or ropes without lifting upthe gearbox.



Ausbau Dismantling 8.

4/6171/4216/0 08-18/28

Stellen Sie sicher, daß das Getriebenicht verkantet.

Make sure that the gearbox is not can-ted.

Lösen Sie die Versorgung des Hydromotors. Disconnect the hydraulic motor from the supplysystem.

Verschließen Sie die Hydraulikleitungen mit Stop-fen.

Close off the hydraulic lines by means of plugs.

Achten Sie darauf, daß kein Schmutzoder Fremdkörper in die Hydrau-likanlage gelangen.

Make sure that no dirt or foreign bo-dies are allowed to enter the hydraulicsystem.

Lösen Sie die Befestigungsschrauben des Getrie-beflansches.

Remove the fastening screws of the gearbox flan-ge.

Das Getriebe hängt nun am Kran. The gearbox is now suspended from the crane.

Führen Sie das Getriebe vorsichtig aus dem Fahr-werksrahmen und legen Sie es ab.

Move the gearbox carefully out of the bogie frameand lay it down.



Ersatzteilbestellung Spare Parts Ordering 10.

4/6171/4216/0 10-19/28

Die im Anhang „E“ aufgeführten Posi-tionen der Teileliste können zum Teilnur als Ersatzteil-Kits wie z.B.:

• Dichtsatz• Bremsen Reparatur-Satz• Planetensteg komplettbezogen werden.Fragen Sie die entsprechenden Kitsüber unseren Verkauf-Ersatzteile an.

Some of the parts list items listed inAppendix „E“ can only be purchasedas spare parts kits, e.g.:

• sealing kit• brake repair kit• planet carrier complete.Please address your enquiries for therequired kits to our spare parts salesdepartment.

Das Anschriftenverzeichnis finden Sieim Anhang A.

For list of addresses, see Appendix A.

Ersatzteile müssen den von L+S festgelegten tech-nischen Anforderungen genügen. Dies ist bei Ori-ginal L+S Ersatzteilen immer gewährleistet.

Spare parts must satisfy the technical requirementsstipulated by L+S. Original spares supplied by L+Salways meet these demands.

Geben Sie Ersatzteilbestellungen schriftlich auf. Indringenden Fällen können Sie auch telefonischoder über Telefax bestellen, wenn Sie dies umge-hend schriftlich bestätigen.

Please submit your spare parts orders in writing. Inurgent cases, the order can also be placed viaphone or fax; however, such orders must be con-firmed in writing without delay.

Richten Sie Ersatzteilbestellungen an die in Ihrer Nähe niedergelassene Außenstelle von L+S oder direkt an das Stammhaus (siehe angefügtes Ver-zeichnis der Anschriften).

Please send your spare parts order to an agency of L+S located in your area or send it directly to our main offices (see attached list of addresses).

Geben Sie bei einer Bestellung folgende Daten an: Spares orders should specify the following details:

- die Fabrikatenummer - the product number - die Auftragsnummer

Sie finden diese Nummern auf dem Typen-schild, das an jedem Produkt angebracht ist.

- the order number These numbers are given on the nameplateattached to each product.

- die Zeichnungsnummer - the drawing number - die Positionsnummer - the item number - die genaue Benennung - the exact designation- die Teil-Nr.

Sie finden diese Nummern in der Teileliste.- the part-no.

These numbers are included in the parts list.

- die Stückzahl der gewünschten Ersatzteile - the required spare parts quantity- die gewünschte Versandart (z.B. Expressgut,

Frachtgut, Luftfracht, Kurierdienst, usw.).- the type of shipment desired (e.g. by express,

freight, air freight, messenger etc.).

Bei Ersatzbestellung des komplettenHydraulikverstellmotors sind die auf der Einbauzeichnung aufgeführtenEinstelldaten mit anzugeben.

Please advise control data specifiedon the installation drawing when sub-mitting a spare order for the completehydraulic variable displacement mo-tor.



Anhang Appendix

4/6171/4216/0 00-20/28



Anschriften Addresses A.

4/6171/4216/0 00-21/28


1. Anschriften RDE 80 103 1. Addresses RDE 80 103



Industrial

Hydraulics

Electric Drives

and Controls

Linear Motion and

Assembly Technology Pneumatics

Service

Automation

Mobile

Hydraulics

Getriebetechnik

AnschriftenProduktbereich Getriebetechnik

AddressesProduct Unit Gear Technology

DenmarkEstoniaFinlandNorway

Sweden

AustriaCroatiaCyprusCzech Rep.GreeceHungaryItalyPolandSlovakiaSloveniaTurkey

FranceGreat BritainIrelandPortugalSpain

BelgiumGermanyLiechtensteinLuxemburgNetherlandsSwitzerland

BahrainBruneiIsraelOmanSaudi-ArabiaU.A.E.

Yemen

IndiaIndonesiaIranPakistan

ChinaHong KongJapanMalaysiaPhilippinesSingaporeSouth KoreaTaiwan

Australia

New Zealand

Canada

USA

Mexico

ArgentinaBrazilChileUruguayVenezuela

AlgeriaAngolaAzoresEgyptGhana

KongoMadeiraMaroccoMauretaniaMauritiusSouth AfricaTunisiaZaire

BulgariaLatviaLithuaniaMoldaviaRussiaRomaniaUkraineWhite RussiaYugoslavia

RDE 80103/02.04Ersetzt: 05.03



Deutschland / Germany

REGION NORDBosch Rexroth AG

Regionalzentrum NordWalsroder Straße 9330853 LANGENHAGENTel. (0511) 726657-0Fax (0511) 726657-94E-Mail haraldbehrens@

boschrexroth.de

REGION MITTEBosch Rexroth AGRegionalzentrum MittePostfach 11 4864526 Mörfelden-WalldorfWaldecker Straße 1364546 Mörfelden-WalldorfTel. (06105) 702-468Fax (06105) 702-455E-Mail josef.meissner@

boschrexroth.de

REGION WESTBosch Rexroth AGRegionalzentrum West

Postfach 150540835 RatingenBorsigstraße 1540880 RATINGENTel. (02102) 409-300

(02102) 409-301(02102) 409-302

Fax (02102) 409-414E-Mail volker.vogelauer@

boschrexroth.de

REGION SÜDWESTBosch Rexroth AG

Regionalzentrum SüdwestSiemensstraße 170736 FELLBACHTel. (0711) 51046-480Fax (0711) 51046-485E-Mail joachim.goerner@

boschrexroth.de

REGION SÜDBosch Rexroth AGRegionalzentrum SüdLandshuter Allee 8 - 1080637 MÜNCHENTel. (089) 12714-0

(089) 12714-190Fax (089) 12714-191E-Mail matthias.goebel@

boschrexroth.de

Bosch Rexroth AGRegionalzentrum SüdHauptmarkt 290403 NÜRNBERGTel. (0911) 24406-22

Fax (0911) 223563E-Mail jan.jasek@

boschrexroth.de

REGION OSTBosch Rexroth AGRegionalzentrum OstWalter-Köhn-Straße 4 d04356 LEIPZIGTel. (0341) 2561-0

(0341) 2561-250

(0341) 2561-251Fax (0341) 2561-259E-Mail thomas.duwe@

boschrexroth.de

DEUTSCHLANDKupplungen

Dr.-Ing. Bender & WippernPostfach 70213622021 HAMBURGLitzowstieg 6

22041 HAMBURGTel. (040) 6525053Fax (040) 6524049E-Mail [email protected]

DEUTSCHLANDGERMANY

Bosch Rexroth AGMobile HydraulicsProduktbereich Getriebetechnik

Postfach 1860D-58408 WITTENMannesmannstraßeD-58455 WITTENTel. +49/2302/877-0Fax +49/2302/88148E-Mail:[email protected]:

www.boschrexroth.com/getriebeVideo-Konferenz-Anlage:

+49/2302/877-261

Vertriebsleitung

Getriebe, Kupplungen,

Sales Manager

Gears, Couplings/Clutches,

Spare Parts

Tel. +49/2302/877-233Fax +49/2302/877-201

Vertrieb GetriebeGear Drive Sales

Tel. +49/2302/877-244Fax +49/2302/877-404

Vertrieb Kupplungen

Sales Couplings/Clutches

Tel. +49/2302/877-245Fax +49/2302/877-400

Vertriebsleitung

Energietechnik

Sales ManagerPower Technology

Tel. +49/2302/877-380Fax +49/2302/877-409

Vertrieb Energietechnik

Sales Power Technology

Tel. +49/2302/877-235Fax +49/2302/877-335

Vertrieb Ersatzteile

Sales Spare Parts

Tel. +49/2302/877-170Fax +49/2302/877-300

Technischer Kundendienst

After-Sales Service

Tel. +49/2302/877-180Tel. +49/2302/877-183Hotline +49/173/2569948Fax +49/2302/877-409E-Mail [email protected]

Marketing / Marketing

Tel. +49/2302/877-382Fax +49/2302/877-201

CHINA

Bosch Rexroth (Beijing)

Hydraulic Co., Ltd.

Xisanqi Deshengmen WaiHaidian DistrictBEIJING 100096

Tel. +86/10/82915261Fax +86/10/82923926

Vertrieb/Service / Sales/Service

[email protected]

USABosch Rexroth Corp.

551 Telser RoadLAKE ZURICH, Illinois 60047Tel. +1/847/550-9800Fax +1/847/550-6300

Vertrieb / [email protected]

Service / Service

[email protected]

RDE 80103/02.04Mobile HydraulicsBosch Rexroth AG2/6 Anschriften/Addresses

Addresses Standorte / Locations



Addresses International

ALGERIAAddress see FRANCE

ANGOLAAddress see SOUTH AFRICA

ARGENTINABosch Rexroth S.A.I.C.Rosario 2302B1606DLD CARAPACHAYPcia. Buenos AiresTel. (0054) 11/4756-0140

(0054) 11/4756-0240Fax (0054) 11/4756-0136

(0054) 11/4721-9153E-Mail ptafler@

boschrexroth.com.ar

AUSTRALIABosch Rexroth Pty. Ltd.P.O.Box 6207BLACKTOWN, N.S.W. 21483 Valediction RoadKINGS PARK / SYDNEY,N.S.W. 2148Tel. (0061) 2/9831-7788Fax (0061) 2/9831-5553

(0061) 2/9831-8188E-Mail warren.roots@

boschrexroth.com.au

AUSTRIABosch Rexroth GmbHStachegasse 131120 WIENTel. (0043) 1/9852540-19Fax (0043) 1/9852540-45E-Mail arpad.nemeth@

boschrexroth.at

AZORESAddress see Portugal

BAHRAINWhole Product Range

without Coupl./ClutchesBahrain HydraulicCompany W.L.L.P.O.Box 50SALMABADTel. (00973) 78/6977Fax (00973) 78/6979E-Mail bahhydco@batelco.

com.bh

Couplings/ClutchesAddress see GREECE

BELGIUMWhole Product Rangewithout Coupl./Clutches

Bosch Rexroth N.V./S.A.Henri Genessestraat 11070 BRUSSELTel. (0032) 2/5823180Fax (0032) 2/5824310E-Mail didier.gillet@

boschrexroth.be

Couplings/Clutches

Address see NETHERLANDS(Bruinhof B.V.)

BOTSWANAAddress see SOUTH AFRICA

BRAZILBosch Rexroth Ltda.Divisao RedutoresAvenida Tégula Nr. 888Unidades 13/14Jd. Ponte Alta12952-440 ATIBAIA - SPTel. (0055) 11/4414-5760

(0055) 11/4414-5600Fax (0055) 11/4414-5713

(0055) 11/4414-5649E-Mail erich.nold@

boschrexroth.com.br

BRUNEIAddress see SINGAPORE

BULGARIABosch Rexroth Sp.z.o.o.

Cherni Vrah Str. 1/3, Et. 31421 SOFIATel. (00359) 2/963-2504

(00359) 2/963-1064Fax (00359) 2/963-1364E-Mail bogdan.wassilev@

boschrexroth.bg

CANADABosch Rexroth Canada Corp.490 Prince Charles Drive SouthWELLAND/Ontario L3B 5X7

Tel. (001) 905/735-0510Fax (001) 905/735-5646E-Mail steve.apps@

boschrexroth.ca

CHILEMaestranza Diesel Ltda.MD OleohidraulicaSanta Elena 1433SANTIAGOTel. (0056) 2/550-2000

(0056) 2/550-2031

Fax (0056) 2/554-3059E-Mail [email protected]

CHINABosch Rexroth (Beijing)Hydraulic Co., Ltd.Xisanqi Deshengmen WaiHaidian DistrictBEIJING 100096Tel. +86/10/82915261Fax +86/10/82923926E-Mail j.ma@

boschrexroth.com.cn

CROATIAUN-TRA d.o.o.1. Ravnice 2a10000 ZAGREB/HRVATSKATel. (00385) 1/2329-266Fax (00385) 1/2329-267E-Mail [email protected]

CYPRUSAddress see GREECE

CZECH REPUBLICBosch Rexroth spol.s.r.o.

Büro OstravaHlubinska 2070200 OstravaTel. (00420) 59/7488149Fax (00420) 59/7488104E-Mail milan.obert@

boschrexroth.cz

DENMARK Bosch Rexroth A/SPostboks 501

Gungevej 12650 HVIDOVRETel. (0045) 36/774466Fax (0045) 36/770866E-Mail [email protected]

EGYPTYasser Fahmy Hydraulic Eng.66 A Saudi Building KobbaP.O.Box 6550SAWAH 11813, CAIROTel. (0020) 2/4520192

Fax (0020) 2/4530638E-Mail Yasserf@yf-hydraulic.

com.eg

ESTONIAWhole Product Rangewithout Coupl./ClutchesAddress see FINLAND(Bosch Rexroth)

FINLAND

Whole Product Rangewithout Coupl./ClutchesBosch Rexroth OyLumpeenkatu 233900 TAMPERETel. (00358) 3/2496-221

(00358) 3/2496-219Fax (00358) 3/2496-200E-Mail kari.mettala@

boschrexroth.fi

Numm ern in ( ) nur Durchwahl aus DNum bers in ( ) direct dial from Germany only

Mobile Hydraulics Bosch Rexroth AG 3/6RDE 80103/02.04 Anschriften/Addresses



Addresses International

FINLANDCouplings/Clutches

KMS Engineering OyLumikintie 3 D 15100820 HELSINKITel. (00358) 0/727986-90Fax (00358) 0/727986-91E-Mail [email protected]

FRANCEWhole Product Rangewithout Coupl./ClutchesBosch Rexroth S.A.B.P. 101

91, bd. Irene Joliot Curie69634 VENISSIEUX CEDEXTel. (0033) 4/7878-5252

(0033) 4/7878-5267Fax (0033) 4/7878-5231E-Mail jerome.pernet@

boschrexroth.fr

Couplings/ClutchesCOMPAS S.a.r.l.Coordination + MarketingPartenaires + Services136 Av. Joseph Kessel Bat. F.78960 VOISINS LE BRETONNEUXTel. (0033) 1/30644040Fax (0033) 1/30571710E-Mail [email protected]

GHANAAddress see SOUTH AFRICA

GREAT BRITAINWhole Product Range

without Coupl./ClutchesBosch Rexroth Ltd.Cromwell RoadST. NEOTS / HuntingdonCambs. PE19 2ESTel. (0044) 1/480-223200

(0044) 1/480-223214Fax (0044) 1/480-219052E-Mail bernd.steinert@

boschrexroth.co.uk

GREAT BRITAINCouplings/Clutches

Marine and Industrial ProductsGeoffrey HewittTwistwood, Hurst RoadWalton-on-the-HillTADWORTH, Surrey KT20 5BNTel. (0044) 1/737-814125Fax (0044) 1/737-814042E-Mail mip.schottel@

btopenworld.com

GREECEWhole Product Range

without Coupl./ClutchesBosch Rexroth S.A.Sp. Patsi 6211855 ATHENTel. (0030) 210/3411600Fax (0030) 210/3422759E-Mail d.borsis@

boschrexroth.gr

Couplings/ClutchesT. E. N. Ltd.Technical Agencies53 - 55 Akti Miaouli18536 PIRÄUSTel. (0030) 210/4293220

(0030) 210/4293221(0030) 210/4613724

Fax (0030) 210/4293222(0030) 210/4628912

E-Mail [email protected]

HONG KONGBosch Rexroth (China) Ltd.19 Cheung Shun Street1st FloorCheung Sha WanKOWLOONHONG KONGTel. (00852) 2/2625100Fax (00852) 2/7867033E-Mail fw.lau@boschrexroth.

com.hk

HUNGARYBosch Rexroth Kft.

Geschäftsbereich Hydraulikund AntriebstechnikAngol utca 341149 BUDAPESTTel. (0036) 1/422-3200Fax (0036) 1/422-3201E-Mail gabor.szoke@

boschrexroth.hu

INDIAWhole Product Rangewithout Coupl./Clutches

Bosch Rexroth (India) Ltd.Vatva, Taluka DascroiAHMEDABAD 382445Tel. (0091) 79/583-3360Fax (0091) 79/583-2715E-Mail wagner.w@

boschrexroth.co.in

Couplings/ClutchesEquip Engineers India Pvt. Ltd.120, Maker Chambers V221 Nariman PointMUMBAI 400021 - BombayTel. (0091) 22/22043635

(0091) 22/23670952Fax (0091) 22/22845910E-Mail [email protected]

INDONESIABosch RexrothBuilding No. 202Cilandak Commercial EstateJL Cilandak KKO12560 JAKARTATel. (0062) 21/7891169Fax (0062) 21/7891170E-Mail [email protected]

IRANNarvan ArraNo. 3, 6th FloorBorje Sayeh, Vally Asr AvenuePostal Code 19677TEHERANTel. (0098) 21/2058691

(0098) 21/2043410Fax (0098) 21/2058473E-Mail masoudreza.assi@

narvanarra.com

IRELANDAddress see GREAT BRITAIN

ISRAELBallas Engineering Co. Ltd.Fluid Power Engineering4, Hamanor St.Postbox 35050TEL AVIV 66558Tel. (00972) 3/518-4943Fax (00972) 3/518-4983E-Mail [email protected]

ITALYBosch Rexroth S.p.A.Via G. di Vittorio, 120063 CERNUSCO s/NAVIGLIO (Milano)Tel. (0039) 02/92365-1

(0039) 02/92365-313Fax (0039) 02/92365-245

(0039) 02/92365-532E-Mail tommaso.senesi@

boschrexroth.it

JAPANWhole Product RangeUchida Hydraulics Co. Ltd.5-1, Higashi-NakanukiTsuchiura-shiIBARAKI-KEN, 300-8588Tel. (0081) 298/318151Fax (0081) 298/330854E-Mail [email protected]

KONGOAddress see SOUTH AFRICA

LATVIAAddress see LITHUANIA

LIECHTENSTEINAddress see SWITZERLAND

LITHUANIAUzdaroji Akcine Bendrove"LINTERA"J. Ralio 7 - 75000 JONAVATel. (00370) 19/61161


Numm ern in ( ) nur Durchwahl aus DNum bers in ( ) direct dial from Germany only

Mobile Hydraulics Bosch Rexroth AG 4/6RDE 80103/02.04 Anschriften/Addresses



Addresses International Numm ern in ( ) nur Durchwahl aus DNum bers in ( ) direct dial from Germany only

LUXEMBURGAddress see BELGIUM

MADEIRAAddress see PORTUGAL

MALAYSIABosch Rexroth Sdn. Bhd.No. 11, Jalan Astaka U8/82Seksyen U840150 SHAH ALAMSELANGORTel. (0060) 3/78448000

Fax (0060) 3/78454800E-Mail [email protected]

MAROCCOAddress see FRANCE

MAURETANIAAddress see FRANCE

MAURITIUSHarel Mallac & Co. Ltd.P.O.Box 3618, Edith Cavell StreetPORT LOUISTel. (00230) 2084802

(00230) 2080861(00230) 2085434

Fax (00230) 2081674E-Mail [email protected]

MEXICOBosch RexrothMexico S.A. de C.V.Apto. Postal 75-204 +Apto. Postal 75-889Neptuno Nr. 72Unidad Industrial VallejoDeleg. Gustavo A. Madero07700 MEXICO D.F.Tel. (0052) 55/57541711

(0052) 55/57541906Fax (0052) 55/57545073E-Mail ventas@

boschrexroth.com.mx

MOLDAVIAAddress see UKRAINE

MOZAMBIQUEAddress see SOUTH AFRICA

NAMIBIAAddress see SOUTH AFRICA

NETHERLANDSWhole Product Rangewithout Coupl./ClutchesBosch Rexroth B.V.P.O.Box 32/BL5280 AA BOXTELKruisbroeksestraat 1

5281 RV BOXTELTel. (0031) 411/651-951(0031) 411/651-366

Fax (0031) 411/651-483E-Mail henk.veulings@

boschrexroth.nl

Couplings/ClutchesFlender Bruinhof MarinePostbus 96073007 AP ROTTERDAMBoterdiep 373077 AW ROTTERDAM

Tel. (0031) 10/497-0808Fax (0031) 10/482-4350E-Mail [email protected]

NEW ZEALANDBosch Rexroth Ltd.P.O.Box 58-22145 Greenmount DriveEAST TAMAKI - AUCKLANDTel. (0064) 9/2744172Fax (0064) 9/2746477E-Mail robin@

boschrexroth.co.nz

NORWAYBosch Rexroth A/SP.O.Box 30071402 SkiBerghagan 11405 LANGHUSTel. (0047) 64/864100Fax (0047) 64/869062E-Mail arild.strand@

boschrexroth.no

OMANAddress see GREECE

PAKISTANQadbros Engineering (Pvt.) Ltd.9 - A, Link Ravi RoadBadami BaghLAHORE 54000Tel. (0092) 42/7723387

(0092) 42/7723388(0092) 42/7723389


PHILIPPINESAddress see SINGAPORE

POLANDBosch Rexroth sp.z.o.o.ul. Staszica 105-800 PRUSZKÓWTel. (0048) 22/7381800Fax (0048) 22/7588735E-Mail krzysztof.michalak@

boschrexroth.pl

PORTUGALAddress see SPAIN(Goimendi S.A.)

ROMANIABosch Rexroth Sp.z.o.o.Progress Fluid BukarestStr. Drobeta nr. 4 - 10, ap. 14bl. 70, sc. 1, ap. 1, cp. 39 / F1370258 BUKAREST 2Tel. (0040) 21/210-4824

(0040) 21/210-4825Fax (0040) 21/210-2952E-Mail mirela.gurau@

boschrexroth.ro

RUSSIABosch RexrothWjatskaja ul. 27/15127015 MOSKAUTel. (007) 095/785-7478

(007) 095/785-7479Fax (007) 095/785-7477


SAUDI-ARABIAAddress see GREECE

SINGAPOREBosch Rexroth Pte. Ltd.19, Kian Teck WaySINGAPORE 628740Tel . (0065) 62/656033Fax (0065) 62/650813E-Mail clifton.leong@

boschrexroth.com.sg

SLOVAKIA

TBH Technik S.R.O.Dlhá 8801009 ZILINATel . (00421) 41/5079711Fax (00421) 41/5079726E-Mail [email protected]

SLOVENIALA & Co. d.o.o.Limbuska 422000 MARIBORTel . (00386) 2/1092660


SOUTH AFRICAHYTEC of Southern AfricaPty. Ltd.113 Koornhof Street1610 MEADOWDALE,EdenvaleTel . (0027) 11/573-5400Fax (0027) 11/573-5401E-Mail [email protected]

SOUTH KOREABosch Rexroth Korea Ltd.1515-14 Dadae-DongSaha-KuPUSAN 604050Tel . (0082) 51/260-0731Fax (0082) 51/266-8131E-Mail dongreal.lee@

boschrexroth.co.kr




Addresses International Numm ern in ( ) nur Durchwahl aus DNum bers in ( ) direct dial from Germany only

SPAINWhole Product Range

without Coupl./ClutchesGoimendi S.A.Parque Empresarial ZuatzuApartado de correos 511220018 SAN SEBASTIANTel. (0034) 943/318405


Couplings/ClutchesExpoimsaC/Las Navas, 14 Nave E.

Polig. Rio de Janeiro28110 ALGETE / MADRIDTel. (0034) 91/6291388Fax (0034) 91/6291385E-Mail expoimsa@

expoimsa.com

SWEDENBosch Rexroth ABVaruvägen 7, Älvsjö12581 STOCKHOLMTel. (0046) 8/7279200

(0046) 8/7279390Fax (0046) 8/866053

(0046) 8/997515E-Mail richard.kollig

@boschrexroth.se

SWITZERLANDBosch Rexroth Schweiz AGHemrietstraße 28863 BUTTIKONTel. (0041) 55/4646111

(0041) 55/4646217

Fax (0041) 55/4646222E-Mail roman.furrer@

boschrexroth.ch

TAIWANBosch Rexroth Uchida Co. Ltd.No. 1, Tsu Chiang StreetTu-Cheng Industrial EstateTAIPEI HSIENTel. (00886) 22/268-1346

(00886) 22/268-1347Fax (00886) 22/268-5388


TUNISIAAddress see FRANCE

TURKEYBosch Rexroth A.S.Sögütlüçesme Mah.Fevzi Çakmak Cad. No. 334295 SEFAKÖY/IstanbulTel. (0090) 212/41334-00

(0090) 212/41334-40Fax (0090) 212/41334-17E-Mail tayfun@

boschrexroth.com.tr

UKRAINEBosch Rexroth Sp.z.o.o.Kiev OfficeVasilkivskaja Str. 1, off. 209252040 KYJIVTel. (00380) 44/4902680Fax (00380) 44/4902681E-Mail ukraine@

boschrexroth.com.ua

Bosch Rexroth Sp.z.o.o.Sumy Office

Chrevonogvardijska 13, off. 21140030 SUMYTel. (00380) 542/210733Fax (00380) 542/210833E-Mail sumy@

boschrexroth.com.ua

UNITED ARABIANEMIRATESAddress see GREECE

URUGUAYAddress see ARGENTINA

USAWhole Product Rangewithout Coupl./ClutchesBosch Rexroth Corp.551 Telser RoadLAKE ZURICH, Illinois 60047Tel. (001) 847/550-9800Fax (001) 847/550-6300E-Mail dan.lavelle@

boschrexroth-us.com

USACouplings/Clutches

Marine Propulsion Inc.1505 Corbin Ave.HAMMOND,Louisiana 70403-3809Tel. (001) 985/542-5344Fax (001) 985/542-5347E-Mail [email protected]

VENEZUELABosch Rexroth S.A.Av. Ppal. DU 321Centro Industrial Caroni

Galpón No. 3Ciudad Guayana, Edo. BolivarPUERTO ORDAZTel. (0058) 86/940554

(0058) 86/940379Fax (0058) 86/940618E-Mail pedro.solorzano@

boschrexroth.com.vz

WHITE RUSSIABosch Rexroth Sp.z.o.o.ul. Janki Kupaly 25 - 201/1

220030 MINSK (Belarus)Tel. (00375) 17/206-6045Fax (00375) 17/210-5790E-Mail marian.schamrey@

boschrexroth.by

YEMENAddress see GREECE

YUGOSLAVIABosch RexrothBul. Mihajla Pupina 10Z/IVPP 1411070 NUOVI BEOGRADTel. (00381) 11/134936

(00381) 11/140400Fax (00381) 11/3116693E-Mail dejan.sijakovic@

boschrexroth.co.yu

ZAIREAddress see SOUTH AFRICA

ZAMBIAAddress see SOUTH AFRICA

ZIMBABWEAddress see SOUTH AFRICA




Schmieröle Lube Oils B.

4/6171/4216/0 00-22/28


1. SchmierölempfehlungÜbersicht LSN 935 1400-DE

1. Recommendation of Lube OilsOverview LSN 935 1400-EN

2. SchmierölempfehlungCLP 220 LSN 935 1410-7-DE

2. Recommendation of Lube OilsCLP 220 LSN 935 1410-7-EN



Werknorm

Getriebeschmierung

SchmierölempfehlungÜbersicht

LSN 935 1400-DE2003-05-02

Lohmann + Stolterfoht GmbH erstellt: NOR, Moormann Mobile Hydraulics

Postfach 18 60 • D-58408 Witten geprüft: EVG,

Telefon: (02302) 8 77-167 • Telefax: (02302) 8 77-478 erstel lt in: MS Word 97

Daten- oder Maßangaben dienen nur der unverbindlichen Information über grundsätzliche Produktmerkmale ! Seite 1/5

1 Allgemeines

Die in der LSN 935 1410, ...1420, ...1430 aufgeführten Öle sind eine Auswahl der von L+S empfohlenenSchmieröle für Stirnrad,- Kegelrad- und Planetengetriebe. Es sind CLP-Industriegetriebeöle, Kfz-Getriebeöleund HD-Motorenöle, die die von L+S zwingend vorgeschriebenen Anforderungen erfüllen. Die Empfehlungenbasieren auf einschlägigen Produktinformationen sowie einer zum Teil jahrelangen Erfahrung.

Die Auswahl der Ölsorte, (Mineralöl, Synthetiköl, Kfz-Getriebeöl oder Motorenöl) wird primär durch den Anwender vorgenommen. Hierbei spielt unter anderem die Logistik eine wesentliche Rolle. Eine qualitativeBewertung zwischen diesen Ölen kann hieraus nicht abgeleitet werden.

Alle aufgeführten Öle sind mit dem bei L+S eingesetzten Einkomponentenlack (kein Nitrolack) alsInnenanstrich sowie den standardmäßigen Elastomeren aus NBR und FPM (einsatztemperaturabhängig)verträglich. Bei den mineralölbasischen Getriebeölen sollte eine Ölbaddauertemperatur von +85°C nichtüberschritten werden. Kurzfristig sind Spitzentemperaturen von +100°C zulässig, wobei diese dieGebrauchsdauer des Schmiermittelserheblich herabsetzen können. Höhere Dauertemperaturen führen zueiner erheblichen Herabsetzung der Betriebsviskosität und zum frühzeitigen Altern des Schmierstoffes. DasÜberschreiten einer zulässigen Grenztemperatur bewirkt eine chemischen Zersetzung der Ölmoleküle, diesich durch Geruch, Ablagerungen und Rückstände im System bemerkbar machen. Sind höhereTemperaturen zu erwarten oder zeigt die Praxis höhere Dauertemperaturen, so sind synthetische Öle auf Basis von Polyalphaolefinen (POA) vorzusehen, da diese einen erheblich flacheren Temperatur-Viskositätsverlauf aufweisen.

Achtung!Eine, für den Anwender bindende Vorgabe ist die auf dem Typenschild und /

oder in der Bedienungsanleitung angegebene Viskosität sowie Sonderhinweise.

Bei Verwendung einer anderen Viskosität oder eines anderen als hier empfohlenen Getriebeöles übernimmt der Betreiber die Verantwortung für dietechnische Eignung des Schmierstoffes. Die Benutzung von Schmierstoffen, dienicht den nachfolgend spezifizierten Qualitätsanforderungen entsprechen, kannunter Umständen die L+S-Gewährleistungsbedingungen außer Kraft setzen. Eswird ausdrücklich darauf hingewiesen, daß jeder Ölhersteller beziehungsweiseÖllieferant für die Qualität seines Produktes verantwortlich ist, zum BeispielVerunreinigungen oder Chargenunterschiede.

Hinweis: Bei der L+S Verzahnungsberechnung nach DIN 3990 mit zusätzlicher Grauflecken-

berechnung nach FVA-Nr. 54 wird die erforderliche Schadenkraftstufe (SKS) für dasÖlausgewiesen. Sollte hier eine SKS > 9 errechnet werden, muss in der Bedienungsanleitung ein Hinweis auf eine eingeschränkte Ölauswahl mit der Grauflecken-Tragfähigkeitsklasse „hoch“ erscheinen!

Hinweis: Die oberen und unteren Gebrauchstemperaturen einzelner Getriebeöle können zu dentechnischen Kennwerten „Flammpunkt und Pourpoint“ stark abweichen. Diese sowieweitere Daten und Eigenschaften der Getriebeöle sind stets den technischenDatenblättern der Ölhersteller zu entnehmen.

Nach Angaben der Schmierstoffhersteller sind die aufgeführten Produkte weltweit unter dem selben

Handelsnamen verfügbar und weisen vergleichbare technologische Eigenschaften auf.

Ersatz für: 2000-11-27



Seite 2/5Getriebeschmierung, Schmierölempfehlung LSN 935 1400-DE : 2003-05-02

1.1 Synthetische Öle auf Basis von Polyalphaolefinen PAO

Synthetische Öle haben einen höheren Viskositätsindex (VI) als Mineralöle und vermindern somit dieViskositätsabhängigkeit von der Temperatur. Die aufgelisteten synthetischen Öle auf Basis vonPolyalphaolefinen (Spalte LS 3) sind zwar in jedem Verhältnis mit Mineralölen mischbar, um jedochEintrübungen und Additivausfällungen zu vermeiden, sollten nicht mehr als 5 bis 10% Restöl im Gehäuseverbleiben.

1.2 Synthetische Öle auf Basis von Polyglykolen PG (zur Zeit nicht zulässig für L+S-Getriebe)

Hinweis: Synthetische Öle auf Basis von Polyglykolen sind aufgrund eventueller Unverträglichkeitenmit dem Anstrich, den Standarddichtungen und den eingesetzten Ölschauglasmaterialienohne vorherige Rücksprache mit dem Getriebehersteller nicht zugelassen!

Achtung!Eine Vermischung von Mineralölen mit Polyglykolen muss unter allenUmständen vermieden werden!

1.3 Biologisch schnell abbaubare Öle auf Basis synthetischer Ester HEES

Unter bestimmten Umständen können auch, hier nicht aufgeführte, biologisch schnell abbaubare Schmieröle(synthetische Ester HEES) eingesetzt werden. Die Ergebnisse diverser Forschungsvorhaben, zum BeispielFKM-Nr. 051950, das VDMA-Arbeitsblatt 24 569 sowie auch einschlägige Erfahrungen vonDichtungsherstellern und Ölfirmen zeigen bei Einsatz von biologisch schnell abbaubaren Ölen möglicheUnverträglichkeiten mit bestimmten Dichtungsmaterialien und Anstrichstoffen sowie Reibwertminderungenbei Lamellen. Für den Einsatz dieser Öle werden unter Umständen Sondermaterialien (nicht standardmäßigeL+S-Materialien) notwendig, die Verträglichkeitsuntersuchungen erfordern.

Hinweis: Vor Einsatz eines biologisch schnell abbaubaren Öles, (Erstbefüllung oder Umstellung) ist

Rücksprache mit dem Getriebehersteller zu nehmen!

2 LSN 935 1410 „Schmierölempfehlung CLP ISO VG 22 – 680“

In dieser Werknorm sind Mineralöle aufgeführt, die nach DIN 51517 T.3 die Mindestanforderungen für CLP-Öle erfüllen. Sie enthalten Wirkstoffe zur Erhöhung des Korrosionsschutzes und der Alterungsbeständigkeitsowie zur Herabsetzung des Verschleißes im Mischreibungsgebiet (Hochdruckzusätze, sogenannte Extrem-Pressure Additives). Die Schadenkraftstufe im FZG-Normaltest A/8,3/90 nach DIN 51354 T.2 beträgtmindestens 12. Im FZG-Graufleckentest gemäß FVA-Nr. 54/I-IV erreichen diese Öle eineGraufleckentragfähigkeit „hoch“ (SKS 10) oder aber mindestens „mittel“ (SKS 9).

Andere Öle, wie zum Beispiel Hydrauliköle HLP oder synthetische Öle HC, die die CLP-Bedingungenerfüllen oder übertreffen, sind hier integriert.

Die LSN 935 1410 ist nach ISO Viskositätsklassen abgestuft. Die niedrig viskosen Öle werden fastausschließlich für den Einsatz in Lamellenbremsen benötigt. Sie sind vom Lamellenhersteller auf Verträglichkeit und Reibwertverhalten getestet.

Nicht alle in dieser Werknorm aufgeführten Öle eignen sich für jeden Anwendungsfall. Aus diesem Grundwurden die L+S Gruppen LS 1 und LS 3 festgelegt.

Hinweis: Die erforderliche L+S-Gruppe ist von der Konstruktion vorzugeben! Sie ist in der Bedienungsanleitung und / oder auf dem Typschild genannt. Bei der Auswahl eines Öles ist

darauf zu achten, daß alle von der Konstruktion angegebenen L+S Gruppen erfüllt werden.Erfüllt ein Öl darüber hinaus noch weitere L+S Gruppen, so kann auch dieses Öl eingesetztwerden.




LS 1: Verschärfter FZG-Test

Diese Öle haben auch beim verschärften FZG-Test A / 16,6 / 90 (doppelte Umfangsgeschwindigkeit) dieSchadenkraftstufe 12 erreicht.

L+S Bezeichnung für ein Schmieröl mit verschärftem FZG-Test der Viskosität ISO VG 100 CLP 100 LS 1

LS 3: Vollsynthetische Öle (Polyalphaolefine PAO)

Bei der Umstellung von Mineralöl auf Polyalphaolefinöl können 5 bis zu 10% des Mineralöles nach dem Ablassen im Gehäuse verbleiben. Eine Vermischung beider Ölsorten in dieser Größenordnung kannbedenkenlos vorgenommen werden.

Hinweis: Bei einer Vermischung mit Resten des von L+S eingesetzten Konservierungsöles neigenPAO jedoch zur Schaumbildung. Daher ist bei der Erstbefüllung eines konserviertenGetriebes ein Spüllauf durchzuführen oder ein Mineralöl als Einlauföl zu verwenden.

L+S Bezeichnung für ein synthetisches Schmieröl der Viskosität ISO VG 100 CLP 100 LS 3

3 LSN 935 1420 „Schmierölempfehlung Motoren-Schmieröle HD SAE 30, 40, 50“

Bei den aufgeführten Motorenölen handelt es sich um Einbereichsmotorenöle nach DIN 51511 (unlegiertoder nur mild legiert), die den Reibwert in Lamellenkupplungen (Sinterbelag oder organischer Belag) nichtherabsetzen.Die FZG-Laststufe (DIN 51354 T2) beträgt mindestens 11 und in der Graufleckentragfähigkeit erreichendiese Öle eine Schadenkraftstufe min. 9.

L+S Bezeichnung für ein Motorenöl der Viskosität SAE 40 HD SAE 40

4 LSN 935 1430 „Schmierölempfehlung Kfz-Getriebeöl HYP SAE

In dieser Werknorm sind Ein- und Mehrbereichsöle für Kfz-Getriebe nach DIN 51512 aufgeführt und der API-Klassifikation GL 4 und / oder GL 5 zugeteilt. Sie sind unter anderem unter dem Gesichtspunkt einer definierten Ist-Viskosität (ISO-Viskosität) ausgewählt, da die bei Kfz-Getriebeölen übliche SAE-Viskosität inmehrere ISO-Viskositätsklassen fallen kann (siehe nachfolgendes Schaubild). Für diese Öle liegen nochkeine Grauflecken-Testergebnisse vor, weshalb sie ausschließlich für L+S-Mobilgetriebe zur Anwendungkommen dürfen.

Hinweis: Für die Auswahl einer HYP-Ölsorte ist die Viskositätsangabe auf dem Typenschild und/oder in der Bedienungsanleitung mit der Ölspezifikation der Bedienungsanleitung abzugleichen.

L+S Bezeichnung für ein Kfz-Getriebeöl der Viskosität SAE 80W-90 HYP SAE 80W-90

? S c h u t z v e r m e r k D I N

3 4 b e a c h t e n ? - ? C o p y r i g h t r e s e r v e d




5 Vergleich der Viskositäts-Einteilung verschiedener Öle

6 Ölwechsel / Ölauffüllung

Die Lebensdauer und Betriebssicherheit eines Getriebes wird wesentlich beeinflusst von dem Reinheitsgraddes verwendeten Öles. Für den ersten Ölwechsel nach der Inbetriebnahme des Getriebes sowie die

weiteren Ölwechsel sind die Vorschriften in den Bedienungsanleitungen zu beachten. Die beim Ölwechsel imGetriebe verbleibenden Restmengen sollten so gering wie möglich gehalten werden.

Hinweis: Beim Nachfüllen oder Mischen von Ölen sollten unbedingt die Qualitäts- undViskositätsanforderungen beachtet werden. Ein Vermischen von Ölen unterschiedlicher Hersteller bei gleicher Viskosität kann zu Qualitätsminderungen führen. Hier sollte vorher der Schmierstofflieferant auf mögliche Verträglichkeitsprobleme angesprochen werden.

Achtung!Die aufgeführten Schmierstoffe dürfen auf keinen Fall mit anderen Stoffenvermischt werden. Nach dem Spülen sowie Reinigen mit Petroleum oder anderen Reinigungsmitteln muss das Getriebe vollkommen rückstandsfrei vonden zuvor genannten Mitteln sein. Vor Inbetriebnahme ist ein zusätzlicher Spüllauf durchzuführen.




7 Verwendete Abkürzungen und Kurzzeichen

AGMA American Gear Manufacturers Association

API American Petroleum Institute

DIN Deutsches Institut für Normung

EP Extrem Pressure

FKM Forschungskuratorium Maschinenbau e.V.

FVA Forschungsvereinigung Antriebstechnik

FZG Forschungsstelle für Zahnräder und Getriebebau, TU München

GfT Gesellschaft für Tribologie

GL Gear Lubricant

HD Heavy Duty

HYP Hypoidöl

SAE Society of Automotive Engineers

VDMA Verband Deutscher Maschinen- und Anlagenbau e.V.

VG Viskositätsgrad (Viskosität bei 40°C in mm²/s)

VI Viskositätsindex

8 Literaturangaben, mitgeltende DIN-Normen

DIN 51502 Kurzbezeichnung der Schmierstoffe

DIN 51511 SAE-Viskositätsklassen für Motoren-Schmieröle

DIN 51512 SAE-Viskositätsklassen für Kraftfahrzeuggetriebe

DIN 51517 T3 Schmieröle CLP „Mindestanforderungen“

DIN 51354 T2 FZG-Zahnrad-Verspannungs-Prüfmaschine „Prüfverfahren“

FVA-Nr.54/I-IV Graufleckentragfähigkeit

9 Änderungen gegenüber Ausg. 2000-11-27

Hinweis auf Lamellenverträglichkeit LS 2 entnommen.



Werknorm

Getriebeschmierung

SchmierölempfehlungViskositätsklasse ISO VG 220 bei 40°C mm² / s (cSt) DIN 51519

LSN 935 1410-7-DE2003-05-02

Lohmann + Stolterfoht GmbH erstellt: NOR, Moormann Mobile Hydraulics

Postfach 18 60 • D-58408 Witten geprüft: EVG,

Telefon: (02302) 8 77-167 • Telefax: (02302) 8 77-478 erstel lt in: MS Word 97

Daten- oder Maßangaben dienen nur der unverbindlichen Information über grundsätzliche Produktmerkmale ! Seite 1/2

Kennz. n. L+S Gruppe 3)Ölfirma ÖlsorteDIN 51502

Pourp.1)

in °CGFT 2)

LS1 LS3 ADDINOL ECO GEAR 220 M CLP -15 hoch x

ECO GEAR 220 S CLP HC -45 hoch x x Agip BLASIA 220 CLP -20 x Aral Degol BG 220 Plus CLP -24 hoch x

Degol PAS 220 CLP HC -50 hoch x xBP Energol GR-XF 220 CLP -21 hoch x

Enersyn HTX 220 CLP HC -36 mittel x xCastrol Alpha SP 220 CLP -9

Alphasyn T 220 CLP HC -45 xChevron Gear Compound EP 220 CLP -21 mittel x

Synth. Gear Lub. Tegra 220 CLP HC -51 xDEA Falcon CLP 220 CLP -18 mittel xIntor HCLP 220 CLP HC -36 hoch x x

ESSO SPARTAN EP 220 CLP -21 hoch xSPARTAN SYNTHETIC EP 220 CLP HC -45 mittel x

ELF REDUCTELF SP 220 CLP -18 mittelREDUCTELF SYNTHESE 220 CLP HC -45 mittel x

FINA GIRAN L 220 CLP -18Fuchs RENOLIN CLP 220 PLUS CLP -24 hoch

RENOLIN UNISYN CLP 220 CLP HC -51 hoch xKlüber Klüberoil GEM 1-220 CLP -10Kuwait Q8 Goya NT 220 CLP -12 hoch

Q8 El Greco 220 CLP HC -24 hoch x

Mobil Mobilgear XMP 220 CLP -24 hoch xMobilgear SHC XMP 220 CLP HC -45 hoch x x

MOTOREX GEAR COMPOUND PLUS CLP -21 hochGEAR SINTEC 220 CLP HC -51 hoch x

OPTIMOL OPTIGEAR BM 220 CLP -15 hochOPTIGEAR SYNTHETIC A 220 CLP HC -36 hoch x

Shell Omala Oil F 220 CLP -21 hoch xOmala Oil HD 220 CLP HC -48 hoch x x

Texaco MEROPA 220 CLP -21 hoch xPINNACLE EP 220 CLP HC -48 mittel x x

TOTAL CARTER EP 220 CLP -12 xCARTER EP/HT 220 CLP HC -39 x

Tribol TRIBOL 1100 / 220 CLP -25 hochTRIBOL 1510 / 220 CLP HC -42 hoch x

1) Der Pourpoint ist nicht gleichzusetzen mit der niedrigsten Temperatur des Einsatzbereiches!2) Graufleckentragfähigkeit GFT gem. FVA Nr. 54 / I – IV:3) Fehlt bei der Angabe des zu verwendenden Getriebeschmieröles der Hinweis auf eine bestimmte

L+S Gruppe, so kann jedes der hier aufgeführten Öle eingesetzt werden.

LS1: Verschärfter FZG-Test:Diese Öle haben auch im verschärften FZG-Test A/16,6/90 die Schadenskraftstufe = 12.

LS3: Vollsynthetische Öle ( Polyalphaolefine POA )Diese Öle sind mit Mineralölen mischbar.PAO-Öle neigen bei einer Vermischung mit Resten von Konservierungsöl zur Schaumbildung!Es ist ein Spüllauf mit geeignetem Spülöl durchzuführen oder ein Mineralöl als Einlauföl zu verwenden.

Ersatz für: 2000-11-27


3 4 b e a c h t e n ? - ? C o p y r i g h t r e s e r v e d ?





Seite 2/2Getriebeschmierung, Schmierölempfehlung LSN 935 1410-7-DE : 2003-05-02

Hinweis: Bestandteil dieser Schmierölempfehlung ist die allg. Übersicht LSN 935 1400-DE

Hinweis: Ölwechsel nach Betriebsanleitung !

Änderungen gegenüber Ausg. 2000-11-27 Hinweis auf Lamellenverträglichkeit (Gruppe LS 2) entnommen



Shop Standard Specification

Gearbox Lubrication

Recommendation on Lube OilsOverview

LSN 935 1400-EN2003-05-02

Lohmann + Stolterfoht GmbH Prepared: NOR, Moormann Mobile Hydraulics

Post Box 18 60 • D-58408 Witten Checked: EVG,

Phone: (02302) 8 77-167 • Fax: (02302) 8 77-478 Text MS Word 97

! Any data or dimensions referred to are exclusively meant to provide nonbinding info on basic product Pa e 1/5

1 General

The oils listed in LSN 935 1410, ...1420, ...1430 are a selection of lube oils recommended by L+S for use incylindrical, bevel and planetary gearboxes. CLP industrial gear oils, motorcar transmission oils and HD motor oils meet the requirements specified by L+S as mandatory. These recommendations are based onapplicable product information and many years of experience in this field.

The lube oil brands (mineral oil, synthetic oil, or motor oil) are primarily selected by the Operator. In thiscontext, logistics play an important role. The recommendations are not meant to provide quality standards for the individual lube oils.

All oils listed are compatible with one-pot paint material (not nitrocellulose lacquer) L+S uses for inside paintcoatings as well as the standard elastomers of NBR and FPM (depending on application temperature). Asregards mineral-oil based gearbox lube oils an oil bath temperature of +85°C should not be exceeded. For short operating periods peak temperatures of +100°C are admissible, but it should be noted that these mayconsiderably reduce the useful life of the lubricant. Continuously prevailing higher temperatures will reducethe operating viscosity significantly and lead to premature ageing of the lubricant. If an admissibletemperature limit is exceeded the oil molecules chemically decompose and cause smell, deposits andresidues in the system. If higher temperatures are to be expected or higher continuous temperatures areexperienced in operating practice, synthetic oils based on polyalphaolefins (PAO) are to be used that featurea considerably flatter temperature-viscosity characteristic curve.

Attention!A mandatory requirement specified on the nameplate and/or in the operatingmanual are the viscosity indication and the special notes.

If the viscosity requirements are not met or a gearbox lube oil other than listedis used the responsibility for technical suitability of the lubricant lies solelywith the Operator. The use of lubricants not meeting the quality standardsdescribed below may result in L+S‘ warranty obligations becoming forfeited. Itis expressly pointed out that any lubricant manufacturer or supplier isresponsible for the quality of its product, eg with respect to impurities or differences between individual batches.

Note: L+S‘ gearteeth calculation according to DIN 3990 (including micro-pittingdetermination to FVA No. 54) shows the required breakdown-load stage (SKS) for theoil. If a breakdown-load stage SKS of > 9 is determined here, a note must be included

in the operating manual saying that the lubricant selection is restricted to brandsfeaturing a „high“ micro-pitting (frosting) load carrying property.

Note: The maximum and minimum application temperatures of individual gear oils maydeviate significantly with regard to the technical parameters of „flashpoint and pour point“. Relevant data and properties of the gear oils must always be taken from thetechnical data sheets issued by the oil producers.

As pointed out by the lubricant producers, the products listed are available under the same tradename on aworldwide basis and have comparable technological characteristics.

Replaces: 2000-11-27



Pa e 2/5Gearbox Lubrication, Recommendation on Lube Oils LSN 935 1400-EN : 2003-05-02

1.1 Synthetic oils on polyalphaolefin basis - PAO

Synthetic oils have a higher viscosity index (VI) than mineral oils and are thus able to reduce the influence of temperature on viscosity. Although the polyalphaolefin-based synthetic oils listed (Column LS 3) can bemixed with mineral oil at any desired ratio, care should nevertheless be taken to limit the amount of residualmineral oil in the gearbox casing to 5 to 10% to avoid clouding and additive precipitation.

1.2 Synthetic oils on polyglycols basis - PG (presently not permissible for L+S gearboxes)

Note: In view of the fact that synthetic oils on polyglycol basis may be incompatible with thepaint coat, standard seals and oil sightglass materials employed, these lubricantsmust not be used without prior consent obtained from the gearbox maker!

Attention! Mixing polyglycols with mineral oils is strictly prohibited!

1.3 Quickly biodegradable oils on synthetic-ester basis - HEES

Under certain conditions, quickly biodegradable lubricant oils (synthetic ester – HEES) not listed here mayalso be employed. Results of various research projects, for example FKM No. 051950, VDMA Data Sheet24 569 as well as applicable experience gained by seal manufacturers and oil companies indicate thatquickly biodegradable oils may be incompatible with certain seal and gasketing materials and paint materialsor may reduce the friction characteristics of multiple plates. If such oils are to be used, special materials(not L+S standard materials) may be needed that have to be tested to ensure they are compatible with theoil.

Note: Before using quickly biodegradable oil (first filling or brand change) consult with thegearbox manufacturer!

2 LSN 935 1410 „Lube Oil Recommendation CLP ISO VG 22 – 680“

The mineral oils listed in this shop standard specification meet the minimum requirements given inDIN 51517 T.3 for CLP oils. They contain constituents that improve corrosion protection and ageingresistance as well as reduce wear in the mixed friction range (extreme pressure additives). When subjectedto normal FZG testing A/8,3/90 to DIN 51354 T.2 a breakdown-load stage of min. 12 is achieved. Whensubjected to a FZG micro-pitting test as per FVA No. 54/I-IV these oils reach the micro-pitting (frosting)load-carrying property category „high“ (SKS 10) or at least „medium“ (SKS 9).

Other oil brands meeting or exceeding CLP requirements are included such as hydraulic oils HLP or

synthetic oils HC.

LSN Specification 935 1410 describes ISO viscosity categories. Low-viscosity oils are almost exclusivelyneeded for use with multiplate brakes. They have been tested by the multiple-plate manufacturer for compatibility and friction behavior.

Not all of the lubricants listed in this shop standard are suited for any conceivable application. For thatreason, L+S Groups LS 1, LS 3 were established.

Note: The Design Department hast to specify the required L+S Group! This group will be indicatedin the operating manual and/or on the nameplate. When selecting an oil brand care must betaken to ensure that all the requirements of a given L+S Group are met. In the event an oil

meets requirements of additional L+S Groups this lubricant can be used as well.




LS 1: Aggrevated FZG test:

Even when FZG tested under aggravated conditions (test A / 16,6 / 90 – double peripheral speed) these oilshave reached the properties of breakdown-load stage 12.

L+S identification for a lube oil passed aggravated FZG testing of viscosity ISO VG 100 CLP 100 LS 1

LS 3: Fully synthetic oils (polyalphaolefins PAO)

When replacing mineral oil by polyalphaolefin-based oil 5 to 10% of the mineral oil are allowed to remain inthe casing after draining. Mixing both lube oil types is perfectly allowable if this mixing ratio is observed.

Note: However, PAO oils tend to foaming when mixed with residues of preservation oil asused by L+S. Therefore, prior to initial filling of a preserved gearbox the unit musteither be flushed out or a mineral oil is to be used as running-in oil.

L+S identification for a synthetic lube oil of viscosity ISO VG 100 CLP 100 LS 3

3 LSN 935 1420 „Recommendation for Motor Lube Oils HD SAE 30, 40, 50“

The motor oils listed are unigrade oils to DIN 51511 (non-doped or just moderately additive-treated) that willnot lower the friction value in multiplate couplings (sintered linings or organic lining). The FZG load stage(DIN 51354 T2) is min. 11 and the micro-pitting (frosting) load-carrying property of these oils correspond tobreakdown-load stage of min. 9.

L+S identification for motor oil of viscosity SAE 40 HD SAE 40

4 LSN 935 1430 „Recommendation for Motorcar Transmission Oil HYP SAE

This shop standard specification lists unigrade and multigrade lube oils for motorcar transmission units toDIN 51512 and assigns them to API classification GL 4 and/or GL 5. The selection of these lube oils isbased, inter alia, on a defined ‚actual‘ viscosity (ISO viscosity) because the SAE viscosity parameter commonly applied to motorcar transmission units may appear in several ISO viscosity categories (seefollowing diagram). It is to be noted that micro-pitting (frosting) test results are not yet available for these oilsso that they must exclusively be used for L+S mobile gears.

Note: When selecting a HYP lubricant brand the viscosity specification on the nameplateand/or in the operating manual is to be compared and adapted to the lubricantspecification included in the operating manual.

L+S identification for a motorcar transmission oil of viscosity SAE 80W-90 HYP SAE 80W-90




5 Viscosity Classification Comparison of Various Lubricants

6 Oil Change / Topping up Oil

The life and operational safety of a gear unit is greatly dependent on the purity of the oil employed for lubrication. For the first oil change after commissioning of the gearbox as well as further oil changes theinstructions given in the relevant operating manuals are to be followed. The oil volume remaining in thegearbox should be kept to a minimum.

Note: When topping up oil or if oils are to be mixed the quality and viscosity requirementshave to be carefully observed. Mixing lubricants of different makers may bring downthe quality standard even if the viscosity properties coincide. In such a case thelubricant supplier should be consulted in advance to check if there are compatibilityproblems.

Attention!The lubricants listed must never be mixed with other substances.Flushing/purging media or petroleum or other agents used for cleaning the

gearbox have to be thoroughly removed without residues left. The unit mustagain be flushed out before it is commissioned.






7 Abbreviations and Symbols Used

AGMA American Gear Manufacturers Association

API American Petroleum Institute

DIN Deutsches Institut für Normung

EP Extreme pressure

FKM Forschungskuratorium Maschinenbau e.V.

FVA Forschungsvereinigung Antriebstechnik

FZG Forschungsstelle für Zahnräder und Getriebebau, TU München

GfT Gesellschaft für Tribologie

GL Gear lubricantHD Heavy duty

HYP Hypoid oil

SAE Society of Automotive Engineers

VDMA Verband Deutscher Maschinen- und Anlagenbau e.V.

VG Degree of viscosity (viscosity at 40°C in mm²/s)

VI Viscosity index

8 References, Co-applicable DIN Standards

DIN 51502 Abbreviation used for the lubricants

DIN 51511 SAE- viscosity categories for motor lube oils

DIN 51512 SAE- viscosity categories for motorcar transmission lube oils

DIN 51517 T3 Lube oils „minimum requirements“

DIN 51354 T2 FZG- gear test rig „method“

FVA-Nr.54/I-IV Micro-pitting (frosting) load-carrying property category

9 Changes versus issue 2000-11-27

Notes on multiplate oil compatibility have been omitted.



Shop Standard Specification

Gearbox Lubrication

Recommendation of Lube OilsViscosity Class ISO VG 220 at 40°C mm² / s (cSt) DIN 51519

LSN 935 1410-7-EN2003-05-02

Lohmann + Stolterfoht GmbH Prepared: NOR, Moormann Mobile Hydraulics

Post Box 18 60 • D-58408 Witten Checked: EVG,

Phone: (02302) 8 77-167 • Fax: (02302) 8 77-478 Text MS Word 97

Any data or dimensions referred to are exclusively meant to provide nonbinding info on basic product Pa e 1/2

Identific. L+S Group 3)Supplier Oil BrandDIN 51502

Pourp 1)

in °CGFT 2)

LS1 LS3 ADDINOL ECO GEAR 220 M CLP -15 high x

ECO GEAR 220 S CLP HC -45 high x x Agip BLASIA 220 CLP -20 x Aral Degol BG 220 Plus CLP -24 high x

Degol PAS 220 CLP HC -50 high x xBP Energol GR-XF 220 CLP -21 high x

Enersyn HTX 220 CLP HC -36 medium x xCastrol Alpha SP 220 CLP -9

Alphasyn T 220 CLP HC -45 xChevron Gear Compound EP 220 CLP -21 medium x

Synth. Gear Lub. Tegra 220 CLP HC -51 xDEA Falcon CLP 220 CLP -18 medium xIntor HCLP 220 CLP HC -36 high x x

ESSO SPARTAN EP 220 CLP -21 high xSPARTAN SYNTHETIC EP 220 CLP HC -45 medium x

ELF REDUCTELF SP 220 CLP -18 mediumREDUCTELF SYNTHESE 220 CLP HC -45 medium x

FINA GIRAN L 220 CLP -18Fuchs RENOLIN CLP 220 PLUS CLP -24 high

RENOLIN UNISYN CLP 220 CLP HC -51 high xKlüber Klüberoil GEM 1-220 CLP -10Kuwait Q8 Goya NT 220 CLP -12 high

Q8 El Greco 220 CLP HC -24 high x

Mobil Mobilgear XMP 220 CLP -24 high xMobilgear SHC XMP 220 CLP HC -45 high x x

MOTOREX GEAR COMPOUND PLUS CLP -21 highGEAR SINTEC 220 CLP HC -51 high x

OPTIMOL OPTIGEAR BM 220 CLP -15 highOPTIGEAR SYNTHETIC A 220 CLP HC -36 high x

Shell Omala Oil F 220 CLP -21 high xOmala Oil HD 220 CLP HC -48 high x x

Texaco MEROPA 220 CLP -21 high xPINNACLE EP 220 CLP HC -48 medium x x

TOTAL CARTER EP 220 CLP -12 xCARTER EP/HT 220 CLP HC -39 x

Tribol TRIBOL 1100 / 220 CLP -25 highTRIBOL 1510 / 220 CLP HC -42 high x

1) The pour point is not to be confused with the lowest application range temperature!2) Micro-pitting (frosting) load-carrying property GFT as per FVA-Nr. 54 / I – IV.3) If a gearbox lube oil specified for use lacks an indication of a certain L+S group, any of the lube oils listed here can be

used.

LS1: Aggravated FZG test:Even when FZG tested (A/16,6/90) under aggravated conditions these oils reach the properties of breakdown-load stage = 12.

Replaces: 2000-11-27


3 4 b e a c h t e n ? - ? C o p y r i g h t





Pa e 2/2Gearbox Lubrication, Recommendation of Lube Oils LSN 935 1410-7-EN : 2003-05-02

LS3: Fully synthetic oils (polyalphaolefins PAO)These oils can be mixed with mineral oils.PAO oils tend to foaming when mixed with residues of preservation oil!The unit must either be flushed out using a suitable purge oil or a mineral oil must be used as running-in oil.

Note: Part this recommendation on lube oils is the generally overview LSN 935 1400-EN

Note: Change oil as prescribed in the operating manual!

Changes versus issue 2000-11-27

Notes on multiplate oil compatibility have been omitted.



Anbauteile Attachment Parts C.

4/6171/4216/0 00-23/28


1. SicherheitsbestimmungenRDE 90301-01 08.92

1. Safety regulationsRDE 90301-01 08.92

2. Ersatzteilliste für A10VT 45 HZ/10W300-NN31B010R902085457

2. Spare part list for A10VT 45 HZ/10W300-NN31B010R902085457



IC500 / IC600INSTRUCTION MANUAL



IC500 / IC600 Instruction Manual

Version 2.5 2/75

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.




Version 2.5 3/75

TABLE OF CONTENTS

1 PRECAUTIONS .................................................. ............................................................ ............................... 5

1.1 HANDLING I NFORMATION.......................................................... ........................................................... ........ 5

1.1.1 Storage................................................................................................................................................5

1.1.2 Transport............................................................................................................................................51.1.3 Function Keys................................................................ ............................................................ ......... 5

1.2 WELDING OF THE U NIT .................................................... ........................................................... .................. 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 IC500 / IC600SYSTEM ..................................................... ........................................................... .................. 7

2.2 R UN MODE .................................................. ........................................................... ...................................... 8

2.3 ADMINISTRATIONMODE.................................................. ........................................................... .................. 8

2.4 SERVICE MODE ...................................................... ........................................................... ............................ 8

3 DISPLAY WINDOWS ........................................................... ................................................................ ........9

3.1 STRUCTURE AND ORDER OF THE DISPLAY WINDOWS ....................................................... ............................ 9

3.2 GENERAL I NFORMATION.................................................. ........................................................... ................ 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 STARTING THE PROCESS WITH MANUAL CONTROL (HYDRAULIC CRUSHER DRIVE) ................................. 27

14.2 STOPPING THE PROCESS WITH MANUAL CONTROL .................................................... .............................. 27

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

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

16 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




Version 2.5 4/75

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

17 DIAGNOSTICS ................................................. ....................................................... .................................... 44

17.1 TRACK DRIVE DIAGNOSTICS........................................................... ....................................................... 45

17.2 PUSH BUTTON TEST .................................................... ........................................................... ................ 46

18 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 Parameter explanations 47

2 Engine diagnostics codes SAE J1939 50

3 Input/Output list 58




Version 2.5 5/75

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 electricalequipment.

1.3 Battery Charging

1.3.1 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.




Version 2.5 6/75

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.




Version 2.5 7/75

2 General

2.1 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




Version 2.5 8/75

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.




Version 2.5 9/75

3 Display Windows

3.1 Structure and Order of the Display Windows

Figure 3.1.1 Structure of display windows




Version 2.5 10/75

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 Main window

1 Unit information

1.1 Feeder information

1.2 Crusher information

1.3 Engine information

1.4 Hydraulics information

2 Help

3 Process options

3.1 Manual control

3.1.1 Tracks movement

4 Parameters: general, feeder, crusher, tracks, engine and hydraulics, update, Hub,

language, supervisor access, contrast adjustment, time and units

5 Diagnostics / Troubleshooting5.1 Track drive, control test

5.2 Control keys and push button test

5.3 Log files

5.3.1 Alarm log

5.3.2 Diesel diagnostic trouble codes

5.3.3 Temperature history log

5.3.4 Parameter log

5.3.5 Factory settings

5.4 Module versions

5.5 Module input/output status

5.6 Device control module, XM1 input/output status5.7 Device control module, XM2 input/output status

5.8 Device control module, XM3 input/output status

5.9 Engine control module XM1 input/output status



5.12 Hydraulic control module XM1 input/output status






Version 2.5 11/75

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.

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).

F1 = Unit

information

F2 =

Help

F3 =

Processoptions

F4 =

Settings

F5 = Diagnostics/

troubleshooting




Version 2.5 12/75

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.




Version 2.5 13/75

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 isopposite 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 Emergency stop 6 Process ON

2 Lubrication unit 7 Key switch

3 Radio key 8 Signal horn

4 Water pump 9 Process OFF

5 Display 10 Work light




Version 2.5 14/75

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 Feeder control % and control mode (M = manual, A = automatic)2 Crusher speed (rpm)

3 Crusher pressure bar/psi

4 Engine running speed (rpm)

5 Engine load %

6 Material capacity according to the belt scale (optional)

7 Radio control / Drive box symbol

8 Material level detector symbol visible when beam is blocked

9 Fuel amount

10 Window number

11 Time

12 Unit information (=F1)

13 Help (=F2)

14 Process options (=F3)

15 Settings (=F4)

16 Diagnostics (=F5)

17 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 hasstarted the message field informs you when the engine is ready for starting.




Version 2.5 15/75

Figure 6.1.2 Main window with unit type: LT200HP (and LTX00HP)

Explanations:

1 Lifting conveyor feeder control % and control mode (M = manual, A = automatic)

2 Lifting conveyor speed %

3 Feed rate (Requested by the crusher cavity level * crusher speed, * crusher pressure)

4 Crusher load kW

5 Crusher setting mm / ‘’.

6 Device pump pressure

7 Radio control / Drive box symbol

8 Cavity level symbol when high level

9 Fuel amount

10 Window number

11 Time

12 Unit information (=F1)

13 Help (=F2)

14 Process options (=F3)

15 Settings (=F4)

16 Diagnostics (=F5)17 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)




Version 2.5 16/75

• 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




Version 2.5 17/75

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.




Version 2.5 18/75

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 Symbol of the window

2 Feeder data (to the window 1.1)

3 a) Jaw crusher data (to the window

1.2)

b) Impact crusher data (to thewindow 1.2)

c) Cone crusher data (to the

window 1.2)

4 Engine data (to the window 1.3)

5 Hydraulic data (to the window 1.4)

6 Time counters (to the window 1.5 )

7 Back (to the previous window) (F1)

8 Help (F2)

9 Enter (F3)

10 Backwards (F4)11 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.




Version 2.5 19/75

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 Feeder speed ( LC-feeder)

Symbol of the running status:

= Stop

= Running

= Pause

1c Lifting conveyor control voltage

2 Manual/automatic operation

3 Manual stop for feeder (start not enabled)4 Feeder speed decrease/increase

5 Feeder valve control %

5c -Lifting conveyor speed in %

6 Control voltage

7 Crusher speed

8a)

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)

9 Crusher pressure

9c Crusher power kW

10 Hydraulic oil temperature

11 Feed rate % (generated by the IC600 )

12 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.




Version 2.5 20/75

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 Crusher speed

2 Number of material level alarms in a

selected period of time

3 Crusher operating hours

4 Clamping pressure / Return rod cylinder

pressure5 Setting sensor

6 Crusher pressure

7 Control current of the jaw crusher pump

8 Status of the service platform control buttons + / - (setting)

9 Status of the service platform control buttons 0 / 1 (setting direction)

10 Control current of the impact crusher pump

11 Control current of the impact crusher adjust motor




Version 2.5 21/75

Figure 9.1.1b Cone crusher information

1 Crusher speed

12 Clamping pressure ( 1 = ok , 0 = crusher start / feed prevented)13 Cooler symbol visible when cooler running

14 Release pressure ( 1 = ok, 0 = crusher start / feed prevented)

15 Lubrication pump running status:

Pump speed with hydraulically driven lubrication pump

0 or 1 with electrically driven lubrication pump

16 –Lubrication tank oil temperature C / F. Symbol is blinking when heater is on.

17 Return oil temperature C/ F

18 Feed state:

19 Feed rate %

20 Crusher power kW

21 Material level in crushing chamber %22 Crusher setting

23 Counter shaft pressure 0 ( off ) 1 ( on )

24 Main conveyor running state

25 Crusher running state

26 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.






Version 2.5 22/75

10 Engine

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

obtain the engine information window.

Figure 10.1.1 Engine information

1 Engine coolant temperature

2 Engine load

3 Engine oil pressure

4 Engine operating hours

5 Fuel consumption6 System voltage

7 Engine speed, required

8 Engine speed, actual

9 Engine coolant level % (0 = no coolant, 1 = coolant)

10 Engine intake air temperature

11 Engine intake air restricted (Filter condition indicator)

12 Cooler fan control current

These are the actual engine values.



1

2

3

4

5

6

7

8

9

10

11

12




Version 2.5 23/75

11 Hydraulics

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

the hydraulics information window.

Figure 11.1.1 Hydraulics information

1 Hydraulic oil temperature (circuit # 1)

2 Hydraulic oil temperature (optional circuit # 2)

3 Device pump pressure (pump # 1)

4 Crusher pump pressure

5 Hydraulic oil filter (0 = OK/ 1 = not OK)

6 Hydraulic oil level (1 = OK/ 0 = not OK)

7 Device pump pressure ( pump # 2)

8 Lifting conveyor rpm

9 Main conveyor rpm

10 Screen discharge conveyor speed

Actual hydraulics information.



1

2

3

4

5

6

7

8

9

10




Version 2.5 24/75

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 Tracks driving active hours

2 Process operating hours

3 Feeder operating hours

4a)

Impact crusher operating hours b)

Jaw crusher operating hoursc) Cone crusher operating hours

These are actual operating hours.

NOTE: The time counters can not be adjusted.





Version 2.5 25/75

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 Magnetic separator off/on

2 Side conveyor off/on

3 Screen rotation (counter-clockwise /

clockwise)

4 Hydraulic output on continuously (1)

5 Hydraulic output off continuously

6(6a) Hydraulic output on during the process

6b Hydraulic output active when

lubrication oil heating required

7 Manual control of the devices

7c1 Manual control of the devices

7c2 Manual control of the cone crusher functions

8 Selection of impact crusher target speed 1, 2 or 3 (2)

8c Selection of cone crusher target speed 1,2 or 3

9 Selected target speed

Move in the window with F4 or F5. Confirm your selection with F3. For example, move with F4or 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 26/75

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 hardwiring 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 Main conveyor off/on

2 Side conveyor off/on3 Magnetic separator off/on

4 Feeder off/on

5 a)

Jaw crusher off/on b)

Impact crusher off/on

6 Engine speed adjustment

7 Screen off/on

8 Screen conveyors (2 pieces) off/on 11 Lifting conveyor off/on

9 Tracks movement 12 By pass conveyor off/on

10 Scalper off/on (impact crushers only) 13 Return conveyor 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




Version 2.5 27/75

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 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.

2 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.

3 Start the screen (see Figure 14.1.1, number 7). Highlight button 1 and activate it by

pressing F3.

4 Start the main conveyor (see Figure 14.1.1, number 1). ). Highlight button 1 and activate it

by pressing F3.

5 Start the crusher (see Fig. 14.1.1, number 5a/b). Highlight button 1 and activate it by

pressing F3.

6 Start the magnetic separator (see Fig. 14.1.1, number 3). Highlight button 1 and activate it

by pressing F3.

7 Start the side conveyor (see Fig. 14.1.1, number 2). Highlight button 1 and activate it by

pressing F3.

8 Start the feeder (see Fig. 14.1.1, number 4). Highlight button 1 and activate it by pressing

F3. 9 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 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).

2 Stop the feeder (see Fig. 14.1.1, number 4). Highlight button 0 and activate it by pressing

F3.

3 Stop the side conveyor (see Fig. 14.1.1, number 2). Highlight button 0 and activate it by

pressing F3.

4 Stop the magnetic separator (see Fig. 14.1.1, number 3). Highlight button 0 and activate it

by pressing F3.

5 Stop the crusher (see Fig. 14.1.1, number 5). Highlight button 0 and activate it by pressing

F3.

6 Stop the main conveyor (Figure 14.1.1, number 1). ). Highlight button 0 and activate it by

pressing F3.

7 Start the screen (Figure 14.1.1, number 7). Highlight button 1 and activate it by pressing

F3.

8 Stop the screen module conveyors (see Fig. 14.1.1, number 8). Highlight button 0 and

activate it by pressing F3. 9 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.




Version 2.5 28/75

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.

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 / on5 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 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

2 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.

3 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.

4 Start the main conveyor (see Figure 14.1.1, number 1). ). Highlight item #1 button 1 and

activate it by pressing F3.4 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 )

1

2

3

4

5




Version 2.5 29/75

5 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.

6 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.

7 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 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.

2 wait until crusher is free from crushed material

3 Stop the crusher (Fig 14.1.2). Highlight the item #4 button 0 and activate by pressing F3

4 Keep lubrication on at least two minutes to cool down the bearing surfaces.

5 Stop the crusher lubrication pump. (Fig 14.1.2). Highlight the item #2 button 0 and activate

by pressing F3 6 Stop the cooling fan. Highlight the item #3 button 0 and activate by pressing F3

7 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.

8 Stop main conveyor. (See Figure 14.1.1, number 1). ). Highlight item #1 button 0 and

activate it by pressing F3




Version 2.5 30/75

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 Left track backwards

2 Left track forward

3 Right track backwards

4 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.




Version 2.5 31/75

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




Version 2.5 32/75

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 General parameters

2 Feeder parameters

3a)

Jaw crusher parameters b)

Impact crusher parametersc)

Cone crusher parameters

4 Tracks parameters5 Engine parameters

6 Hub junction module

7 UPD (Module update)

8 Language

9 Service code:

-lock open: access to user and service parameters

-lock closed: access to user parameters

10 Contrast adjustment

11 Time

12 Date

13 Units (metric/imperial)

14 Hydraulic overload parameters

14c Cone crusher setting calibration page

15 Lubricating unit parameters




Version 2.5 33/75

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.




Version 2.5 34/75

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 higherthe 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 primaryunit’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.




Version 2.5 36/75

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 LIMITFeed 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




Version 2.5 37/75

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 secRange; 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 SENSORSensor 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




Version 2.5 38/75

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 achievedDefault; 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 crushersNote: 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.


Range: 400 – 900 rpm Used with: impact and cone crushers.




Version 2.5 39/75

C25 CRUSHER TARGET SPEED 2



Range: 400 – 900 rpm Used with: impact and cone crushers.

C26 CRUSHER TARGET SPEED 3



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




Version 2.5 40/75

E1 ENGINE MIN SPEED

Diesel minimum speed

Default: 850 rpmRange: 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 conveyorDefault; 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




Version 2.5 41/75

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




Version 2.5 42/75

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.

Figure 16.5 Cone crusher calibration page

1 Setting value

2 Operating hours after the last setting calibration

3 Time & date of last setting calibration

4 kWh consumed after the last setting calibration

5 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.

1

2

3

4

5




Version 2.5 43/75

(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 Check the setting according to instruction manual Nordberg 100, 200, 300, 400, 500

cone crushers / chapter 3.11.

2 Compare the measured setting to the setting value #1 in window 4.1.

3 If a difference is noticed in actual setting and display value, calibrate the setting.

4 Activate calibration by pressing F3 button.

5 Adjust the new measured actual crusher setting value to the calibration window by

adjusting the actual value with buttons F4 & F5.

6 Confirm the new value to the control system by pressing button F3.

7 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.




Version 2.5 44/75

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 Tracks (window 5.1)

2 Control keys window 5.2)

3 Log files (window 5.3)

4 Module program versions (window 5.4)

5 Status of information by each connector of the device control module

6 Status of information by each connector of Hub junction module

7 Status of information by each connector of engine control module

8 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.




Version 2.5 45/75

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 Drive box / radio control

2 Left track "forward" control received (radio/drive box)3 Left track "backward" control received (radio/drive box)

4 Right track "forward" control received (radio/drive box)

5 Right track "backward" control received (radio/drive box)

6 Left track control percentage

7 Left track control voltage percentage

8 Right track control percentage

9 Right track control voltage percentage

10 Left track forward output. When activated, the triangle is black.

11 Left track backward output. When activated, the triangle is black.

12 Right track forward output. When activated, the triangle is black.

13 Right track backward output. When activated, the triangle is black.14 Engine rpm down or feeder off with radio control received

15 Engine rpm up or feeder on with radio

16 Engine rpm down output. When activated, the triangle is black.

17 Engine rpm up output. When activated, the triangle is black.

18 Tracking controls active in radio

19 Crushing controls active in radio

20 Feeder speed down control received from radio

21 Feeder speed up control received from radio




Version 2.5 46/75

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 Feeder off/on / Feed on/off2 Feeder speed decrease / increase

Feed decrease / increase

3 Crusher off/on (jaw crusher only)

4 Crusher swing clockwise / counter

clockwise (jaw crusher only)

5 Crusher setting increase / decrease (jaw

crusher only)

6 Engine key switch, start, running status

7 Process key switch off/on

8 Radio control off/on

9 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.




Version 2.5 47/75

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 Alarm history

2 Diesel diagnostics trouble codes

3 Temperature history log

4 Factory settings

5 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).





Version 2.5 48/75

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 theinformation 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 themalfunction.

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.


17.1.1 Alarm list

HUB JUNCTION MODULE ( ALARM LIST )




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Code Message

HB1 Process disabled alarm1. On (1), Off (0)

HB2 Crusher over pressure alarm 2. On (1), Off (0).

HB3 Crusher pressure rising too fast on start alarm 3. On (1), Off (0)

HB4 Clamping pressure alarm 4. On (1), Off (0).

HB5 Toggle plate condition alarm 5. On (1), Off (0).HB6 Crusher pressure rising too slowly on start alarm 6. On (1), Off (0)

HB7 Crusher speed rising too slowly on start alarm 7. On (1), Off (0).

HB8 Crusher speed low alarm 8. On (1), Off (0).

HB9 Hydraulic oil temperature high, feeder stopped alarm 9. On (1), Off (0).

HB10 Fuel level low alarm 10. On (1), Off (0).

HB11 No connection to diesel engine alarm 11. On (1), Off (0).

HB12 Engine red stop alarm 12. On (1), Off (0).

HB13 Engine amber warning alarm 13. On (1), Off (0).

HB14 Hydraulic oil level low alarm 14. On (1), Off (0).HB15 Hydraulic oil filter clogged alarm 15. On (1), Off (0).

HB16 Hydraulic oil main valve closed alarm 16. On (1), Off (0).

HB17 Hydraulic oil temperature high alarm 17. On (1), Off (0).

HB18 Main conveyor safety switch left alarm 18. On (1), Off (0).

HB19 Main conveyor safety switch right alarm 19. On (1), Off (0).

HB20 Crusher critical overload alarm 20. On (1), Off (0).

HB21 Conveyor maintenance safety switch alarm 21. On (1), Off (0).

HB22 Screen over size conveyor safety switch alarm 22. On (1), Off (0).

HB23 Screen under size conveyor safety switch alarm 23. On (1), Off (0).

HB24 Side conveyor safety switch left side alarm 24. On (1), Off (0).

HB25 Side conveyor safety switch right side alarm 25. On (1), Off (0).

HB26 Drive box remote stop alarm 26. On (1), Off (0).

HB27 Radio remote stop alarm 27. On (1), Off (0).

HB28 Emergency stop pressed from control panel alarm 28. On (1), Off (0).

HB29 Emergency stop pressed from service platform alarm 29. On (1), Off (0).

HB30 Emergency stop pressed from engine module alarm 30. On (1), Off (0).

HB31 Emergency stop pressed from hydraulic center alarm 31. On (1), Off (0).

HB32 Wrong program in one of the control modules alarm 32. On (1), Off (0).

HB33 Ultrasonic sensor not in range alarm 33. On (1), Off (0).

HB34 Clamping pressure sensor not in range alarm 34. On (1), Off (0).

HB35 Device pump pressure sensor not in range alarm 35. On (1), Off (0).

HB36 Toggle plate pressure sensor not in range alarm 36.

(Setting pressure) Not in use, On (1), Off (0).

HB37 ECM module missing alarm 37. On (1), Off (0)

HB38 HCM module missing alarm 38. On (1), Off (0).

HB39 DCM module missing alarm 39. On (1), Off (0).

HB40 Device pump pressure high alarm 40. On (1), Off (0).

HB41 Crusher pressure sensor not in range alarm 41. On (1), Off (0).HB42 Hydraulic overload device / setting sensor detected overload alarm 42. On (1), Off

(0).

HB43 Toggle plate failure alarm 43. On (1), Off (0).




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HB44 Bypass conveyor safety alarm 44 On(1), Off(0)

HB45 Bypass conveyor motor overload alarm 45.On (1), Off (0).

HB46 Return conveyor safety alarm 46. On (1), Off (0).

HB47 Return conveyor motor overload alarm 47. On (1), Off (0).

HB48 Generator voltage alarm 48. On (1), Off (0).

HB49 Generator thermistor alarm 49. On (1), Off (0).

HB50 Generator frequency alarm 50. On (1), Off (0).

HB51 Cone crusher feedback alarm 51. On (1), Off (0).

HB52 Vibration chute motor overload alarm 52. On (1), Off (0).

HB53 Feeder hopper level sensor not in range alarm 53. On (1), Off (0).

HB54 Feed stop, metal detected alarm 54. On (1), Off (0).

HB55 Lifting conveyor rotating sensor alarm 55. On (1), Off (0).

HB56 Lifting conveyor safety alarm 56. On (1), Off (0).

HB57 Lifting conveyor oil pressure high alarm 57. On (1), Off (0).

HB58 Lifting conveyor oil temperature high alarm 58. On (1), Off (0).HB59 LC-feeder motor overload alarm 59. On (1), Off (0).

HB60 Side conveyor motor overload alarm 60. On (1), Off (0).

HB61 Crusher stop without ramp alarm 61. On (1), Off (0).

HB62 Feed authorization lost alarm 62. On (1), Off (0).

HB63 Lifting conveyor speed low alarm 63. On (1), Off (0).

HB64 Lifting conveyor oil pressure out of range alarm 64. On (1), Off (0).

HB65 Impactor speed low alarm 65. On (1), Off (0).

HB66 Impactor cover open alarm 66. On (1), Off (0).

HB67 Impactor speed sensor faulty or jammed alarm 67. On (1), Off (0).HB68 Impactor feedback fault alarm 68. On (1), Off (0).

HB69 Cone crusher in service mode On (1), Off (0).

HB70 Process disabled cone crusher alarm On (1), Off (0).

HB71 Connection between IC600 and IC70 is lost On (1), Off (0).

HB72 Winter mode with internal power supply in activated alarm On (1), Off (0).

HB73 Main conveyor low speed alarm On (1), Off (0).

HB74 Engine cooler current feed back fault alarm On (1), Off (0).

HB75 System voltage low alarm On (1), Off (0).

HB76 Screen discharge conveyor jammed or low speed alarm On (1), Off (0).

HB77 Lubrication oil tank temperature sensor not in range On (1), Off (0).

HB78 Process disabled: Lubrication tank oil too cold On (1), Off (0).

HB79 Lubrication return oil temperature sensor not in range On (1), Off (0).

HB80 Lubrication oil too hot On (1), Off (0).

HB81 Crusher speed sensor fault or crusher jammed alarm On (1), Off (0).

HB82 HP crusher slow speed On (1), Off (0).

HB83 HP Crusher hydraulic pump feedback fault alarm

HB84 HP crusher excessive power limit alarm On (1), Off (0).

HB85 Clamping pressure fault alarm On (1), Off (0).

HB86 Release pressure fault alarm On (1), Off (0).

HB87 Counter shaft pressure fault On (1), Off (0).

HB88 Cone lubrication oil level low On (1), Off (0).




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HB89 Lubrication pump low speed alarm On (1), Off (0).

HB90 Analog cavity level sensor not in range On (1), Off (0).

HB91 Lubrication pump safety device tripped On (1), Off (0).

HB92 Setting sensor A fault On (1), Off (0).

HB93 Setting sensor B fault On (1), Off (0).

HB94 Gearbox Clutch pressure alarm On (1), Off (0).

HB95 Lubricationb oil cooler safety device tripped On (1), Off (0).

HB96 Oil heating alarm due to lifting conveyor safety or conveyor maintenance switch On

(1), Off (0).

HB 130 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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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.


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 cross-

referencing 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 FMI Cnt

111 1 1

Translation: SPN = Coolant level

FMI = Data valid but below normal operational range - most severe level

Cnt = 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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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.


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.





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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.





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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 Device control module2 Engine control module

3 hydraulic control module

4 Hub junction module

5 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 Module

2 Number of the terminal / pin

3 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 TroubleshootingGenerally 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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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 Default values by LT type

Code General 95 105 1110 1213 200

GS1 Delay between device start, range 1 - 15 sec. 5 5 5 5 5

GS2 Delay after feeder stopped with "Process stop" sequence, range10 - 45 sec.

20 20 20 20 20

GS3 Delay between the shut down of the devices, range 5 - 45 sec. 10 10 10 10 10

G4 Vibrating chute in use (1), not in use (0). --- --- --- --- 0

G5 Generator in use (1), not in use (0). --- --- --- --- 0

G6 Bypass conveyor in use (1), not in use (0). --- --- --- --- 0

G7 Dust removal in use (1), not in use (0). --- --- --- --- 0

G8 Dust removal fan time, range 1 - 180 min. --- --- --- --- 120

G9 Dust removal vibrating time, range 5 - 200 sec. --- --- --- --- 10

G10 Return conveyor in use (1), not in use (0). --- --- --- --- ---

GS11 Unit type (Select from the parameter list). 1 1 2 2 ---

GS12 Radio controller type: 0 = I/O-radio, 1 = CAN-radio 1 0 1 1 ---

GS13 Lifting conveyor feeder in use (0=not in use, 1=in use ) 0

GS14 Feed hopper in use (0=not in use, 1=in use ) 0

GS15 Scalper in use (1), not in use (0). --- --- 0 0 ---

G16 Magnetic separator in use on (1), not in use (0). 0

G17 Side conveyor in use on (1), not in use (0). 0

GS18 Separate crusher automation (IC70) in use on (1), not in use (0). 0

Code FEEDER

F1 Feeder MIN speed, range 55 - 70 %. 63 63 66 66 ---

F2 Feeder MAX speed, range 70 - 90%, MAX speed must be higherthan MIN speed.

80 80 84 84 ---

F3 Crusher level high alarms time period, range 0 - 20 min. If 0adaptive control will not be used.

0 0 --- --- 0

F4 Crusher level high count before feeder speed reduction, range 0 – 5

1 1 --- --- 0

F5 Automatic (0) /manual (1) feeder speed setting mode selection. 1 1 0 0 0

F6 Level sensor ON (1) / OFF (0). 1 1 --- --- ---

F7 Feeder speed increase/decrease step, range 0 - 100 % (%between min and max speed setting)

5 5 --- --- 0

FS8 Crusher pressure OK limit, range 100 - 300 bar. 200 200 180 180 ---

FS9 Crusher pressure HIGH limit, range 200 - 400 bar. 250 250 300 300 ---

FS10 Crusher pressure high limit time delay, range 1 - 20 sec. 3 3 1 1 ---

FS11 Crusher speed OK limit, range 260 - 370 rpm. 310 310 --- --- ---

FS12 Crusher speed LOW limit, range 210 - 320 rpm. 295 295 --- --- ---

FS13 Crusher speed low limit time delay, range 1 - 10 sec. 1 1 --- --- 2

FS14 Hydraulic oil temp OK limit, range 65 - 85oC. 75 75 75 75 ---

FS15 Hydraulic oil temp HIGH limit, range 70 - 90oC. 85 85 85 85 85

F16 Crusher level high alarm delay, range 1 - 20 sec. 1 1 --- --- 20




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Appendix 1 / 2 (4) F17 Feeder start minimum time 5 5 1 1 1

F18 Crusher level high alarm time of the possible second LT, range 1- 20 sec.

5 5 5 5 5

FS19 The length of the feeder acceleration and decelerationramp in seconds, range 5 - 25 sec.

10 10 15 15 ---

FS20 Feeder-hopper analog level detector 0% mA value, range 4- 19

mA..

--- --- --- --- 18

FS21 Feeder-hopper analog level detector 100 % mA value range,4 – 19 mA

--- --- --- --- 6

F22 Feed-hopper analog level detector, “0” not in use, “1” in use 0

F23 Feeder-hopper low cavity level, , range 0 –100 % --- --- --- --- 25

F24 Feeder-hopper high cavity level, range 0 – 100 % --- --- --- --- 90

F25 Lifting conveyor acceleration and deceleration ramp timetime from min to max), range 0 - 30 sec

--- --- --- --- 3

F26 Lifting conveyor min speed, range 0 - 100 % --- --- --- --- 16

F27 Lifting conveyor max speed, range 0 - 100 % --- --- --- --- 46

F28 Feed hopper analog sensor in use (0=not in use, 1=in use ) 0

F30 Metal detector stop time, range 0 - 5.0 sec. (If set to 0, metaldetector not in use)

--- --- --- --- 0

F31 Lifting conveyor min speed time, range 0 - 15 sec. --- --- --- --- 0

F33 Hydraulic oil slow down limit, range 60 - 80oC. --- --- --- --- 75

F34 Lifting conveyor speed alarm, range 0 - 500 rpm. (If set to 0,sensor not in use)

--- --- --- --- 0

F35 LC feeder min speed, range 0 - 100 %. --- --- --- --- 50

F36 LC feeder max speed, range 0 - 100 %. --- --- --- --- 80

F38 Stop delay between LC feeder and lifting conveyor,range1-60

F40 Lifting Conveyor / LC feeder control manual (0), automatic (1) --- --- --- --- 1

F41 LC feeder min speed start time, range 0 - 10 sec. --- --- --- --- 0

F42 Screen discharge conveyor low speed limit, range 0 – 400rpm --- --- --- --- 0

F43 Cavity level sensor type (0=not in use, 1=analog, 2=digital ) --- --- --- --- 2

F44 Cavity level sensor current at 0%. Range 4 – 20 mA 18

F45 Cavity level sensor current at 100%. Range 4-20 mA 5

F46 Feed power mode in use (0=not in use, 1=in use ) 1

F47 Crusher power OK limit, range 40 – 400 kW 130

F48 Crusher power high limit, range 100 – 400kW 150

F49 Power high feed pause delay, range 1 – 20 sec. 5

F50 Crusher low speed alarm limit, range 500 - 1500 700

Code CRUSHER

C1 Crusher speed control current maximum value in milliampers,range 200 - 650 mA.

600 580 --- --- ---

CS2 Crusher speed control current minimum value in milliamperes,range 100 - 400 mA.

250 250 --- --- ---

CS3 Toggle plate (0) / hydraulic cylinder protection (1) / mechanicalsetting adjustment (2) !! Select !!

0 0 --- --- ---

CS4 Minimum clamping pressure range 80 - 300 bars.Note! CS10: Minimum pressure value 10 bar.

95 120 --- --- ---

CS5 Max. clamping press. , Range 100-300 bar. Note! Max. valuemust be higher than min

125 170 --- --- ---

CS6 Crusher starting low pressure alarm limit, range 0 - 200 bar. 50 50 --- --- ---

CS7 Crusher starting low pressure alarm delay, range 0 - 60 sec. 10 10 --- --- ---

CS8 Crusher starting high pressure alarm limit, range 100 - 300 bar. 200 200 --- --- ---

CS9 Crusher starting high pressure alarm delay, range 0 - 30 sec. 5 5 --- --- ---




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Appendix 1 / 3 (4) CS10 Low clamping pressure limit, range 80 - 150 bar. Note! Minimum

press. value 10 bar80 110 --- --- ---

CS11 Crusher over pressure alarm delay, range 1 - 20 sec. 10 10 10 10 ---

CS12 Crusher over pressure alarm limit, range 100 - 400 bar. 300 300 380 380 ---

CS13 Crusher start ramp time, range 8 - 25 sec. 15 15 25 25 20

CS14 Crusher stop ramp time, range 10 - 30 sec. 20 20 30 30 30

CS15 Setting sensor 4 mA reading (Ultrasonic) in mm. 0 0 --- --- ---

CS16 Setting sensor signal range (Ultrasonic) in mm. 0 0 --- --- ---

CS17 Crusher overload when setting is n % of fully open. 5 5 --- --- ---

CS18 Normal setting movement during crushing. 15 15 --- --- ---

C19 Crusher speed sensor in use (1), not in use (0). 1 1 1 1 1

C24 Crusher target speed 1, default 500, range 400-900rpm --- --- 500 480 830



CS27 Crusher speed sensor, detected pulses perone round, range 1 - 50

--- --- 6 1 4

CS28 Pump zero speed for impact crusher target speed 1,

range 200 - 750 mA

--- --- 560 560 540

CS29 Adjust motor zero speed for impact crushertarget speed 1, range 200 - 750 mA

--- --- 0 0 ---

CS30 Pump zero speed for impact crusher target speed 2,range 200 - 750 mA

--- --- 590 590 580


--- --- 225 0 ---

CS32 Pump zero speed for impact crusher target speed 3,range 200 - 750 mA

--- --- 638 638 630


--- --- 320 0 ---

CS34 Crusher target speed change hysteresis, range 5-100 --- --- 20 20 20

CS35 Crusher target speed ramp fastness mA/s,range 0.2 - 3.0 mA/s

--- --- 2.0 2.0 2,0

C36 Crusher auto speed. 0 = not in use, 1 = in use --- --- 1 1 1CS37 Crusher idling power limit, default 30 kW, Range 10-100kW 25

CS38 Hydraulic motor size default 180 cm3 range: 50-500cm3 180

CS39 Hydraulic motor v-belt pulley diameter default 250 mm 224

CS40 Clamping fault delay, default 20 sec range:0-60 sec 1

CS41 Release fault delay , default 20 sec range:0-60 sec 1

CS42 Excessive power alarm limit : range:100-400kW 160

CS43 Excessive power alarm delay default 10 sec range:0-20 sec 5

CS44 Crusher soft start time default 20 sec range 0- 60 sec 35

CS45 Crusher prelubrication time default 120 sec range:1- 300sec 120

CS46 HP crusher setting change per tooth default 0,18mm range0,10- 0,39 mm

0,18

CS47 Crusher drive type 0=hydraulic 1=Katsa gear box 0CS48 Diesel engine size default 317 kW range 200 –600kW 317

CS49 Power draw without Crusher default 90kW range: 0-400kW 90

CS50 Hydraulic pump size default 250cm3 range:50-500cm3 250

Code TRACKS

T1 MIN value for right track backward, range 50.0 - 95.0 %. 65 65 65 65 65

T2 MIN value for right track forward, range 5.0 - 50.0 %. 35 35 35 35 35

T3 MIN value for left track backward, range 50.0 - 95.0%. 65 65 65 65 65




Version 2.5 60/75

Appendix 1 / 4 (4) T4 MIN value for left track forward, range 5.0 - 50.0%. 35 35 35 35 35

T5 Fast speed rpm, range 1500 - 2300 rpm. 2000 2000 2000 2000 2000

T6 Normal speed rpm, range 1000 - 2000 rpm. 1200 1200 1200 1200 1200

T7 Stop ramp, range 1 - 300 ms. 20 20 20 20 20

Code ENGINE AND HYDRAULICS E1 Diesel MIN speed, range 700 - 1200 rpm. 1000 850 850 850 850

E2 Diesel MAX speed, range 1900 - 2500 rpm. 2300 2100 2100 2100 2100

E3 Fuel level alarm limit, range 0 - 20 %. 5 5 5 5 5

ES4 Fuel level sensor min output voltage, range 0 - 5 V. 1,20 1,20 1,20 1,20 1,20

ES5 Fuel level sensor max output voltage, range 0 - 5 V. 0,01 0,01 0,01 0,01 0,01

ES8 Engine cooler control in use 0 = not in use, 1 = in use 0

ES9 Cooler max mA value Range 400 – 750 mA 600

ES10 Cooler min mA value Range 0 – 400 mA 200

ES11 Coolant temperature OK limit, Range 60 – 85oC 70

ES12 Coolant temperature high limit, range86 – 100oC 98

ES13 Charge air temperature ok limit, Range 35 – 45oC 43

ES14 Charge air temperature high limit, Range 46 – 70 oC 50

ES15 Cooler speed ramp fastness range 1 – 5 sec 0,5

ES16 Diesel engine type “0” = CAT, “1” = Cummins 1 0 0 0 ---

H1 Device pump pressure alarm limit, range 0 - 350 bar. 250 250 290 290 0

HS2 Hydraulic oil temperature sensor gain (mV/100oC). 905 905 905 905 905

HS3 Hydraulic oil temperature sensor 0oC voltage reading. 2.13 2.13 2.13 2.13 2.13

HS4 Hydraulic oil temperature limit for monitoring oil filter. 20 20 20 20 20

HS5 Crusher pressure sensor 4 mA value. 0 0 0 0 0

HS6 Crusher pressure sensor range. 600 600 600 600 600

HS7 Clamping pressure sensor 4 mA value. 0 0 0 0 0

HS8 Clamping pressure sensor range. 600 600 600 600 600HS9 Device pump and lifting conveyor pressure sensor 4 mA value. 0 0 0 0 0

HS10 Device pump and lifting conveyor pressure sensor range. 600 600 600 600 600

HS11 Toggle plate pressure sensor 4 mA value. 0 0 0 0 0

HS12 Toggle plate pressure sensor range. 0 0 0 0 0

H13 Lifting conveyor pump pressure limit, range 0 - 350 bar. --- --- 0 0 0

H14 Main conveyor speed alarm, range 0 – 500 rpm. “0” =not in use --- --- --- --- 200

Code LUBRICATION UNIT

LS1 Tank oil temperature sensor 4 mA-value; range –30 - 100 oC 0

LS2 Tank oil temperature sensor range; 0 - 1000 oC 100

LS3 Return oil temperature sensor 4 mA-value; range –30 - 100

o

C 0LS4 Return oil temperature sensor range; 0 - 1000

oC 100

LS5 Tank oil heaters off limit range; 0 – 100oC 30

LS6 Return oil hot, feed stop limit temperature range 0 – 100oC 55

LS7 Return oil too hot, crusher alarm limit temperature 0 - 100 oC 60

LS8 Counter shaft pressure alarm delay range; 0 – 10 sec. 5

LS9 Lubrication pump low speed limit range; 1000 – 1400 rpm 1250

LS10 Oil cooler on temperature limit range 30 – 50oC 45

LS11 Oil cooler off temperature limit range;20 – 40 oC 35

LS12 Lubrication pump motor type; 0 = Hydraulic , 1 = Electric 0

LS13 Tank oil temperature process enable limit range; 0 – 30oC 20

LS14 Lub.pump running time after crusher stop range; 1 –300 sec. 120

LS15 Lub.pump speed sensor pulses per one round range; 1 -50 38

LS16 Lube oil cooler motor type; 0 = hydraulic, 1 = electric 0

LS17 Oil heating hydraulic pump time range; 0 – 300 sec. 0




Version 2.5 61/75

Engine diagnostic codes Appendix 2 / 1 (8)

ENGINE DIAGNOSTIC CODES

SPN ( Suspected Parameter Number )

PID Parameter

Single data character length parameters

0 Request parameter

1(1)

Invalid data parameter (see appendix A)

2(1)

Transmitter system status (see appendix A)

3(1)

Transmitter system Diagnostic (see appendix A)

4 Reserved - to be assigned

5(1)

Underrange warning condition (see appendix A)

6(1)

Overrange warning condition (see appendix A)

7 Axle # 2 lift air pressure

8 Brake system air pressure low warning switch status9 Axle lift status

10 Axle slider status

11 Cargo securement

12 Brake stroke status

13 Entry assist position/deployment

14 Entry assist motor current

15 Fuel supply pump inlet pressure

16 Suction side fuel filter differential pressure

17 Engine oil level remote reservoir

18 Extended range fuel pressure

19 Extended range engine oil pressure20 Extended range engine coolant pressure

21 Engine ECU temperature

22 Extended engine crankcase blow-by pressure

23 Generator oil pressure

24 Generator coolant temperature

25 Air conditioner system status # 2

26 Estimated percent fan speed

27 Percent Exhaust gas recirculation valve # 1 position

28 Percent accelerator position # 3

29 Percent accelerator position # 2

30 Crankcase blow-by pressure

31 Transmission range position

32 Transmission splitter position

33 Clutch cylinder position

34 Clutch cylinder actuator status

35 Shift finger actuator status # 2

36 Clutch plates wear condition

37 Transmission tank air pressure

38 Second fuel level (right side)

39 Tire pressure check interval

40 Engine retarder switches status

41 Cruise control switches status

42 Pressure switch status43 Ignition switch status

44 Attention/warning indicator lamps status




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45 Inlet air heater status

46 Vehicle wet tank pressure

47 Retarder status

48 Extended range barometric pressure

49 ABS control status50 Air conditioner system clutch status/command # 1

51 Throttle position

52 Engine intercooler temperature

53 Transmission synchronizer clutch value

54 Transmission synchronizer brake value

55 Shift finger actuator status # 2

56 Transmission range switch status

57 Transmission actuator status # 2

58 Shift finger actuator status

59 Shift finger gear position

60 Shift finger rail position61 Parking brake actuator status

62 Retarder inhibit status

63 Transmission actuator status # 1

64 Direction switch status

65 Service brake switch status

66 Vehicle enabling component status

67 Shift request switch status

68 Torque limiting factor

69 Two speed axle switch status

70 Parking brake switch status

71 Idle shutdown timer status

72 Blower bypass value position

73 Auxiliary water pump pressure

74 Maximum road speed limit

75 Steering axle temperature

76 Axle # 1 lift air pressure

77 Forward rear drive axle temperature

78 Rear rear-drive axle temperature

79 Road surface temperature

80 Washer fluid level

81 Particulate trap inlet pressure

82 Air start pressure

83 Road speed limit status84 Road speed

85 Cruise control status

86 Cruise control set speed

87 Cruise control high-set limit speed

88 Cruise control low-set limit speed

89 Power takeoff status

90 PTO oil temperature

91 Percent accelerator pedal position

92 Percent engine load

93 Output torque

94 Fuel delivery pressure95 Fuel filter differential pressure




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96 Fuel level

97 Water in fuel indicator

98 Engine oil level

99 Engine oil filter differential pressure

100 Engine oil pressure101 Crankcase pressure

102 Boost pressure

103 Turbo speed

104 Turbo oil pressure

105 Intake manifold temperature

106 Air inlet pressure

107 Air filter differential pressure

108 Barometric pressure

109 Coolant pressure

110 Engine coolant temperature

111 Coolant level112 Coolant filter differential pressure

113 Governor droop

114 New battery current

115 Alternator current

116 Brake application pressure

117 Brake primary pressure

118 Brake secundary pressure

119 Hydraulic retarder pressure

120 Hydraulic retarder oil temperature

121 Engine retarder status

122 Engine retarder percent

123 Clutch pressure

124 Transmission oil level

125 Transmission oil level high/low

126 Transmission filter differential pressure

127 Transmission oil pressure

Double data character length parameters

128 Component-specific request

129 Injector metering rail # 2 pressure

130 Power specific fuel economy

131 Exhaust back pressure

132 Mass air flow

133 Average fuel rate

134 Wheel speed sensor status

135 Extended range fuel delivery pressure (absolute)

136 Auxiliary vacuum pressure reading

137 Auxiliary gage pressure reading # 1

138 Auxiliary absolute pressure reading

139 Tire pressure control system channel functional mode

140 Tire pressure control system solenoid status

141 Trailer # 1, tag # 1, or push channel # 1 tire pressure target

142 Drive channel tire pressure target

143 Steer channel tire pressure target

144 Trailer # 1, tag # 1, or push channel # 1 tire pressure145 Drive channel tire pressure




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146 Steer channel tire pressure

147 Average fuel economy (natural gas)

148 Instantaneous fuel economy (natural gas)

149 Fuel mass flow rate (natural gas)

150 PTO engagement control status151 ATC control status

152 Number of ECU resets

153 Crankcase pressure

154 Auxiliary input and output status # 2

155 Auxiliary input and output status # 1

156 Injector timing rail pressure

157 Injector metering rail pressure

158 Battery potential (voltage) - switched

159 Gas supply pressure

160 Main shaft speed

161 Input shaft speed162 Transmission range selected

163 Transmission range Attained

164 Injection control pressure

165 Compass bearing

166 Rated engine power

167 Alternator potential (voltage)

168 Battery potential (voltage)

169 Cargo ambient temperature

170 Cab interior temperature

171 Ambient air temperature

172 Air inlet temperature

173 Exhaust gas temperature

174 Fuel temperature

175 Engine oil temperature

176 Turbo oil temperature

177 Transmission # 1 oil temperature

178 Front axle weight

179 Rear axle weight

180 Trailer weight

181 Cargo weight

182 Trip fuel

183 Fuel rate (instantaneous)

184 Instantaneous fuel economy

185 Average fuel economy

186 Power takeoff speed

187 Power takeoff set speed

188 Idle engine speed

189 Rated engine speed

190 Engine speed

191 Transmission output shaft speed

Variable and long data character length parameters

192 Multisection parameter

193(1)

Transmitter system diagnostic table (see appendix A)

194 Transmitter system diagnostic code and occurrence count table




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195 Diagnostic data request/clear count

196 Diagnostic data/count clear response

197 Connection management

198 Connection mode data transfer

199 Traction control disable state200 Reserved - to be assigned









209 ABS control status, trailer

210 Tire temperature (by sequence number)211 Tire pressure (by sequence number)

212 Tire pressure target (by sequence number)

213 Wheel end assembly vibration level

214 Vehicle wheel speeds

215 Brake temperature

216 Wheel bearing temperature

217 Fuel tank/nozzle identification

218 State line crossing

219 Current state and country

220 Engine torque history

221 Anti-theft request

222 Anti-theft status

223 Auxiliary A/D counts

224 Immobilizer security

225 Reserved for text message acknowledged

226 Reserved for text message to display

227 Reserved for text message display type

228 Speed sensor calibration

229 Total fuel used (natural gas)

230 Total idle fuel used (natural gas)

231 Trip fuel (natural gas)

232 DGPS differential correction

233 Unit number (power unit)

234 Software identification

235 Total idle hours

236 Total idle fuel used

237 Vehicle identification number

238 Velocity vector

239 Vehicle position

240 Change reference number

241 Tire pressure by position

242 Tire temperature by position

243 Component identification

244 Trip distance245 Total vehicle distance




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246 Total vehicle hours

247 Total engine hours

248 Total PTO hours

249 Total engine revolutions

250 Total fuel used251 Clock

252 Date

253 Elapsed time

Special parameters

254 Data link escape

255 Extension

Single data character length parameters

(modulo 256 value identified in parentheses)

256 (0) Request parameter

257(1) Cold restart of specific component

258(2) Warm restart of specific component259(3) Component restart response

260-361 Reserved (page 2) to be assigned

362(106) Percent exhaust gas recirculation valve # 2 position

363(107) Hydraulic retarder control air pressure

364(108) HVAC unit discharge temperature

365(109) Weighing system status command

366(110) Engine oil level high/low

367(111) Lane tracking system status

368(112) Lane departure indication

369(113) Distance to rear object (reverse)

370(114) Trailer pneumatic brake control line pressure

371(115) Trailer pneumatic supply line pressure

372(116) Remote accelerator

373(117) Center rear drive axle temperature

374(118) Alternator AC voltage

375(119) Fuel return pressure

376(120) Fuel pump inlet vacuum

377(121) Compression unbalanced

378(122) Fare collection unit status

379(123) Door status

380(124) Articulation angle

381(125) Vehicle use status

382(126) Transit silent alarm status

383(127) Vehicle acceleration

Double data character length parameters

384(128) Component-specific request

385-405 Reserved (page 2 ) -to be assigned

406(150) HVAC blower motor speed

407(151) Axle group full weight calibration

408(152) Axle group empty weight calibration

409(153) Axle group weight

410(154) Extended range road surface temperature

411(155) Recirculated engine exhaust gas differential pressure

412(156) Recirculated engine exhaust gas temperature413(157) Net vehicle weight change




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414(158) Air conditioner Refrigerant low side pressure

415(159) Air conditioner refrigerant high side pressure

416(160) Evaporator temperature

417(161) Gross vehicle weight

418(162) Transmission # 2 oil temperature419(163) Starter circuit resistance

420(164) Starter current (average)

421(165) Alternator/generator negative cable voltage

422(166) Auxiliary current

423(167) Extended range net battery current

424(168) DC voltage

425(169) Auxiliary frequency

426(170) Alternator/generator field voltage

427(171) Battery resistance change

428(172) Battery internal resistance

429(173) Starter current peak430(174) Starter solenoid voltage

431(175) Starter negative cable voltage

432(176) Starter motor voltage

433(177) Fuel shutoff solenoid voltage

434(178) AC voltage

435(179) Cargo ambient temperature (by location)

436(180) Trip sudden decelerations

437(181) Trailer # 2, tag # 2, or push channel # 2 tire pressure target

438(182) Trailer # 2, tag # 2, or push channel # 2 tire pressure

439(183) Extended range boost pressure # 1

440(184) Extended range boost pressure # 2

441(185) Auxiliary temperature # 1

442(186) Auxiliary temperature # 2

443(187) Auxiliary gage pressure reading # 2

444(188) Battery # 2 potential (voltage)

445(189) Cylinder head temperature bank B (right bank)

446(190) Cylinder head temperature bank A (left bank)

447(191) Passenger counter

Variable and long data character length parameters

448(192) Page 2 multisection parameter

449(193) Reporting interval request

450(194) Bridge filter control

451-497 Reserved (page 2) -to be assigned

498(242) Send keypress command

499(243) Driver interface unit (DIU) object/form command

500(244) Intersection preemption status and configuration

501(245) Signage message

502(246) Fare collection unit - point of sale

503(247) Fare collection unit - service detail

504(248) Annunciator voice message

505(249) Vehicle control head keyboard message

506(250) Vehicle control head display message

507(251) Driver identification

508(252) Transit route identification509(253) Mile post identification




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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 Data valid but above normal operational range - most severe level

1 Data valid but below normal operational range - most severe level

2 Data erratic, intermittent or incorrect

3 Voltage above normal or shorted to high source

4 Voltage below normal or shorted to low source

5 Current below normal or open circuit

6 Current above normal or grounded circuit

7 Mechanical system not responding or out of adjustment

8 Abnormal frequency or pulse width or period

9 Abnormal update rate

10 Abnormal rate of change

11 Root cause not known

12 Bad intelligent device or component

13 Out of calibration

14 Special instructions

15 Data valid but above normal operating range - least severe level16 Data valid but above normal operating range - moderately severe level

17 Data valid but below normal operating range - least severe level

18 Data valid but below normal operating range - moderately severe level

19 Received network data in error

20 – 30 Reserved for SAE assignment

31 Not available or condition exists




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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 useXH4/4 = Not in useXH4/5 = Not in useXH4/6 = Not in useXH4/7 = Not in use

XH4/8 = Not in useXH4/9 = GroundXH4/10 = GroundXH4/11 = Emergency stop, service platformXH4/12 = Emergency stop, control panelXH4/13 = Emergency stop, engine moduleXH4/14 = Emergency stop, hydraulic moduleXH4/15 = BSLXH4/16 = CAN2 HXH4/17 = CAN2 LXH4/18 = RS485 HXH4/19 = RS485 LXH4/20 = Not in useXH4/21 = Not in useXH4/22 = Ref +XH4/23 = Ref -

Terminology: AI = Analog input AO = Analog outputPI = Pulse input

FB = FeedbackO/ = OutputO-PWM = Pulse Width Modulation outputBSL = Boot sequence line




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DCM Input/Output data


XM1/1 = O/Primary feeder authorization pauseXM1/2 = O/ Dust removal unit vibratorXM1/3 = O/ Dust removal unit fanXM1/4 = Key switch on start positionXM1/5 = Not in useXM1/6 = Not in useXM1/7 = Process start buttonXM1/8 = Process stop buttonXM1/9 = GroundXM1/10 = Ground

XM1/11 = GroundXM1/12 = Fuel level sensor /AIXM1/13 = (+24 V)XM1/14 = Metal detector alarmXM1/15 = O/ screen support legs upXM1/16 = O/Crusher runningXM1/17 = Not in useXM1/18 = Sound alarm hornXM1/19 = Not in useXM1/20 = Radio operation selectedXM1/21 = Feeder support legs are downXM1/22 = O/Primary feeder authorization

XM1/23 = Lifting conveyor safety switch

XM2/1 = Hydraulic hammer operating switchXM2/2 = Not in useXM2/3 = Not in useXM2/4 = Not in useXM2/5 = Secondary LT level, feeder pausedXM2/6 = Secondary LT level, feeder stoppedXM2/7 = Fuse indicator 1XM2/8 = Fuse indicator 2XM2/9 = Secondary LT connectedXM2/10 = Feeder speed + (service platform)XM2/11 = (+24 V)XM2/12 = Feeder speed – (service platform)XM2/13 = GroundXM2/14 = GroundXM2/15 = GroundXM2/16 = Feeder start (service platform)




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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 VXM3/2 = +5 VXM3/3 = GroundXM3/4 = GroundXM3/5 = Drive box right track forward

XM3/6 = Drive box left track forwardXM3/7 = Drive box right track backwardXM3/8 = Module identification /AIXM3/9 = +12 VXM3/10 = +5 VXM3/11 = GroundXM3/12 = GroundXM3/13 = Drive box left track backwardXM3/14 = Crusher setting sensor /AIXM3/15 = BSLXM3/16 = Crusher speed /PIXM3/17 = Crusher level high

XM3/18 = Lifting conveyor rotation detectorXM3/19 = Drive box engine rpm +XM3/20 = Drive box engine rpm –XM3/21 = Drive box connectedXM3/22 = Drive box remote stopXM3/23 = Not in use

Terminology:

AI = Analog input AO = Analog outputPI = Pulse inputFB = FeedbackO/ = OutputO-PWM = Pulse Width Modulation outputBSL = Boot sequence line




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I/O List Appendix 3 / 4 (7) ECM Input/Output data


XM1/1 = O/ Flash alarmXM1/2 = O/ Vibration chuteXM1/3 = O/ Distribution gearbox “choke”XM1/4 = By pass conveyor electric motor protective switch okXM1/5 = FB/ Engine cooler controlXM1/6 = Not in useXM1/7 = Generator voltage protection circuit alarmXM1/8 = Air filter conditionXM1/9 = GroundXM1/10 = GroundXM1/11 = GroundXM1/12 = AI / Cone crusher analog / digital cavity level

XM1/13 = (+24 V)XM1/14 = O/ Lubrication tank oil temperature ok. / Return conveyorXM1/15 = O/ HP crusherXM1/16 = O/ HP crusher soft startXM1/17 = Not in useXM1/18 = Counter shaft pressureXM1/19 = Lubrication oil levelXM1/20 = Not in use (RADIO)XM1/21 = Electric driven lubrication pump protective switch okXM1/22 = Side conveyor electric motor protective switch okXM1/23 = 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 valveXM2/2 = O/Crusher speed reverse direction (current in mA)

O/Impact crusher hydraulic adjust motor valveXM2/3 = FB/Crusher speed both directions (current in mA)

FB/Impact crusher hydraulic pump valveXM2/4 = FB/Impact crusher hydraulic adjust motor valveXM2/5 = O/Engine startXM2/6 = O/Engine stop solenoidXM2/7 = O/HornXM2/8 = Generator frequency alarmXM2/9 = Generator thermistor alarmXM2/10 = O/ hydraulic cooler fan / lubrication oil cooler fanXM2/11 = (+24 V)XM2/12 = Hydraulic oil temperature /AIXM2/13 = GroundXM2/14 = GroundXM2/15 = GroundXM2/16 = Hydraulic oil filters




I/O List Appendix 3 / 5 (7) XM2/17 = Hydraulic oil levelXM2/18 = Hydraulic oil main valveXM2/19 = Clamping pressure switchXM2/20 = Release pressure switchXM2/21 = Distribution gearbox clutch pressure switch

XM2/22 = PWM / Engine cooler controlXM2/23 = O/ cone crusher lubrication pump

XM3/1 = +12 VXM3/2 = +5 VXM3/3 = GroundXM3/4 = GroundXM3/5 = Cone crusher lubrication tank oil temperatureXM3/6 = Crusher pressure /AIXM3/7 = Cone crusher lubrication oil return oil temperatureXM3/8 = Module identification /AI

XM3/9 = +12 VXM3/10 = +5 VXM3/11 = GroundXM3/12 = GroundXM3/13 = AI/ Distribution gearbox clutch pressureXM3/14 = Not in useXM3/15 = BSLXM3/16 = PI/ crusher speedXM3/17 = PI/ Cone crusher setting sensor AXM3/18 = PI/ Cone crusher setting sensor BXM3/19 = PI/ Crusher drive shaft speedXM3/20 = PI/ Speed of hydraulic driven lubrication pump

XM3/21 = Vibrating chute motor protective switch okXM3/22 = Hydraulic pump safety deviceXM3/23 = Electric driven lubrication oil cooler fan motor protective switch ok

Terminology:

AI = Analog input AO = Analog outputPI = Pulse inputFB = FeedbackO/ = OutputO-PWM = Pulse Width Modulation outputBSL = Boot sequence line

lt95 - lt95s instruction manual (new addition)

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