LOKOTRACK LT106 INSTRUCTION MANUAL 140561-EN
SAFETY INSTRUCTIONS
Safety instructions
Table of Contents INTRODUCTION 1.1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2
Definitions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
GENERAL SAFETY INSTRUCTIONS 2.1
SAFE PRODUCTS AND THE CRUSHING PLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 SAFETY AND YOU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.2.1 Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.2.2 Safety Signs, Labels And Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.2.3 Some General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.2.4 Blasting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 2.2.5 Portable Plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 2.2.6 Mobile Equipment Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2.3 TYPICAL RISKS IN CRUSHING PLANT WORKING ENVIRONMENT . . . . . . . . . . . . . . . 2-7 2.3.1 Typical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2.3.2 Typical Injury Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 2.4 PERSONAL PROTECTIVE EQUIPMENT AND CLOTHING . . . . . . . . . . . . . . . . . . . . . . 2-22 2.4.1 Hearing Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 2.4.2 Eye And Face Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 2.4.3 Respiratory Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 2.4.4 Foot Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 2.4.5 Head Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 2.4.6 Hand Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 2.4.7 Safety Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 2.4.8 Work Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 2.4.9 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 2.4.10 Safety Locks And Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
MACHINE SAFETY 3.1 PROTECTIVE DEVICES AND ACCESSORIES FOR MACHINE SAFETY . . . . . . . . . . . . 3-1 3.1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1.2 Emergency-Stop (E-Stop). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1.3 Safety Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1.4 Additional Warning Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.1.5 Walkways, Service Platforms, Ladders And Railings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.2
Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3
Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4 At the work-site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3.4.1 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3.4.2 During operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
09/2005
Safety instructions
Table of Contents SAFETY DURING MAINTENANCE AND REPAIR 4.1
GENERAL INFORMATION AND SAFETY LOCKOUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 MECHANICAL SAFETY DURING MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . . . . 4-2 4.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.2.2 Fire Safety During Maintenance And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.2.3 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.2.4 Confined Spaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.3 ELECTRICAL SAFETY DURING MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . . . . . 4-4 4.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.3.2 Electrical Fault Situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 4.3.3 Program Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.4
HYDRAULIC SAFETY DURING MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . . . . . 4-6
4.5
GENERAL MAINTENANCE WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
09/2005
INTRODUCTION
SECTION
1
1.1 General
This manual, together with specific instruction manuals for individual equipment, has been prepared by Metso Minerals Crushing and Screening Business Line to increase the knowledge and awareness of all persons involved in the operation, supervision, service and maintenance of crushing and screening equipment with regard to safety and operations. A copy of this manual must be provided to and studied by each person entering the machine areas of the Crushing Plant, or otherwise involved in the operation of the Crushing Plant. It is the responsibility of the Owner to always keep this manual and other written instructions either in the Crushing Plant or its vicinity for Operator reference. Knowledge of the machines and the potential hazards they present are essential to a safe workplace. Knowledge of and compliance with all state, provincial, and federal safety laws, safety regulations, and Crushing Plant safety procedures, warnings and instructions also are essential to a safe workplace. Failure to do so can result in serious injury or death. When in doubt - don’t! Never bypass instructions or procedures to save time. Never place foreign items, tools, rods, or any part of your body into an operating machine. Never reach over, around or beyond safety devices. Never operate a machine if safety devices are missing or disabled. Never replace an OEM safety device with a non-OEM device.
Please read this manual carefully. Know its contents. If you have any questions, contact your Metso Minerals representative without delay for advice. Keep in mind that there are different types of risks, hazards and injury types (see Section 2.3 Typical risks in Crusher Plant working environment), which are related to each other. Foresee and prevent such risks and hazards as well as resulting injuries and other consequences from occurring by all available means. Never compromise when the question is about safety! Metso Minerals, as the machinery manufacturer and supplier, regards safety as of the utmost importance, and deems the following as essential prerequisites to the safe operation of the Crushing Plant: – That the Owner makes available this manual, before using the machinery, to each person involved with the operation, supervision, service, or maintenance of the Crushing Plant.
Never service equipment until all potentially moving parts are secured and power has been locked out and tagged out to prevent unexpected movement. The Operator is responsible for using care and common sense at all times. Remember, safety is everyone’s business. You are responsible not only for your safety, but for the safety of those around you.
09/2005
EN REV-A
– That compliance with and adherence to this manual be mandated and supervised by the Owner. – That all personnel involved in the operation, supervision, service, or maintenance of the Crushing Plant
METSO MINERALS SAFETY INSTRUCTIONS 1-1
SECTION 1 - INTRODUCTION
become familiar with the contents of this manual prior to such involvement. – That every person involved in the operation, supervision, service, or maintenance of the Crushing Plant be properly trained and have adequate professional skills as required for the performance of the respective tasks.
programs. The information may also not include all practices that must be observed, such as insurance requirements or governmental regulations.
– That all visitors to the Crushing Plant be properly informed of applicable safety precautions and risks, and that safety precautions be adequately maintained and in connection with any such visits, including, but not limited to, adherence to this manual. No changes shall be made in the operation of the machinery supplied by Metso Minerals or the contents of this manual without express written approval of Metso Minerals. All operation, service, maintenance, handling, modifications, or other use of Crushing Plant equipment and/or systems is the responsibility of the Owner. Metso Minerals shall not be liable for any injury, death, damage or cost caused by any act or omission on the part of the Owner, Operator or other personnel, agents, contractors, vendors, or others. All applicable safety rules, regulations, standards, instructions, and procedures must be complied with; as must be those of this manual as well as any other instructions, specifications, and recommendations by Metso Minerals.
If you have questions or concerns regarding safety aspects of machinery supplied by Metso Minerals, contact us before using, operating, servicing or repairing the machinery. IMPORTANT! Safe operation of the machine requires alertness and safety-consciousness on the part of all operating personnel. It should be operated only by knowledgeable and trained personnel.
This manual is based upon the safety laws, rules and regulations in effect on the date hereof. The owner and operator bear sole responsibility for complying with any amendments, additions or other changes to safety law, rules or regulations arising subsequent to the date on which this manual was drafted. Although these instructions are intended to be as comprehensive as possible, there may be hazards that cannot be anticipated, hazards associated with a particular work-site or hazards covered by special comany safety
1-2
METSO MINERALS SAFETY INSTRUCTIONS
EN REV-A
09/2005
SECTION 1 - INTRODUCTION
1.2 Definitions:
“Crushing Plant” means a combination or part of various equipment, components, systems and parts for crushing and/or screening of rock, minerals, recycling or other crushable materials. For the purposes of this manual, the Crushing Plant means also stand-alone crushing or screening equipment as applicable. Throughout this manual, words such as “machine”, “machinery”, “equipment” and “crusher” are used interchangeably to refer to the Crushing Plant and its component parts. “Owner” means the entities or individuals who own or lease the Crushing Plant and/or the entities or individuals who are in charge of operating and/or servicing the Crushing Plant. “Operator” means the individuals who either operate the Crushing Plant or perform actual maintenance, service, repairs, supervision or any other activity on or for it. “This manual” means, as applicable, this general safety instructions, together with any specific instructions for individual equipment, as amended from time to time, provided by or on behalf of Metso Minerals.
09/2005
EN REV-A
METSO MINERALS SAFETY INSTRUCTIONS 1-3
SECTION 1 - INTRODUCTION
This Page Left Intentionally Blank.
1-4
METSO MINERALS SAFETY INSTRUCTIONS
EN REV-A
09/2005
GENERAL SAFETY INSTRUCTIONS
SECTION
2
GENERAL SAFETY INSTRUCTIONS FOR A CRUSHING PLANT OR PLANT ENVIRONMENT 2.1 SAFE PRODUCTS AND THE CRUSHING PLANT
2.2 SAFETY AND YOU
All machines require human involvement. Like any other heavy machinery, a Crushing Plant has inherent dangers that must be identified, understood and taken into account in order to avoid accidents and injuries. Metso Minerals, as machinery manufacturer and supplier, is committed to promoting safety at the Crushing Plant by providing safety devices and features, and by providing training, services, manuals and instructions.
Safety is everyone's responsibility; safety is your responsibility.
Safety is the concern of all personnel. With your actions, you participate in establishing the safety of the working environment. Metso Minerals products are designed and constructed with safety in mind. The machines incorporate high quality safety features used. To assure safe operation, all personnel must be alert when operating or working on or around the machine. Be aware of real and potential hazards. Only properly trained personnel should operate, supervise, maintain, or service the machine. Personnel must carefully study all aspects of the specific machine, including: – operating instructions – service, trouble-shooting and maintenance instructions – automated features and motions of the machine
09/2005
EN REV-A
METSO MINERALS SAFETY INSTRUCTIONS 2-1
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
– specific safety features and instructions
IMPORTANT!
•
If unsure of any procedure, check the operation manuals and/or contact your supervisor before proceeding.
•
Follow all lockout and safety procedures before entering the machine.
•
Be constantly aware of the location of each worker on or around the machine.
•
Observe all safety instructions.
•
Do not remove or disable any guard, safety device, sign or warning.
2.2.1 Objective
The objective of these instructions is to minimize risks and to avoid or prevent accidents and injuries. Accidents are often caused by carelessness or disregard of important instructions. Knowledge of the machine operation and continuous safety training are necessary for a safe working environment. Safety can be summarized in three main themes: – MACHINE KNOWLEDGE – SAFE OPERATION AND MAINTENANCE – GOOD HOUSEKEEPING
2-2
METSO MINERALS SAFETY INSTRUCTIONS
EN REV-A
09/2005
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
2.2.2 Safety Signs, Labels And Symbols
The following symbol is used in this manual and on the machine to call attention to instructions, which will help prevent machine related injuries.
DANGER
When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.
WARNING CAUTION Sign
Figure 2.1 Alert Symbol
This manual uses the alert symbol, with words such as DANGER, WARNING or CAUTION, to alert you and other Crushing Plant personnel of actions or conditions that pose a potential safety hazard, with an attending risk of personal injury (including death) or property damage. The machine also displays safety signs, labels and tags at appropriate points to show safety risks that may exist.
09/2005
Description Immediate hazards or unsafe practices DANGER that will result in severe personal injury or death. Hazards or unsafe practices that could WARNING result in severe personal injury or death Hazards or unsafe practices that could CAUTION result in minor personal injury or equipment damage Figure 2.2 Danger, Warning, Caution Signs And Their Meaning
EN REV-A
METSO MINERALS SAFETY INSTRUCTIONS 2-3
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
2.2.3 Some General Safety Instructions
1. Do not remove, cover or disable any installed safety devices, guards, warning signs or tags. They are attached to equipment to warn personnel of possible danger and prevent injury. Use OEM replacements in the event any safety devices, warning signs or tags become damaged or unreadable. Observe all instructions. Keep warnings signs and tags clean, visible and readable. (Warning signs are listed and their locations described in the machine safety instructions.) 2. Make sure that all required walkways, handrails, barriers, safety devices, and guards are in place before starting the machine. Do not use non-OEM walkways, handrails, barriers, safety devices or guards, when such items are available from OEM. 3. Keep the machine itself and the area around the machine clean and clear of obstructions. Be aware of dust, smoke or fog, which may obscure your vision. 4. Wipe up any substance, such as spilled oil, grease, water or ice, which may cause a person to slip or fall. Good housekeeping practices prevent injuries. Be a good housekeeper. Keep the machine environment and walkways clean and free from oil, grease, rags, cables, chains, buckets, rocks and other obstructions. Keep loose parts in a toolbox or return them there promptly. 5. Keep clothing and all parts of the body away from nip points and rotating or moving equipment. Be especially alert to avoid contact with parts that move intermittently. 6. Know the weight limitations of lifting devices and their loads. Never detach a lifting device from a load until the load is stable and secured from unintended movement.
2-4
METSO MINERALS SAFETY INSTRUCTIONS
7. Do not climb or stand on equipment other than in areas, which are designed for that purpose. Do not overreach. 8. Emergency-Stop buttons should be tested on a regular schedule for proper operation, as should electrical interlocks and related limit switches. Safety defects should be repaired prior to continuing operation, and thereafter tested and certified for appropriate operation by skilled personnel. 9. Personal protective equipment and safety uniforms, safety shoes, helmets, safety glasses, heavy gloves, ear protection devices etc. should be used at all times. Safety shoes should be used by all personnel entering into the Crushing Plant. Persons with loose clothing, neck ties, necklaces, unprotected long beard or long hair should not go near the machine. Wrist watches and rings can be dangerous.Rings should be removed or covered with tape. Keep your pockets free of loose objects. 10.Keep all non-operating and non-trained personnel clear of the Crushing Plant at all times. Injury or death may result if this is not done. 11.The equipment at the control panel should be handled with care. Do not place objects on the keyboard, color display or other equipment. All equipment can fail if put in contact with liquids, or excessive heat or excessive humidity. Allow good air flow around the equipment at all times. Keep magnets away from computer components, particularly hard drives and PLC cabinets. 12.A knowledgeable and properly trained Operator familiar with this manual, safety requirements, and automatic operation of the machine should be stationed at the controls whenever the machine is operating.
EN REV-A
09/2005
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
13.Do not consume any alcoholic beverages or other intoxicants before coming to work or while on the job. Do not operate the Crushing Plant after taking any medicines, tranquilizers or other drugs, which can impair the senses. 14.Familiarize yourself with the safety signs on the Crushing Plant. Never remove or damage any safety signs, nameplates or other safety related warnings, symbols or components. Replace them as necessary with OEM equipment. 15.Do not paint over safety signs, name plates or warnings.
2.2.4 Blasting
The use of the Crusher Plant’s radio control device is strictly forbidden during blasting operations, as it may cause a premature explosion. Move the mobile Crushing Plant far enough away from dangerous area when blasting. Do not store or transport explosives on mobile crushing plant or screening plants.
WARNING:
2.2.5 Portable Plants
Only qualified and properly trained operators and servicemen should operate or service the machine. Everyone else should stay clear of the machine when it is operating, or under service or maintenance!
If the Crushing Plant includes of portable equipment (i.e. crushing and screening equipment mounted on trailers), trailer footing or cribbing is extremely important for safe operation. Your machine must be on as solid and level footing as possible. If the ground is not naturally level, it must be leveled so that the unit will operate safely and effectively. The ground must support the weight of entire unit and keep it from sinking or shifting. Use heavy timber mats as needed. Trailers must be raised so that trailer wheels do not touch the ground. Place jacks at each corner of the trailer or as near the corner as possible and to other suggested support points at mid-frame. All corner jacks must be at an equal distance from each end. Adjust each jack until the unsupported portion of the trailer beams stops vibrating or until vibrations are reduced to a minimum. Lock jacks and adjustable support legs mechanically with locking pins when applicable. Periodically recheck trailer footing for stability.
09/2005
EN REV-A
METSO MINERALS SAFETY INSTRUCTIONS 2-5
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
2.2.6 Mobile Equipment Transportation
Remove all shipping brackets before re-starting the Crushing Plant. Carefully assemble all of the parts previously disassembled. Perform any start up in accordance with the instruction manual.
Use only appropriate transportation and lifting equipment with adequate capacity. Provide a supervisor to direct lifting operations. Follow all disassembly and assembly instructions carefully. Disconnect all external power supplies before moving any part of the equipment.Transport or hoist components and handle any parts in accordance with the instructions and advice provided. Fasten the lifting equipment only to the points meant for lifting. Use only proper means of transport with adequate transporting capacity. Fasten the load carefully. For lifting use only the fastenings shown in instructions. Secure all component parts of the equipment immediately after loading to avoid any accidental shifting. Attach required warning signs to the load.
After the system is running, check all gauges and instruments to see that they are working correctly. Check that all controls function normally and properly. Listen for unusual noises. Shut system down immediately if any component of the system does not operate normally.
When moving your trailer, check bridges before crossing. Make sure they will support the weight of the machine. Check clearances under bridges, for overhead lines or any overhead obstruction. Never travel with near capacity loads. Check local laws, especially on weight limitations. When travelling on the highway make sure all headlights, clearance lights and tail lights are on, as applicable. Use proper traffic warning flags and signs.
2-6
METSO MINERALS SAFETY INSTRUCTIONS
EN REV-A
09/2005
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
2.3 TYPICAL RISKS IN CRUSHING PLANT WORKING ENVIRONMENT
– sharp edges – high-pressure hydraulic equipment – electrical equipment – automatic functions and unexpected start-ups – toxic and corroding agents – machine inertia – hot surfaces and fires – zinc
Even though every Metso Minerals machine is designed with many safety features, it is impossible to design out all safety risks. There are potential hazards, that must be recognized and avoided. Noise levels may interfere with normal discussion when the machine is operating. By their nature, Crushing Plant and auxiliary equipment can create dust. Crushing itself and some other machine processes may momentarily obstruct the view of some machine parts. In general, high levels of respirable silica and other dust in the air may expose Operator to health risks for lung disease depending upon the length and amount of exposure and type of material being crushed. In addition, there are some risks or hazards which cannot be completely guarded or avoided because of interference with machine operations. Accordingly, working on the Crushing Plant requires constant alertness by all personnel in the area. Accidents happen unexpectedly. Below are some typical hazards and types of accidents that everyone working at, on or around the Crushing Plant should be aware of.
– conveyor belts – dust – noise and vibration – improper work methods – rotating equipment and moving components – ejection of material from the crusher – falling material from conveyors, and from loading, unloading and feeding operations – crushing cavity These typical hazards are discussed more fully in Section 2.3.1 of this chapter. Be aware of these hazards. All personnel working on or around the machine should be properly trained in avoiding these hazards. Typical Injury Types
Typical Hazards
– crushing – slipping, tripping and bumping – falling
– nips, gaps, and pinch points
– cutting
– poor housekeeping
– entanglement
– elevated or narrow working areas
– burns and electrical shocks
– lifting and shifting heavy loads
– respitary organ illnesses
– cranes and mobile cranes
– asphyxiation
09/2005
EN REV-A
METSO MINERALS SAFETY INSTRUCTIONS 2-7
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
2.3.1 Typical Hazards
ladders and floors. Tidiness provides a safer working environment by preventing or helping reduce tripping, slipping, fire hazards and electrical shocks.
Nips, Gaps, and Pinch Points
Elevated or Narrow Working Location
An ingoing nip is formed by drive devices such as belt and pulley, chain and sprocket or gears. Similarly, a pinch point may be formed by rotating or moving equipment. DANGER:
Nips and gaps are serious hazards in a Crushing Plant. They are usually guarded by nip guards, railings, or location. In all cases, extreme care must be taken to avoid nips, gaps, and pinch points or serious injury or even death may occur.
Crushing Plants are tall structures. The walkways and platforms, designed to be used during machine operation, are furnished with railings to help prevent falling. When working on an elevated surface be aware of machine movements and other activities in the area. Do not run on the walkways. Do not reach over or beyond walkway railings while the machine is running. Do not stand on railings or toe plates.
Poor Housekeeping
There may be narrow access routes for maintenance purposes. Do not use these routes while the machine is operating. Do not enter any close quarters within the Crushing Plant when the machine is operating. Promote good housekeeping. Keep machine environment, walkways, platforms etc. clean and dry and free of debris. Oily or wet machine environment, walkways, platforms, steps and hand rails are slippery. In cold weather, watch out for ice and snow. Wet spots, especially near electrical equipment, are dangerous. Return tools to their proper place after use. Even then extreme caution should be used. Follow established Crushing Plant safety procedures. Clean slippery deposits from walkways,
2-8
METSO MINERALS SAFETY INSTRUCTIONS
EN REV-A
09/2005
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
Lifting And Shifting Heavy Loads IMPORTANT!
•
When using a crane, always operate within the rated capacity of the crane. The safe rated capacity includes weight of hook, block and any materials handling devices such as cables, slings, spreader bars, etc. Subtract the weight of all these items from the rated capacity to find the true weight of the load that can be handled safely. Always follow the crane manufacturer's operational and safety instructions.
Cranes
Crushing Plants, like any other type of mechanical equipment, require regular periodic maintenance. One of the most flagrant Crushing Plant safety violations is the use of inadequate and unsafe lifting equipment. Although a Crushing Plant is a finely tuned piece of equipment, the internal parts of a Crushing Plant should be assembled and disassembled with crane facilities that have the capability of gently and slowly lifting and lowering the various parts that make up a Crushing Plant. Do not use chain hoists (chain blocks) to assemble or disassemble a Crushing Plant. These lifting devices lack the stability and robustness required in lifting and positioning heavy components. Do not use impact hammer boom or any other equipment which are not designed for lifting, for assembly or disassembly purposes. Affix the load securely to its destination. Never detach a lifting device from a load until the load is stable and secured from unintended movement. When it comes to safety, don't compromise!
IMPORTANT!
The weight indicated in machine plates tells the weight of standard configuration. In many cases the actual weight may differ greatly from that indicated in machine plate due to, e.g., options or ancillary equipment. Always verify the weight of the object you are lifting before attempting to lift it.
•
Mobile cranes
Safe ratings are based on operating the crane on firm, level ground; outriggers must be properly extended and/or lowered whenever required. Avoid fast swings, hoists or sudden braking; these can cause overloads. Do not handle large, heavy loads in strong winds. When moving your crane, check bridges before crossing, make sure they will support the total weight in question. Check clearances under bridges for overhead electrical lines and any overhead obstruction. Be sure your hitcher is clear before starting lift. Make sure the load is securely attached. IMPORTANT!
When using a mobile crane, always operate within the rated capacity of the machine to avoid buckling the boom or tipping.
09/2005
EN REV-A
METSO MINERALS SAFETY INSTRUCTIONS 2-9
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
Sharp Edges Take the following precautions when lifting heavy loads: – Follow all established Crushing Plant procedures. – Follow all instructions and safety procedures recommended by the crane manufacturer. – Plan the lifting and maintenance procedures in advance. Read and understand specific instructions for proper use of lifting equipment prior to using (e.g instructions of the machine, lifting device and local regulations).
Sharp edges may occur on any metal structures. Equipment damage may uncover or produce unexpected sharp edges. Sharp edges may inflict deep and serious cuts. Wear protective gloves when handling materials, parts, etc. with sharp edges. Repair or guard detected sharp edges immediately.
– Clean the working environment beforehand to prevent slipping and tripping hazards.
High-pressure Equipment - Hydraulic or Air
– Make sure that the crane and other lifting devices such as chains and slings have sufficient capacity and are in good working order. – Do not attempt to ride or sit on moving loads. – Be sure that crane operators, riggers and other personnel have been properly trained. – Rig the load firmly to prevent any unintened movement and assure stable and accurate positioning. – Make sure nobody is below or on the path of the load and that the transfer routes are clear and proper protective clothing and gear are used.
High pressure oil can be dangerous. Relieve all pressure before opening or removing any hydraulic or air pressure lines, valves, fittings, etc. Do not touch pressurized components since the pressure from a pin hole leak is so strong that it can easily penetrate the skin or eyes. Always exercise caution when handling hydraulic devices. Regularly check the condition of hoses, pipes, valves and various connections. Replace them as necessary. Before starting any maintenance work, stop all hydraulic pumps, lock out pump motors, and depressurize the system, bringing all components to a zero energy state. Remember to also depressurize the accumulators through
2-10
METSO MINERALS SAFETY INSTRUCTIONS
EN REV-A
09/2005
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
the bleed valve for each accumulator. Do not disconnect any hoses until the actuator has been brought to a zero energy state and properly secured. Bleed the hydraulic system regularly to remove entrapped air that may interfere with normal expected machine operation or cause a hazard during maintenance. WARNING!
Poorly tightened or damaged hydraulic components may inject dangerous jets of fluid. Before restarting the machine, be sure that the hydraulic system is ready for operation, and personnel are clear of affected areas. WARNING!
Electrical Equipment
Be especially cautious when working with or near electrical equipment. An electric shock can be fatal. Crushing Plant electrical outlets must be grounded and have ground fault interruption protection. Tools plugged into the outlets must be double insulated. Never expose electrical equipment to mechanical damage or humidity. Protect all electrical equipment from direct contact with water or high humidity. Protect electrical devices that move as part of the machine from dirt and mechanical damage. Regularly check the operability of these devices.
Machine parts may move unintentionally and cause a risk of injury. Before restarting the machine, make sure that all personnel are clear of affected areas where machine movement may occur.
DANGER:
There is a risk of an electric shock, if sufficient precautions are not taken. An electric shock can be fatal. For maintenance work, disconnect all devices from electric and hydraulic power sources and follow Crushing Plant lockout procedures.
The lockout program, locks, tags and the blocking/restraining devices provided are designed for your protection. Your responsibility is to follow the program and use the proper equipment. Remember: – Follow procedures. – Stay alert. – Do not take anything for granted. – Verify lockout. – Each person working on the unit must have his own lock with only 1 key.
09/2005
EN REV-A
METSO MINERALS SAFETY INSTRUCTIONS 2-11
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
– Tag must identify the work being done and the person(s) who locked and tagged the control. – Locks and tags are changed with each shift that comes on. Work to prevent injury or death. Follow proper procedures at all times!
WARNING:
Machine parts may move unintentionally and cause a risk of injury. Absence of safety functions may cause dangerous machine movements.
Maintenance, repair and installation of electrical equipment must be performed only by qualified personnel who are familiar with the machinery and equipment in question.
Do not tamper with limit switches or other safety devices included in the system.
Automatic Functions and Unexpected Start-ups
DANGER:
If danger zones are not respected during machine operation or maneuvres there is a risk of serious injury or death. Many devices operate automatically, following certain sequences which have been programmed into the logic system (i.e. programmable logic controller, microcontroller, relay system or similar). The danger zone is any area within the confines of moving machine elements, feed material or beneath any objects being lifted. Do not enter these danger zones unless the machine has been properly safeguarded according to the Crushing Plant lockout procedure and manufacturer's instructions.
Unexpected start-ups during maintenance: – Lock out and tag machine controls before performing maintenance or repairs to avoid unexpected start-up. Failure to properly lock out the machine can lead to injury or death. Someone may accidentally start the machine from the control room or an unexpected occurrence may activate a control. For example, a power surge may alter the logic of the control system status causing an unexpected machine movement or sequence.
2-12
METSO MINERALS SAFETY INSTRUCTIONS
EN REV-A
09/2005
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
Welding Equipment IMPORTANT!
All maintenance personnel who use cutting and/or welding torches should be advised if there are hydraulic components in the immediate area in which they are working.
IMPORTANT!
Weld repairs are to be performed only by qualified personnel. Welders and welder’s helpers must wear protective clothing and equipment. Precautions must be taken when torch cutting and/or welding due to the health hazards posed by many metals. Anyone performing these types of procedures should avoid breathing the fumes. Such procedures should be done outdoors or in a well ventilated area with either a separate clean air supply provided to the mechanic or with local exhaust of fumes. Please refer to EU, OSHA, MSHA or other applicable standards as appropriate. One of the most frequently used tools around the Crushing Plant is the cutting torch. Crushing Plants which are equipped with hydraulic components and/or conveyor belts and/or v-belts should have these components depressurized and adequately covered with flame-proof material so that sparks, weld spatter, etc., cannot reach theses areas. Ruptured high pressure hydraulic lines will quickly vaporize the hydraulic fluid as it reaches the atmosphere. This vaporized fluid can quickly become a mass of flames, resulting in severe burns for personnel in the immediate area. Adequate precautions should be made to avoid contact with these components. Never perform welding or torch cutting activities in the presence of flammable materials. WARNING:
Risk of injury. Fire may break out. Never perform welding or torch cutting activities in the presence of flammable materials.
09/2005
Contact Metso Minerals or its authorized representative prior to any welding of major Crushing Plant components such as main frame, adjustment ring, bowl, etc. Performing welding on the Crushing Plant components can be detrimental. Before welding, always verify that material is weldable! Failure to do so may result in weldment failure and present a risk of injury and/or property damage.
Toxic, Corroding and Irritating Agents
Before handling chemicals, carefully read the safety instructions from the supplier of the respective chemical. Hazardous chemicals may be in use. Wear protective clothing, gloves, boots, glasses, and respirator when necessary. Refer to the MSDS (Material Safety Data Sheets) and Crushing Plant procedures for handling of these materials. Avoid prolonged contact with fluids, such as gasoline, diesel fuel, hydraulic oil and cleaning solvents, which may cause skin irritation or other reactions.
EN REV-A
METSO MINERALS SAFETY INSTRUCTIONS 2-13
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
Machine Inertia
Due to the large inertial forces of the Crushing Plant and Crushing Plant components, the machine can not be stopped abruptly. This is potentially hazardous to personnel. All personnel must stay clear of rotating elements and other moving parts until the machine has come to a complete stop. Regularly inspect the structural elements to maintain safe operation. Hot Surfaces and Fires
There are hot surfaces on Crushing Plants. Protective gloves and coveralls help protect against burns. Be aware of hydraulic system, hoses, fittings, and pipes. Regularly inspect and observe high temperature lines, and fluid lines for leaks or damage. On mobile equipment be cautious around the engine because of exhaust gases.
In case of a fire, the machine must be equipped with a fire extinguisher or fire extinguishing system, and marked according to the regulations. Legislation and regulations about suitable equipment may vary by country. Familiarize yourself with applicable standards. Personnel must also be trained properly to be able to use fire extinquishing equipment. A trained person with sufficient fire extinguishing equipment must be present during welding maintenance work. Cold water on hot metal surfaces may cause a violent explosion. Monitoring after welding must be arranged as required by laws and regulations. If no other regulations apply, monitoring time is a minimum of one half hour. Fire Hazards
When in contact with hot temperatures, or when heated themselves, some hydraulic oils may ignite at around 392°F (200°C). Attention must be paid to the condition of hydraulic hoses and couplings. Remove immediately oil spills from floor, walkways, and pits. Fix all sources of oil leaks and clean up spills.
– Do not smoke while refueling, or when handling fuel containers. – Shut off engine when refueling and use extra caution if engine is hot. – When pouring fuel into the tank, ground the funnel or spout against the filler neck to avoid static electric spark.
2-14
METSO MINERALS SAFETY INSTRUCTIONS
EN REV-A
09/2005
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
– Do not use gasoline or diesel fuel for cleaning parts. Good commercial, nonflammable solvents should be used. – Do not smoke while using flammable cleaning solvents. Whenever possible, use non-flammable cleaning solvents. – Do not let greasy, oily rags accumulate in a poorly ventilated area. Store oily rags and other combustible material in a safe place.
completely eliminated the possibility of workers being accidentally burned due to molten zinc either spilling or exploding when it comes in contact with wet surfaces. When epoxy backings are used, care should also be taken when removing the liners with a cutting torch . Do not use molten zinc as backing material. Use epoxy only according to specific instructions from the manufacturer. Conveyor Belts
– Never use an open flame to check fuel, battery electrolyte or coolant levels, or to look for hydraulic leaks anywhere on the equipment. Use a flashlight. Know where fire extinguishers are kept, how they operate, and for what type of fire. Check regularly, at least monthly, to be sure they are in the working area. – Do not weld or cause open flame in the presence of flammable materials.
WARNING:
Do not use conveyor belts as walkways. Do not climb on them. Always stay clear of any falling or dropping materials or components. Never attempt to stand on, walk on, or step across a conveyor. Never stand below a running conveyor. Do not use loose clothing, neck ties, necklaces or other loose items when near conveyors or other moving or rotating equipment. Emergency pull cords should be used only in case of emergency -do not use them for routine stoppage of conveyor. Never attempt to service the conveyor while it is energized. Keep in mind hazardous nip points.
– In the event of a fire, shut down the Crushing Plant, hydraulic power unit and lubrication system if this can be safely done. Warn other people in the area and commence fire fighting activities according to applicable rules. It is the responsibility of the Owner to maintain proper training and instructions in these respects. Epoxy Versus Zinc
Many Crushing Plants require some type of backing when replacing the crushing members. Epoxy resin backing compounds have almost
09/2005
EN REV-A
METSO MINERALS SAFETY INSTRUCTIONS 2-15
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
Crushing Plant Dust IMPORTANT!
Metso Minerals highly recommends that dust protective devices such as an appropriate respirator be worn by anyone exposed to airborne dust to prevent its inhalation.
WARNING:
By their nature, Crushing Plant and auxiliary equipment such as chutes, transfer stations, screens, etc. can create dust and, if not contained, the dust can escape into the air. In general, high levels of dust (particularly, respirable silica) in the air can create a hazard of lung disease, depending upon the concentrations of dust, the length of exposure, and the type of material being crushed. Dust protective devices and dust warnings may be required by OSHA, MSHA or local laws.
Breathing dust may be hazardous to the health of anyone working at, on, or around the Crushing Plant. It can cause serious or fatal respiratory diseases including silicosis! It is the responsibility of the Owner and Operator to determine the necessity and adequacy of protective devices and warnings, to provide them, and to ensure that they are used and followed!
The Owner and Operator of the Crushing Plant must identify the material being crushed and ascertain whether respirable dust from the application poses a health hazard to personnel in the vicinity of the Crushing Plant.If the material presents such a hazard the Owner and Operator must take all necessary measures to ensure that personnel are protected from the dust. Such measures include, but are not limited to providing dust collection system, using water spray bars at the feed and discharge points, crusher transfer points and screens and providing adequate personal respiratory protection devices to workers. Crushing with a choke level may also reduce the amount of dust issuing from the Crushing Plant itself. Because the configuration of each rock crushing installation is different, Metso Minerals recommends that the Owner and Operator consult Metso Minerals or a dust consultant about possible alternative means of dust reduction.
2-16
METSO MINERALS SAFETY INSTRUCTIONS
EN REV-A
09/2005
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
Noise and Vibration
is an increased risk of falling on a vibrating platform. Avoid standing on a vibrating Operator's platform or walkway. Unexpected or excessive vibrations may be a sign of wear and/or maintenance needs. Excessive vibrations associated with a portable crushing or screening plant is frequently caused by improper cribbing.
•
Crushing Plant Noise
Crushing Plant by its very nature is noisy and the auxiliary equipment found at, on or around the Crushing Plant such as chutes, transfer stations, screens, etc., can at times be noisier than the Crushing Plant itself. Typical Crushing Plant noise level while crushing range from 100 - 110 dB measured at 1 m (3ft) from the Crushing Plant.
It is recommeded to regularly monitor vibration levels of machine components including, but not limited to: – bearings – shafts – rollers – structural members (including conveyor frames, walkways, platforms, hoppers, chutes, etc.)
Metso Minerals recommends wearing ear protection at, on and around Crushing Plant, particularly when the noise level exceeds 85dB. It is recommended that the Owner develop a signaling communication system in noisy environments to reduce the risk of accidents. Proper machine maintenance and replacement of worn parts can help reduce noise. The most commonly applied noise reduction procedures are: – use of isolation techniques – equipment enclosures – operator enclosures – silencers Allowable noise levels and exposure limits are regulated by various agencies such as ISO, OSHA, MSHA, etc. Refer to applicable safety regulations for permissible noise exposures, and take steps to ensure compliance with those regulations. •
Vibration
Long term exposure of Operator to vibration may result in detrimental health effects.There
09/2005
EN REV-A
METSO MINERALS SAFETY INSTRUCTIONS 2-17
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
Improper Work Methods
typically checked with a tachometer. Make sure that any access openings have a protective cover in place at all times except when RPM readings are being taken. Never change sheave combinations without first consulting your Metso Minerals representative. Ejection of Objects from the Crushing Plant
Improper work methods and motions may cause physical injuries. Use suitable tools, cranes or jacks for moving large and heavy objects. Overreaching and improper support for loads may lead to injuries to the back or other parts of the body. If you are unsure of proper work methods, contact your safety director or other person responsible for ensuring the safety at your work place.
Ejected objects from the Crushing Plant may cause bodily injury. For example rock can be thrown several meters (several yards) into the air out of the crushing cavity during operation. Ejected materials may include rock, tramp metal, metal rods and work implements. Do not look into crushing cavity while crusher is in operation. Never attempt to clear jam on feeder, crushing cavity or conveyors when system is energized.
When lifting equipment by hand, protect your back by lifting close to your body and using your legs without twisting. Use hoists whenever possible. Stand clear of hoisted loads and lifting cables. Rotating Equipment and Moving Components
Rotating and moving components provide pinch points, snagging possibilities and other potential hazards. Keep clear of all moving parts until they come to a complete stop. Do not use any body part, tool or other foreign object to attempt to stop, adjust, clear, or clean any area in proximity to moving equipment such as vibrating feeder, conveyor belts, drives or other rotating parts of the crusher. Engaging in such activities can result in severe personal injury, including death. Crushers, designed to operate within a specific RPM range for maximum efficiency, are
2-18
METSO MINERALS SAFETY INSTRUCTIONS
EN REV-A
09/2005
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
2.3.2 Typical Injury Types
Falling Material from Conveyors, Loading, Unloading and Feeding Operations
Crushing In general, avoid areas where you may be exposed to expected or unexpected machine movements. Crushing injuries typically occur either between two rotating or moving parts, or between a moving component and a stationary object.
Rocks or other objects may fall from conveyors during loading, unloading and feeding operations. Impact of falling material may cause serious bodily injury. To assure safe operation, all personnel must be alert when operating or working at or around the machine. Wear proper protective clothing (including also helmet) and protective devices. Keep all non-operating and non-trained personnel clear of the Crushing Plant at all times.
Keep all body parts, clothing and tools away from areas where they may get trapped, pinched, or crushed, or otherwise come into contact with moving parts on the Crushing Plant. When moving equipment, be sure the path is clear. Horns and lights, where provided, are for your safety to alert you of moving objects. Pay attention to all such devices. Slipping, Tripping, and Bumping
Never walk under any equipment included in loading, feeding, crushing, conveying, discharging or stockpiling material.
Items such as hoses, tools, etc., on walkways and Crushing Plant floors impede movement and create a tripping and slipping hazard. Good housekeeping reduces the risks considerably. Personnel should wear safety shoes that reduce the risk of slipping and provide protection against falling objects or crushing. Hydraulic oil leaked or spilled on the floor must be cleaned up immediately. To help avoid injury, be aware of parts positioned close to the floor level or protruding machine components, changes in elevation of platforms, walkways, and narrow access points. It is recommended that safety shoes be worn at all times. Wear safety helmets and other safety equipment as appropriate.
09/2005
EN REV-A
METSO MINERALS SAFETY INSTRUCTIONS 2-19
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
Falling
Cutting
Do not reach in or enter: Use only designated access routes designed for the purpose, for example walkways and platforms. Walkways and platforms are furnished with railings designed to meet applicable standards. However, in some work phases, railings or platforms may have to be temporarily shifted aside. In those cases, special caution signs or temporary barriers must be used when working on the machine. Use personal fall protection gear , temporary barriers, interlocks, or other warning devices where appropriate. Never attempt to operate, service, or repair the Crushing Plant without first ensuring proper protection against falling. Guards that are moved aside must be installed immediately after maintenance work and before the machine is returned to operation. Never climb or stand on areas of the Crushing Plant not specifically designated for that purpose. WARNING:
Do not operate any equipment until all guard rails and safety devices have been re-installed or returned to their proper operating condition. Failure to do this could result in serious injury or death.
– the movement paths of cutting equipment – between moving machine components – between moving loads and machine structures Entanglement
To avoid entanglement, avoid wearing loose clothing that could be caught by rotating shafts, conveyors, and other moving parts .and materials. Remove neckties, necklaces, rings, and other jewelry before performing work assignments. Also protect a long beard or hair from entanglement. Do not touch a rotating roller, sheave, pulley, idler or moving conveyor belts with any body part or work implement, as you may become entangled and pulled into a hazardous area. Never attempt to service, repair, or troubleshoot any moving part of the Crushing Plant while it is energized or otherwise capable of movement. WARNING:
KEEP THE AREA CLEAN!
2-20
METSO MINERALS SAFETY INSTRUCTIONS
Keep safety gates, shrouds, guards, and other protective devices in place and in good working condition at all times. Test emergency stop, electrical interlocks, and related limit switches frequently.
EN REV-A
09/2005
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
Burns and Electrical Shocks
from the path of ejected materials, also during lifting, assembly and dissassembly operations. Removal of tramp iron jammed between the crushing members is extremely dangerous. Follow the instructions in the instruction manual. Do not look into crushing cavity while crusher is in operation.
Protective gloves and coveralls help protect against burns. Be cautious around and near hydraulic system hoses, fittings and pipes. Regularly inspect and repair leaking or damaged high temperature lines and fluid lines. To avoid electrical shocks: – Power must be shut off and locked out before any servicing or maintenance work is done. Unplug or disconnect all auxiliary motors and equipment. – DO NOT drill blindly into beams, electrical cabinets or other enclosures. Avoid any contact between moisture or other fluid and electrical equipment. Impact from Ejected Materials
There are several hazards related to falling, flying or otherwise ejected materials when the Crushing Plant is being operated or serviced. For example, rock can be thrown several meters (several yards) into air out of crushing cavity during operation. Ejected materials may include rock, tramp metal, metal rods and work implements. Keep the safety grate down during the operation. Wear proper protective clothing (including helmet) and protective devices. Always use properly maintained and approved tools and work methods. Stay clear
09/2005
EN REV-A
METSO MINERALS SAFETY INSTRUCTIONS 2-21
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
2.4 PERSONAL PROTECTIVE EQUIPMENT AND CLOTHING
appropriate hearing protection of the type and to the extent required by law.
Personal protective equipment and clothing such as foot protection, helmet, hearing protection, dust protective devices, safety glasses or other personal protective clothing and equipment should be worn at all times. All equipment should be maintained in accordance with applicable standards. Respirators, goggles, protective masks, gloves, boots, and other such equipment shall be cleaned and disinfected before being used by another employee. The Owner and Operator are responsible for ensuring that all eye, head, respiratory, and ear protection conforms to applicable standards.
2.4.2 Eye And Face Protection
General requirements should include:
IMPORTANT!
Always use right size of protective equipment.
– The Owner should ensure that personnel for the machine area use appropriate eye or face protection when exposed to eye or face hazards such as flying material, molten metal, liquid chemicals, acids or caustic liquids, chemical gases or vapors. – The Owner should ensure that affected personnel use eye protection that includes side protection from flying objects.
IMPORTANT!
– The Owner should ensure that affected personnel who wear prescription lenses while engaged in operations that involve possible eye hazards wear eye protection that incorporates the prescription in its design, or wear eye protection that can be worn over the prescription lenses without disturbing the proper position of the prescription lenses or the protective lenses.
It is the responsibility of the Owner and Operator to determine the necessity and adequacy of protective devices and warnings, to provide them, and to ensure that they are used and followed.
2.4.1 Hearing Protection
Noise level in the machinery area may exceed 85 dB, and exposure to the machinery area in such circumstances without adequate hearing protection may lead to hearing loss. Therefore, users must be provided with
2-22
METSO MINERALS SAFETY INSTRUCTIONS
EN REV-A
09/2005
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
2.4.3 Respiratory Protection IMPORTANT!
Metso Minerals highly recommends that adequate dust-protective devices such as a respirator be worn by anyone exposed to airborne dust, particularly silica dust, to prevent its inhalation. Respiratory protection is required when the air contains contamination such as harmful dusts, fogs, fumes, mists, gases, smokes, sprays, or vapors. The primary objective is to protect the health of workers.
2.4.4 Foot Protection
Respiratory protection must be provided by the Owner when such equipment is necessary to protect the health of personnel. The Owner shall provide the respiratory protection and training programs, which are applicable and suitable for the purpose intended and comply with the latest requirements and recommendations of health authorities and regulatory agencies. IMPORTANT!
The enormous degree of convenience as well as the high safety factor involved when using plastic backing agents has made the use of molten zinc for Crushing Plant liner backing obsolete. See 2.3.1
The Owner shall ensure that affected personnel use protective footwear when working in areas where there is a danger of foot injuries due to falling or rolling objects piercing the sole, and where feet are exposed to electrical or chemical hazards. 2.4.5 Head Protection
IMPORTANT!
The area should be well ventilated. Epoxy fumes can cause nausea or eye or skin irritation. IMPORTANT!
Breathing dust may be hazardous to the health of anyone working at, on, or around the Crushing Plant.
09/2005
The Owner should ensure that affected personnel wear a protective helmet approved by OSHA, MSHA (or by other applicable authority) when working in areas where there is a potential for head injuries from falling objects or walking throughout areas with low head clearance. The Owner should ensure that a protective helmet designed to reduce electrical shock hazard is worn by personnel when near exposed electrical conductors which could contact the head.
EN REV-A
METSO MINERALS SAFETY INSTRUCTIONS 2-23
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
2.4.6 Hand Protection
The Owner should ensure that personnel use properly sized appropriate hand protection when hands are exposed to hazards such as those from skin absorption of harmful substances, cuts or lacerations, abrasions, punctures, chemical burns, thermal and electrical burns, and harmful temperature extremes. 2.4.7 Safety Harnesses
2.4.9 Tools
The Owner should ensure that personnel use appropriate tools for the job. Use tools that are specially designed to break away or are easily released to help avoid certain accident situations such as unexpected movement at a nip point or a rotating shaft. Under no circumstances must tools be allowed to come into contact with moving parts while the Crushing Plant is energized. When working in humid or damp environments, use hydraulic tools or electrical tools that are suitably grounded, double insulated, or have ground fault interruption circuits.
The Owner should ensure that any person working on elevated areas not protected by railings, or on hazardous places must wear suitable safety equipment, including safety harnesses, if there is a risk of falling. Confined spaces may also require safety harnesses. 2.4.8 Work Clothing
The Owner should ensure that personnel wear appropriate clothing to help protect against hazardous material and hot surfaces. Loose clothing can get caught in a nip, shaft, or other moving machine components.
2-24
METSO MINERALS SAFETY INSTRUCTIONS
EN REV-A
09/2005
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
2.4.10 Safety Locks And Tags
Follow all lock-out tag procedures. Refer to appropriate standards and instructions provided by Metso Minerals. DANGER:
For maintenance work, disconnect all devices from electric power sources. Bring all hydraulic gravity or spring loaded devices to a zero-energy state. Follow lockout procedures.
The lockout program, locks, tags and the blocking/restraining devices provided are designed for Operator’s protection. Operator’s responsibility is to follow the program and use the proper equipment. Remember: – Follow procedures. – Stay alert. – Do not take anything for granted. – Verify lockout. – Tag must identify the work being done and the person(s) who locked and tagged the control. – Locks and tags are changed with each shift that comes on. Work to eliminate injury and death. Follow proper procedures at all times!
09/2005
EN REV-A
METSO MINERALS SAFETY INSTRUCTIONS 2-25
SECTION 2 - GENERAL SAFETY INSTRUCTIONS
This Page Left Intentionally Blank.
2-26
METSO MINERALS SAFETY INSTRUCTIONS
EN REV-A
09/2005
MACHINE SAFETY
SECTION
3.1 PROTECTIVE DEVICES AND ACCESSORIES FOR MACHINE SAFETY
3
The location of local E-stop buttons may vary on different machines; therefore the locations of these buttons must be verified from the operating and maintenance manuals specific to the equipment and/or from proper training.
3.1.1 Overview
The machine system has many built-in safety features. Owners and Operators should make themselves familiar with the function and purpose of each feature and make sure all of the features are enabled. Owners and Operators should never attempt to defeat, bypass or disable any safety features. If any of the features are defeated or become disabled, the machine should not be operated until corrective action is taken and all safety features are restored.
In emergency stop situations, the objective is to stop the machine as soon as possible to minimize potential injuries while maintaining the structural integrity of the machine. CAUTION:
Emergency stop not only stops the machine but often it may initiate other protective sequences.
3.1.2 Emergency-Stop (E-Stop)
NOTE: It may be necessary to engage
reset switches before movement can resume. 3.1.3 Safety Interlocks
Use the emergency stop when injury may occur or human life is in danger from continued operation of the machine. This provides the quickest, most sure way to stop the machine. Due to the large inertial forces of the Crushing Plant and Crushing Plant parts and components, the machine can not be stopped abruptly. Large red emergency stop buttons are typically located in control panels near the vicinity of danger points. Emergency stops can be, and often are, in the form of pull cords that run paraller to conveyors and surround hazards. WARNING:
On large complex systems, the E-stop may control only those components that are in the immediate area.
09/2005
A safety interlock is a device that will interrupt the supply of electricity, hydraulic oil or compressed air to an actuator or motor. A machine already in operation may need to stop quickly due to Operator error, safety violations, or an unexpected machine event. For example, a safety gate may be interlocked to stop a machine if the gate is opened while the machine is running. Interlocks can also be used to prevent sudden unexpected movement of a machine function or component. During operation, the logic system (i.e. programmable logic controller, microcontroller, relay system or similar device) controls the functions of the machine. Interlocks built into the system employ limit switches and other sensors to help assure proper machine operation.
EN REV-A
METSO MINERALS SAFETY INSTRUCTIONS 3-1
SECTION 3 - MACHINE SAFETY
The pilot-controlled throttle valve helps prevent uncontrolled actuator movements.
THEREFORE IT IS IMPORTANT THAT INTERLOCKING ARRANGEMENTS ARE NOT REMOVED, MODIFIED OR BYPASSED, AND THAT THEY ARE CORRECTLY ADJUSTED. LIMIT SWITCHES, AND OTHER SENSORS MUST BE KEPT IN GOOD WORKING ORDER.
Pressure transducers monitor the system pressure for information or control purposes. Safety Gates
Electric Motors
Some safety gates are designed so that opening or closing of the gates will prevent or stop a specific machine function in that area. Hydraulic, hydraulic or electric limit interlock switches may cut off the drive or actuator power or initiate an emergency stop mode.
Electric drives and motors may be controlled to stop or reduce speeds, as determined by the safety interlocks at a particular location. Hydraulic System
For specific operation, see later sections of this manual. WARNING:
Components that help protect the hydraulic system include certain valves, such as hose burst valves, pressure relief valves, counterbalance valves and pilot-controlled throttle valves as well as pressure transducers and drain valves for pressure accumulators. Metso Minerals uses these components where applicable in the hydraulic systems to minimize the potential for hazardous situations to occur. A hose break valve functions to lock up if fluid flow is discharged too rapidly from an actuating cylinder, as happens if a hose breaks and the loads react to gravity. The pressure relief valve prevents the system pressure from rising beyond system capabilities. It helps protect the entire fluid system and any operators in the vicinity from bursting hoses and components.
3-2
METSO MINERALS SAFETY INSTRUCTIONS
Safety gates must not be opened during normal machine operation. Exceptions to this rule are defined in the operating instructions.
Safety gates may also be opened for maintenance purposes when the machine has been stopped. Follow all lockout procedures. Cable Switches
Cables or ropes connected to the electrical switches can be used as interlocks also. They may stop machine function in areas where control panels cannot be closely located but where Operators may be working . Know the locations of e-stop pull cords for conveyors.
EN REV-A
09/2005
SECTION 3 - MACHINE SAFETY
3.1.4 Additional Warning Devices
Horns and Lights
If visual contact between work places is obstructed or if communication is difficult, sound and/or light signaling devices may be used before starting the machine or a machine function. The warning device for start-up should operate so that personnel are given sufficient time to move to a safe distance from the machine. It is the responsibility of the Owner to ensure that the Crushing Plant is always equipped with required horns and lights. Safety Signs and Labels
3.1.5 Walkways, Service Platforms, Ladders And Railings
The design of walkways, ladders and railings follow standards and regulations for the application. The walkways provide access to the machine. Safe operating procedures must be followed when on walkways. Never stand, walk or climb in or on any area of the Crushing Plant not designated for such activity. If an area of the Crushing Plant must be accessed and cannot be reached by designated walkways, ladders, or platforms, then the Owner and Operator must make all necessary arrangements for safe access to the area, including but not limited to safe lifting devices and fall protection. CAUTION:
Extreme caution must always be used on machine walkways.
Safety signs have colors to determine the degree of hazard in particular areas. These signs must not be removed. Temporary placement of safety signs and danger tags should also be used on the control panels to warn of maintenance work and lockout situations. Obey all warning and safety signs on the machine and in the manual. Safety Warning Colors Color of safety warnings are typically safety yellow.
09/2005
EN REV-A
METSO MINERALS SAFETY INSTRUCTIONS 3-3
SECTION 3 - MACHINE SAFETY
3.2 TRANSPORT
3.4 AT THE WORK-SITE
Observe the following precautions before transporting the Crusher Plant:
3.4.1 Precautions
1. Chock chassis tires securely whenever connecting or disconnecting chassis from tractor or dolly. 2. Check tire pressure. Use a protective cage or a clip-on type air chuck and remote in-line valve and gauge when inflating tires. Never exceed maximum inflation pressures of the tire or rim. 3. Check tightness of wheel lug nuts before transport and check frequently during transport.
Observe the following minimum precautions at the work-site: 1. Know the locations of underground and overhead powerlines and other potential hazards. 2. Select the work-site with care. The ground must be firm, level and able to support the weight of the entire plant. Make sure there is enough room for loading ramps, loaders, conveyors, etc. and for safe maneuvering of trucks and loaders.
4. Check that brake system operates correctly.
3. Check that cribbing is secure and that plant has not shifted or settled.
5. Observe maximum axle and tire loading capacities.
4. Make sure that electrical cables are protected from wear and traffic.
6. Protect components being transported using appropriate shipping braces and blocking material.
5. Follow pre-operation checks and start-up procedure covered in the individual manual supplied with your specific unit equipment
7. Travel may be limited to daylight hours only, depending on your specific plant and applicable state regulations. 8. Follow recommended limits on towing speed. 9. Make sure all lights are on and that they are operating correctly. 10. Use traffic warning flags, signs and lights as required. 11. Before moving the Crushing Plant, check all roadways and bridges on the route for weight limits. 12. Check clearance of bridges, overhead lines and other overhead obstructions. 13. Follow all applicable laws and regulations. 3.3 TOWING
Observe the following precautions before towing the Crusher Plant or its components: –
3-4
Check if towing is allowed for each individual equipment.
METSO MINERALS SAFETY INSTRUCTIONS
3.4.2 During operation
Keep watch Do not rely too much on automated systems. Observe Crushing Plant equipment while the system is running. Pay attention to unauthorized persons approaching the site as well as any unusual behavior of the equipment (uncommon noise, vibration, smell, reduced output, etc.). Clearing Crushers Plant equipment can become plugged and stall because of power failures, surges of material or other unplanned events. Clearing Crusher is potentially very hazardous. Shut down the system completely, lock and tag out all applicable controls and follow all instructions in the instruction manual of your specific crusher.
EN REV-A
09/2005
SAFETY DURING MAINTENANCE AND REPAIR 4.1 GENERAL INFORMATION AND SAFETY LOCKOUTS
Detailed instructions for the operation of the machine can be found in following sections of the manual. Because each machine section may incorporate unique functions, some of which may be automated, maintenance personnel should be knowledgeable of the operation of the machine sections in order to perform the maintenance and repair work as safely as possible.
SECTION
4
– Never service any machine or component without first referencing its maintenance manual. – Before handling chemicals, refer to the MSDS (Material Safety Data Sheets) and Crushing Plant procedures for handling of these materials.
DO NOT COMPROMISE SAFETY DUE TO TIME PRESSURES. FOLLOW ALL CRUSHING PLANT SAFETY AND FIRE PREVENTION PROCEDURES. Before starting any repair, maintenance or troubleshooting work on the machine, ensure the following: – If you have not been trained to perform the required repairs, maintenance or troubleshooting, or you are unsure how to safely perform the activity - STOP! Never attempt to repair, maintain or troubleshoot any aspect of the Crushing Plant unless you are thoroughly trained for the activity and understand how to perform the activity in a safe manner. – Be sure to coordinate all repair and maintenance work with other Crushing Plant operations. – Use lockout and warning signs to inform others that maintenance and repair work are in progress. These signs should only be removed (after all work has been completed) by the person who has placed them there. – Transmit all knowledge of the maintenance work to the succeeding shift. – Know the whereabouts of all personnel in, on, at and around the machine.
09/2005
EN REV-A
METSO MINERALS SAFETY INSTRUCTIONS 4-1
SECTION 4 - SAFETY DURING MAINTENANCE AND REPAIR
4.2 MECHANICAL SAFETY DURING MAINTENANCE AND REPAIR
4.2.1 General
DANGER: FOLLOW ALL ESTABLISHED LOCKOUT PROCEDURES. REFER TO THE APPROPRIATE STANDARDS.
For repair, maintenance or troubleshooting work, disconnect all devices from electric, pneumatic and hydraulic power sources and follow lockout procedures.
IMPORTANT!
Be sure all mechanical components are brought to a zero energy state including all spring driven devices, cylinders, accumulators, drive shafts, pulleys, rollers, gears, etc., prior to entering the machine and performing the work. Never attempt to perform repair, maintenance, or troubleshooting work on or in proximity to energized mechanical components.
IMPORTANT!
Block up and support parts as necessary to prevent any unexpected motion when performing maintenance.
The lockout instructions, locks, tags and the blocking/restraining devices provided are designed for your protection. Your responsibility is to follow the instructions and use the proper equipment. Remember: •
Follow procedures
•
Stay alert
•
Do not take anything for granted
•
Verify lockout
•
Tag must identify the work being done and the person(s) who locked and tagged the control.
•
Locks and tags are changed with each shift that comes on.
Work to eliminate injury and death. Follow proper procedures at all times!
4-2
METSO MINERALS SAFETY INSTRUCTIONS
EN REV-A
09/2005
SECTION 4 - SAFETY DURING MAINTENANCE AND REPAIR
4.2.2 Fire Safety During Maintenance And Repair
– Protect yourself and others from sparks with proper personal protective equipment and clothing.
4.2.3 Preventive Maintenance
Observe all regulations on fire safety. Sources for fires include, but are not limited to the following: – sparks from grinding – flames and molten metal from welding or torching – electrical arcing – spontaneous combustion – smoking. Before starting any work take the following steps to prevent a fire hazard:
Preventive maintenance will both increase safety and be economically beneficial. It is more safe and economical to replace a worn part during a scheduled shut-down than to repair a broken device in the middle of a production cycle. A machine or device that is not in proper condition, and that has been left without regular maintenance and inspections, is a safety risk for its user. For instance, without lubrication a bearing may fail, bringing a production line down. Furthermore, the hot bearing may present a fire hazard or cause skin burns. Some preventive maintenance suggestions for a machine include:
– Properly dispose of rags with combustible material to avoid spontaneous combustion.
– observing the maintenance and lubrication instructions of the machine and equipment suppliers
– Move flammable materials 10 m (33 ft) or more away from any fire hazard.
– keeping the machine and surrounding area clean and orderly
– Clean up all oil spills and leaks.
– monitoring the vibration levels of the machine and to help predict bearing failures
– Remove any source of flammable gases, liquids or solids.
– monitoring the power consumption of motors to help detect early failures
– Use proper electrical grounding techniques for welding.
– repairing all leaks as soon as possible to prevent more serious conditions that eventually may occur
– Clean up all debris.
– Provide adequate fire extinguishing equipment; inspect such fire equipment regularly. – Arrange for qualified personnel to guard against fire while welding, cutting, or heating operations are being performed, as well as a sufficient period of time after the work is completed.
09/2005
EN REV-A
– monitoring the condition of pipes and tubes enclosed in ducts; repairing possible leaks
METSO MINERALS SAFETY INSTRUCTIONS 4-3
SECTION 4 - SAFETY DURING MAINTENANCE AND REPAIR
4.2.4 Confined Spaces
A confined space means a space that: 1. is large enough and so configured that a person can enter and perform assigned work; and
4.3 ELECTRICAL SAFETY DURING MAINTENANCE AND REPAIR
4.3.1 General
DANGER:
2. has limited or restricted means for entry or exit (for example, the crushing cavity, tanks, vessels, silos, storage bins, hoppers, vaults, and pits are spaces that may have limited means of entry.); and
Follow all established lockout procedures. For maintenance work, disconnect all devices from electric, pneumatic and hydraulic power sources and follow lockout procedures.
3. is not designed for continuous employee occupancy.
The lockout instructions, locks, tags and the blocking/restraining devices provided are designed for your protection. Your responsibility is to follow the program and use the proper equipment.
Certain confined spaces may require an entry permit program to allow entry. Be sure that all applicable procedures are followed. If you have questions contact your Crushing Plant supervisor for more information.
Remember: DANGER:
•
Follow procedures
Confined spaces may contain high concentrations of gases which may cause injury or death. Follow all established safety procedures.
•
Stay alert
•
Do not take anything for granted
•
Verify lockout
•
Tag must identify the work being done and the person(s) who locked and tagged the control.
•
Locks and tags are changed with each shift that comes on.
Work to eliminate injury and death. Follow proper procedures at all times! Be sure all electrical components are brought to a zero energy state including capacitors and similar electrical devices. Before maintenance work:
4-4
METSO MINERALS SAFETY INSTRUCTIONS
EN REV-A
09/2005
SECTION 4 - SAFETY DURING MAINTENANCE AND REPAIR
– Be sure all control power supplies are turned off, disconnected, and lock out procedures have been followed.
4.3.2 Electrical Fault Situations
– Confirm that ALL power sources are disconnected. Some electrical devices may be supplied by more than one power source.
Diagnostics are provided through pilot lights, alarms, and help messages.
Electrical faults may be caused by component failures such as loose or damaged wiring.
IMPORTANT!
– Be aware that multiple voltage levels may exist in some junction boxes. – Ensure that during lockout procedures, locks and signs are appropriately attached, and subsequently removed only by the person who installed them after all work is completed. Follow Crushing Plant lockout instructions for placement and removal. – For testing and troubleshooting, clear all personnel from the machine just as though the machine were being returned to production mode. Reactivate the necessary power supplies and perform the tests. Then again disconnect all power supplies and follow lockout instructions before further maintenance work is performed. – Be sure electrical supply voltage is disconnected before drilling into any structural frame members. Electrical cables may be inside.
Electrical connections can and do loosen due to vibration in transit and thermal expansion of the wires and lugs in operation. This is especially trua after initial delivery, break in and after major relocation. Loose connections increase current draw, which can result in false trips, intermittent circuits, and burned-out components. As part of the start-up, check and retighten as necessary all electrical connections in the elctrical enclosure. Repeat after the first forty to fifty hours of operation. This work must be performed by properly trained personnel.
IMPORTANT!
Improper phasing will damage backstops in conveyor drive reducers and may damage hydraulic system components.
– Verify that electric motors are disconnected before starting any maintenance work, thereby preventing the supply of electricity to the motor. Generally the disconnects are located in the drive control room. Each person performing maintenance work should install their lock and sign the lockout tag.
09/2005
EN REV-A
METSO MINERALS SAFETY INSTRUCTIONS 4-5
SECTION 4 - SAFETY DURING MAINTENANCE AND REPAIR
4.3.3 Program Changes
4.4 HYDRAULIC SAFETY DURING MAINTENANCE AND REPAIR
WARNING:
Changes to Metso Minerals' supplied control program should be made only by Metso Minerals personnel. Faulty program code may cause the machine to behave unexpectedly. Any changes to interlock circuitry must be made with extreme caution and be reviewed and approved in writing by Metso Minerals before implementation.
DANGER:
Follow all established lockout procedures. For maintenance work, disconnect all devices from electric, pneumatic and hydraulic power sources and follow lockout procedures.
An electric outlet may be supplied in the logic center and control cabinet for programming purposes only. Do not connect any electrical tools to this outlet. The tool may cause electrical disturbances in the machine control system. This could alter the machine control program and cause unpredictable machine operation.
The lockout instructions, locks, tags and the blocking/restraining devices provided are designed for your protection. Your responsibility is to follow the program and use the proper equipment. Remember:
NOTE: Do not use the logic center or control cabinet’s outlet for anything other than a programming device!
•
Follow procedures
•
Stay alert
•
Do not take anything for granted
•
Verify lockout
•
Tag must identify the work being done and the person(s) who locked and tagged the control.
•
Locks and tags are changed with each shift that comes on.
Work to eliminate injury and death. Follow proper procedures at all times!
Before proceeding with any repair, maintenance or diagnostic procedures on the hydraulic system, bring all components to a zero energy state, including cylinders,
4-6
METSO MINERALS SAFETY INSTRUCTIONS
EN REV-A
09/2005
SECTION 4 - SAFETY DURING MAINTENANCE AND REPAIR
accumulators, spring loaded hydraulic devices, circuitry between valves and actuators, etc.
WARNING:
– Mineral and other oils and additives can cause skin irritation. Inhaled oil mist can also cause internal irritation, headache or nausea. Avoid repeated exposure to these materials. Use appropriate personal protective equipment.
Risk of personal injury due to high pressure fluid jets. Do not check for pressurized leaks with bare hands. Use cardboard or other appropriate techniques.
– Purge entrapped air from the hydraulic system. Entrapped air in the hydraulic system can cause erratic and unexpected movements. – Oil mist in the work area or oil leaking onto floors and walkways will cause a serious risk of slipping. Clean up all spills and repair leaks immediately.
Hydraulic hoses are subject to wear and tear. Pressurized hoses tend to straighten up, bend or twist due to reaction forces. Replace all weakened or deteriorated hoses promptly. Keep hoses properly clamped and secured to help prevent being whipped by broken hoses.
– Hydraulic oil temperature may be extremely high;
– When changing a cylinder, or other hydraulic device, plug all open ports and hose ends. Catch spilled oil in a suitable storage device and avoid introducing dirt into the system. Dispose of all waste fluids as presented by law.
WARNING:
Elevated temperatures levels can be hazardous and may cause severe burns. Wait until machine cools down before doing maintenance or repair.
– Tighten disconnected pipe and hose couplings immediately after reinstallation. Before finishing the work, check all parts and connections that have been serviced or repaired.
– A mixture of air and oil mist may explode at higher temperatures. Hydraulic oil spilled on hot machine surfaces may start a fire. – Pressurized hydraulic hoses should not be handled with bare hands since high-pressure leaks may easily penetrate the skin. Hydraulic fluid pressure in the hoses may exceed 3000 PSI/210 bar/21MPa.
09/2005
– Avoid letting dirt and other impurities into the system while doing maintenance work. Use lint free cloths for cleaning the hydraulic components system.
EN REV-A
– Before starting up the pumps, make sure that maintenance work is completely finished in all work areas. When starting up the pumps, stay at a distance from the areas which were repaired. – Before opening the main valves, make sure that there is no one working between any parts of the machine, since pressurization of the system may cause machine motion.
METSO MINERALS SAFETY INSTRUCTIONS 4-7
SECTION 4 - SAFETY DURING MAINTENANCE AND REPAIR
– Once the system is in the pressurized state, test repaired system for proper operation before putting system back into production.
4.5 GENERAL MAINTENANCE WORK
The following are some of the do's and don'ts to be followed as part of normal Crushing Plant procedures
Check the system for possible leaks after repair. Leaking fittings must not be tightened when under pressure. To seal threaded fittings, use appropriate sealing rings or a sealing compound suitable for hydraulics.
– Do not perform any maintenance on moving machinery. This includes such items as adding lubricating oil or greasing parts while the crusher is in operation. – Never clear a jam on or in the feeder, crushing cavity or conveyors when system is energized. – Do not put hands or feet on the release cylinders, which protect the crusher from tramp iron overloads while the crusher is in operation. – Do check the manufacturer's recommendations for periodic maintenance procedures. These maintenance procedures are designed to not only avoid damage to the equipment but also to avoid harm to the Operator. – Do avoid spillage around the crusher. Operator should make it a habit to keep the area immediately adjacent to the crusher free from spillage, which could cause people to trip and fall. – Never look into the crushing cavity while crusher is in operation. – When using a crane or other lifting device to raise or lower a load keep all personnel clear of the area. – Never detach a lifting device from its load until the load is securely affixed at its designation, or steps have been implemented to prevent the load from unintended shifting or falling. – Never walk, stand, crawl or lay under any load hanging from a crane or other lifting device.
4-8
METSO MINERALS SAFETY INSTRUCTIONS
EN REV-A
09/2005
LOKOTRACK LT106 INSTRUCTION MANUAL 140561-EN
LOKOTRACK LT106
CHAPTER
0
This instruction manual is valid for diesel engine driven Lokotrack LT106 manufactured by Metso Minerals. Lokotrack LT106 is a portable jaw crusher unit, which is intented to be used in recycling crushing applications in crushing plants.
Because of the continuous development of the product, the manufacturer reserves a right to alter the technical specifications written in this manual, without any advance information. This is the first edition published in July 2007 in Tampere, Finland.
Manufacturer: Metso Minerals (Tampere) Oy P.O. Box 306 33101 Tampere Finland Tel +358-204-84 142 Fax +358-204-84 143
07/07
0-108-EN
LOKOTRACK LT106 INSTRUCTION MANUAL
0-1
CHAPTER 0 - LOKOTRACK LT106
This Page Left Intentionally Blank.
0-2
LOKOTRACK LT106 INSTRUCTION MANUAL
0-108-EN
07/07
TABLE OF CONTENTS 1 PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3 LT106 MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 MAIN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 DIESEL ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 CRUSHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 FEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 MAIN CONVEYOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 SIDE CONVEYOR (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 MAGNETIC SEPARATOR (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 HYDRAULIC CABIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 HYDRAULIC SETTING CONTROL (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11 FEED HOPPER FOLDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12 ENGINE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13 HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1 3-1 3-2 3-2 3-2 3-2 3-2 3-2 3-2 3-3 3-4 3-4 3-5 3-7
4 CONTROL PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 OPERATING PANEL SWITCHES/BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 DRIVE CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 DRIVING CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 REMOTE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 HYDRAULIC MODULE CENTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 IC500 CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1 4-1 4-2 4-2 4-3 4-4 4-5
5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.1 DRIVING-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.2 BEFORE STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.2.1 Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.2.2 Daily checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5.2.3 Preparing the equipment for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 5.3 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 5.4 CRUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 5.4.1 Before crushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 5.4.2 Restricted area during crushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 5.4.3 Preparing the crushing site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 5.4.4 Driving to the crushing site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 5.4.5 Measures before crushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 5.4.6 By-pass chute. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.4.7 Crusher speed selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 5.4.8 Feed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 5.4.9 Crusher setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 5.4.10 Clearing of the jammed main conveyor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 5.4.11 Removal of the steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 5.4.12 Crushing site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 5.4.13 Feeding measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 5.4.14 Recycling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 5.5 STARTING THE CRUSHING PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 5.6 DURING RUNNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 5.7 MOVING ON THE CRUSHING SITE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 5.8 STOPPING THE CRUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 5.9 SHUTTING DOWN THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 5.10 CONNECTING LOKOTRACK UNITS (INTERLOCK). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 5.11 USING THE PROCESS CONTROL SYSTEM (IC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 5.12 LEVEL DETECTOR AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 5.13 ENGINE PREHEATER (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 5.13.1 Setting the day of the week and the time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 5.13.2 Timer use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 5.13.3 Forced start (manual run) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
6 MOVING AND TRANSPORTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.2 MOVING ON THE SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.2.1 Some hints for turning the LT:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6.3 TRANSPORT FROM ONE SITE TO ANOTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6.3.1 Transport equipment needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6.3.2 Preparing for a transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 6.4 DRIVING ONTO/OFF A TRAILER TRUCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
7 CRUSHING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.1 CRUSHING LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.2 FEEDING MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 7.3 DISCHARGE ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 7.4 CRUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 7.5 BY-PASS CHUTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 7.6 FEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 7.7 MINIMUM SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 7.7.1 Feed material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 7.7.2 Setting adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 7.8 CLEARING OF THE BLOCKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 7.9 REMOVAL OF THE STEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 7.10 RECYCLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 7.11 OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.12 RADIO CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
8 LUBRICANT RECOMMENDATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.2 CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.3 FEEDER / SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.4 TRACK GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.5 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.6 HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 8.7 GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 8.8 FILLING VOLUMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
9 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9.1 PERIODICAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9.2 RUNNING-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 9.2.1 Hydraulic adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 9.3 FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 9.4 FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 9.5 CRUSHER SPACER REMOVAL & ASSEMBLY / TOGGLE PLATE CHANGE . . . . . . . . . . . 9-5 9.6 TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 9.7 ADDING FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 9.7.1 Adding hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 9.7.2 Adding Engine Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 9.7.3 Removing Engine / Hydraulic Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 9.8 ENGINE FILTER CHANGE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 9.8.1 Replacing the Engine Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 9.8.2 Replacing the Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 9.8.3 Engine Air Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 9.8.4 Fuel tank Breather change.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 9.9 REPLACING THE HYDRAULIC OIL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 9.9.1 Crusher Drive Pump Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 9.9.2 Device Pump Circuit Pressure Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 9.9.3 Device Pump Circuit Return Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
10 SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10.2 BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10.2.1 Fluid level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10.2.2 Battery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 10.2.3 Cleaning batteries, terminals and cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 10.3 OTHER ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 10.3.1 Charging circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 10.3.2 Starter circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
10.3.3 Fuse List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 10.4 WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 10.5 PRESSURE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 10.6 CRUSHER SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
APPENDICE Symbol Identification Additional information Noise levels Recycling
PREFACE
SECTION
This instruction manual is intended to assist owners and users of Metso Minerals products in the proper use of the equipment.
1
This instruction manual must be read and used by each person who works with the equipment, typically:
It includes important references to safe, proper and economical operation of the equipment. Following these instructions will help to avoid possible danger, reduce repair costs and breakdowns and to increase the reliability and life of the equipment.
–
operations, including installation, startup, operation, application engineering, materials handling, site labour, environmental engineering and safety departments.
This manual must be complemented by those instructions necessary because of existing national mandatory rules relating to accident prevention and environmental protection.
–
maintenance, including inspection and repair.
–
transport, materials handling and rigging.
A copy of this manual must be kept at the equipment's location and made available to the operators as required. In addition to this manual and accident prevention regulations mandatory in the country of use and at the equipment's place of operation, generally recognized rules for safe and professional operation must be observed.
Note that this instruction manual contains information and instructions on alternative and optional equipment. Normally the machines have only some of them. Before maintaining and servicing, find out which alternative and optional equipment your machine has. See separate instruction manuals for more detailed instructions when servicing the main components. There may be optional equipment which have separate instruction manuals. Those manuals must be read and used by each person who works with the equipment.
01/95
1-00-EN
INSTRUCTION MANUAL
1-1
SECTION 1 - PREFACE
This Page Left Intentionally Blank.
1-2
INSTRUCTION MANUAL
1-OO-EN
01/95
SAFETY
SECTION
2
Please refer to the general Safety Instructions in Part A of this Instruction Manual folder.
01/06
2-00-EN
SAFETY 2-1
SECTION 2 - SAFETY
This Page Left Intentionally Blank.
2-2
SAFETY
2-00-EN
01/06
LT106 MAIN COMPONENTS
CHAPTER
3
3.1 MAIN ASSEMBLY
4
3
1
7
5
6 2
Reference 1 2 3 4
Description
Reference
Diesel engine Tracks Crusher Feeder
5 6 7
Description
Main conveyor Side conveyor (optional) Magnetic separator (optional)
Figure 3.1 Main assembly
07/07
3-116-EN
LOKOTRACK LT106 INSTRUCTION MANUAL
3-1
CHAPTER 3 - LT106 MAIN COMPONENTS
3.2 DIESEL ENGINE The operating power of the LT106 is generated from the Caterpillar diesel engine. The engine runs the hydraulic pumps.
3.3 TRACKS The LT106 moves with tracks. The tracks ensure safe and fast movements of the machine even in the rough terrain.
3.4 CRUSHER The Lokotrack C106 jaw crusher is the heart of the LT106. The crusher crushes the feed material into smaller pieces.
3.5 FEEDER The feeder ensures even and continuous material flow into the crusher. The feed material smaller than the opening of the feeder grizzly goes through the grizzlies passing the crusher. This increases the capacity and prevents material packing in the crusher.
3.6 MAIN CONVEYOR The main conveyor transfers the crushed material from the crusher to the stock pile or to the next process.
3.7 SIDE CONVEYOR (OPTIONAL) The optional side conveyor transfers the material that has passed the crusher through feeder grizzlies to the stock pile beside the machine.
3.8 MAGNETIC SEPARATOR (OPTIONAL) The optional magnetic separator is installed above the main conveyor. It separates magnetic objects from the crushed material and transfers those to a separate pile beside the machine.
3-2
LOKOTRACK LT106 INSTRUCTION MANUAL
3-116-EN
07/07
CHAPTER 3 - LT106 MAIN COMPONENTS
3.9 HYDRAULIC CABIN
7
10
13
8
12 14 15
9
11
16 17
18
1
2
3
4
5
6
LOCATION: on the left front side of the machine Reference
15 16
Right track - Control valve
8
Pressure gauge - device pump Screen module connector - Electrical connection point Socket for service light
Description C-jaw hydraulic setting adjustment valves High pressure water spraying pump (optional) Main conveyor - Control valve Hydraulic Power Take Off - Control valve and output socket Fast drive - Control valve (A -side) Magnetic separator - Control valve (B-Side) Left track - Control valve
17
9
Fuel filling pump (optional)
18
Feeder Side conveyor - Control valve (A -side) Hand valves - Control valve (B-Side)
1
Description Hand valve - Long main conveyor folding (option)
Reference 10
2
Not in use
11
3
Not in use Hand valve - Side conveyor folding up/down
12
4 5 6 7
13
Hand valve - Side conveyor folding in/out
14
Figure 3.2 Location of hydraulic valves
07/07
3-116-EN
LOKOTRACK LT106 INSTRUCTION MANUAL
3-3
CHAPTER 3 - LT106 MAIN COMPONENTS
3.10 HYDRAULIC SETTING CONTROL (OPTIONAL)
3.11 FEED HOPPER FOLDING
1
1
3
Reference Description 1 Left side wall lifting and lowering 2 3
4
2
Rear wall lifting and lowering Right side wall lifting and lowering
3 2
Reference Description 1 Manual valve 2 3 4
Return rod pressurizing Adjustment wedge movement Return rod pressure sensor Figure 3.3 Hydraulic setting control
3-4
LOKOTRACK LT106 INSTRUCTION MANUAL
3-116-EN
07/07
CHAPTER 3 - LT106 MAIN COMPONENTS
3.12 ENGINE MODULE
Figure 3.4 a) Engine module
1. Measuring points of the crusher
4. Oil fill port
a) Crusher drive pump return line (when crusher running to normal direction) b) Crusher drive pump charge pressure c) Crusher drive pump pressure (when crusher running to normal direction) 2. Engine primary fuel filter and water separator
5. Oil filter 6. Charger 7. Coolant expansion tank 8. Crusher circuit filter 9. Hydraulic pressure filter
3. Dipstick
07/07
3-116-EN
LOKOTRACK LT106 INSTRUCTION MANUAL
3-5
CHAPTER 3 - LT106 MAIN COMPONENTS
Figure 3.5 b) Engine module
1. Air cleaner
6. Hydraulic pressure filter
2. Air precleaner
7. Coolant expansion tank
3. Fuel filter, secondary
8. Batteries
4. Mechanical fuel transfer pump
9. Crusher circuit filter
5. Engine electronics
3-6
LOKOTRACK LT106 INSTRUCTION MANUAL
3-116-EN
07/07
CHAPTER 3 - LT106 MAIN COMPONENTS
3.13 HYDRAULIC TANK 1. Hydraulic return filter 2. Breather 3. Hydraulic oil sight glass
07/07
3-116-EN
LOKOTRACK LT106 INSTRUCTION MANUAL
3-7
CHAPTER 3 - LT106 MAIN COMPONENTS
This Page Left Intentionally Blank.
3-8
LOKOTRACK LT106 INSTRUCTION MANUAL
3-116-EN
07/07
CONTROL PANELS
CHAPTER
4
4.1 OPERATING PANEL SWITCHES/BUTTONS 1. Emergency stop
6. Process ON
2. Lubrication unit
7. Key switch
3. Radio key
8. Signal horn
4. Water pump
9. Process OFF
5. Display
07/07
10. Work light
4-102-EN
LOKOTRACK LT106 INSTRUCTION MANUAL
4-1
CHAPTER 4 - CONTROL PANELS
4.2 DRIVE CONTROL BOX 4.2.1 DRIVING CONTROLS 1. Track, left-hand 2. Track, right-hand 3. RPM of diesel engine 4. Emergency stop
4-2
LOKOTRACK LT106 INSTRUCTION MANUAL
4-102-EN
07/07
CHAPTER 4 - CONTROL PANELS
4.3 REMOTE CONTROL 1. Emergency stop
7. Crusher start
2. Feeder stop
8. Crusher, counter-clockwise swing
3. Feeder start
9. Crusher, clockwise swing
4. Feeder speed -
10. Crusher setting - increase
5. Feeder speed +
11. Crusher setting - decrease
6. Crusher stop
07/07
4-102-EN
LOKOTRACK LT106 INSTRUCTION MANUAL
4-3
CHAPTER 4 - CONTROL PANELS
4.4 HYDRAULIC MODULE CENTER 1. Safety switch for conveyors 2. Fuel pump (optional) 3. Socket for screen module 4. Emergency stop 5. Hand valves
4-4
LOKOTRACK LT106 INSTRUCTION MANUAL
4-102-EN
07/07
CHAPTER 4 - CONTROL PANELS
4.5 IC500 CONTROL SYSTEM Please refer to a separate IC500 Instruction Manual for information on usage of this control system. The manual is attached to this Instruction Manual folder.
07/07
4-102-EN
LOKOTRACK LT106 INSTRUCTION MANUAL
4-5
CHAPTER 4 - CONTROL PANELS
This Page Left Intentionally Blank.
4-6
LOKOTRACK LT106 INSTRUCTION MANUAL
4-102-EN
07/07
OPERATION
CHAPTER
5
Daily procedure before startup
Figure 5.1 Before start up
10/2007
5-89-EN
LT106 INSTRUCTION MANUAL 5-1
CHAPTER 5 - OPERATION
5.1 DRIVING-IN PERIOD
5.2 BEFORE STARTUP
Note the special service procedures that must be performed during the first 200 operating hours of the LT. Instructions for those measures are included in the service instructions chapter of the manual.
5.2.1 Refueling IMPORTANT! –
Shut down the engine or set it to idle while refueling.
–
Use only clean diesel fuel or engine fuel oil. Check the quality requirements for fuel from the instruction manual of the Caterpillar engine.
–
In cold operating conditions, note the low temperature properties of the fuel.
–
The fuel must be stored so that the it cannot be contaminated by water or impurities.
–
Replace the fuel filter frequently enough (see the servicing instructions). A clogged or damaged filter may reduce the engine capacity or damage the injection pump or injector nozzles. WARNING! Diesel fuel and engine fuel oil are flammable fuels. Do not smoke, light an open fire or generate sparks when fuel is being handled nearby.
5-2
LT106 INSTRUCTION MANUAL
5-89-EN
10/2007
CHAPTER 5 - OPERATION
5.2.1.1 Refueling with an electric refueling pump 1. Switch the ignition on 2. Open the protective plug of the pipe fitting (1), clean the filling hose and the pipe fittings carefully and connect the charging pipe to the shut-off valve 3. Open the shut-off valve (2). The refueling pump does not tolerate running dry!
5
3
4. Turn the switch (3) to the right and turn on the refueling pump from the control switch (5). The pump stops automatically when the tank is full. 5. Turn the switch of the refueling pump (5) and the switch (3) to the “OFF” position. 6. Close the shut-off valve, remove the filling hose and install the shield plug of the pipe fitting.
Figure 5.3 Refueling pump switch on the auxiliary control panel
If the fuel flows poorly when refueling, the pressure filter (4) may be clogged. Replace the filter, if necessary. 5.2.1.2 Refueling through the filler cap When adding fuel through the filler cap (6), be careful not to let any dirt enter the fuel tank through the opened cap. Clean around the cap before opening it.
NOTE: If the selector switch (3) is switched ON for the hydraulic operation, the process is not able to start.
6
1
2
4 Figure 5.4 Fuel filler cap
Figure 5.2 Filling connections of the electric refueling pump
10/2007
5-89-EN
LT106 INSTRUCTION MANUAL 5-3
CHAPTER 5 - OPERATION
5.2.2 Daily checks 1. Check the condition of the engine air filter and the sealing of the housing. The outer filter element must be replaced every 40...50 hours or weekly, depending on the operating conditions. The clogging indicator (1) of the air filter warns, if the filter is clogged, and the filter element (2) must be replaced. The safety element of the filter (3) must be replaced in conjunction with every third replacement. When replacing the elements, take extra precautions not to let any dust enter the intake channel.
3
1
Figure 5.5 Intake air filter of the engine
FULL
IMPORTANT!
2
Check that the clamps on the pipe of the intake air filter are properly tightened. If the tightening is loosen or insufficient, the engine takes air through the intake filter, which might damage the engine.
ADD
2. Check that the oil level of the engine is between the ADD and FULL marks on the dipstick. Add oil, if necessary. 3. Check that the coolant level is approximately 50 mm (2 in) below the sealing face of the refiller cap. Open the cap carefully if the engine is warm.
Figure 5.6 Engine oil dipstick
4. Check the fuel level from the process control system (IC) screen. 5. Check that the hydraulic shut-off valves (4) are opened. The engine will not start if a shut-off valve is closed.
4
WARNING! Do not open the cooler cap when the engine is hot.
Continued on the following page... Figure 5.7 Hydraulic shut-off valves
5-4
LT106 INSTRUCTION MANUAL
5-89-EN
10/2007
CHAPTER 5 - OPERATION
6. Check the hydraulic oil level from the sight glass. Add hydraulic oil, if necessary.
IMPORTANT! Make sure that there are no leaks in the hydraulic system.
7. Check that the emergency stop button has not been pushed. If any of the buttons are in the down position, the engine cannot be started. 8. Check the possible alarm devices.
Figure 5.8 Sight glass for hydraulic oil
NOTE: When checking the hydraulic oil level, make sure that all hydraulic cylinder functions are in.
10/2007
5-89-EN
LT106 INSTRUCTION MANUAL 5-5
CHAPTER 5 - OPERATION
5.2.3 Preparing the equipment for use 1. Lower the ladders of the working platforms to the down position. 2. Lift up the light pole. 3. Lower the side conveyor, and drive it into the operating position.
IMPORTANT! The side conveyor must not be switched on if it is in transport position Figure 5.10 Side conveyor location
Figure 5.9 Do not switch the side conveyor on while it is in a transport position.
4. Lift the side walls up. 5. Make sure that the unit is on even ground. 6. Make sure that the cavity is empty.
5-6
LT106 INSTRUCTION MANUAL
5-89-EN
10/2007
CHAPTER 5 - OPERATION
5.3 STARTING THE ENGINE WARNING! Never use startup spray or similar to help the engine start, because it might cause a destructive explosion in the induction manifold.
4
1 2
WARNING!
3
Make sure that there is nobody on top of or near the LT. Alert everyone in the vicinity before starting the machine. NOTE: In cold weather (below +5 °C) (41 °F) use of the engine preheater (optional) is recommended before starting the engine. See the preheater instructions, page 5-25.
Figure 5.11 The startup buttons on the control panel
Read the previous paragraph first Before startup on page 5-2. 1. Make sure that the hydraulic shut-off valves are fully open. If the shut-off valves are not fully open, the position switch of the shut-off valves will cause an emergency stop function. See figure 5.12. 2. Switch the power on from the key switch (1) on the control panel by turning the key on position 1. Wait until the process control system starts up and the display panel (4) reports that it is ready to start (fig. 5.11). 3. Start the engine by turning the key switch (1): keep the key turned clockwise in position 2 for a couple of seconds. Release the key when the engine has started (fig. 5.11). NOTE: The machine gives a sound signal before starting the engine as a part of the startup sequence. 4. Monitor the display panel (4) after starting the engine. Observe the running of the engine and the pumps, and pay attention to any unusual noise, smoke or similar, and determine the cause (fig. 5.11).
10/2007
5-89-EN
Figure 5.12 Hydraulic shut-off valve
LT106 INSTRUCTION MANUAL 5-7
CHAPTER 5 - OPERATION
5.4 CRUSHING
5.4.2 Restricted area during crushing
5.4.1 Before crushing
WARNING!
Before starting the crushing, prepare the working site for crushing and perform the necessary inspections described in the next paragraps.
Before starting the crushing process and during the crushing, make sure that the restricted area is clear of people.
23000
R3
0 00
17000
3800
R
R3500
0 450
4700
Figure 5-13 Restricted area during crushing
5.4.3 Preparing the crushing site
IMPORTANT!
In order to ensure the efficient and safe operation of the LT, the crushing must be performed on as steady and as level a platform as possible. Apply a layer of crushed material on the crushing site and level the surface.
Before starting the machine, make sure that there are no personnel in the vicinity of the machine, whose safety may be endangered! Walk around the machine and make sure that there is no-one on, next to or under it. Before starting the machine, caution everybody in its vicinity that you are about to start the machine.
5.4.4 Driving to the crushing site
IMPORTANT!
Drive the equipment as instructed in section 6.2.
5-8
LT106 INSTRUCTION MANUAL
Do not initiate the process before the feeder side panels have been raised in order not to damage the rubber rams!
5-89-EN
10/2007
CHAPTER 5 - OPERATION
5.4.5 Measures before crushing 1. Check the tension of the crusher belts. The belt deflection must be 20 mm (D) when pressed with a force of 35-50 N (F) in the middle of the belt pulleys.
F
2. Check the condition of the crusher wear parts. 3. Check the oil level of the vibrators. The oil level of the vibrators is checked by opening the check nipple, located in the vibrating equipment. Make sure that a drop of oil comes out when opening the nipple. When checking the oil level make sure that the unit is on an even surface. Refer to a separate vibrating equipment manual.
D
Figure 5.14 Checking the tension of the crusher V-belts
4. Make sure that the bearings are lubricated in accordance with the instructions. 5. If the unit is equipped with a side conveyor, lower the side conveyor by the means of hand valves located in the hydraulic cabin (Refer to figure 4.11). –
Turn the side conveyor down
–
Erect the conveyor to it’s full lenght
–
Secure the side conveyor with swinging locks See figure 6.4.
Figure 5.15 Check the oil level of the vibrators
NOTE: If the side conveyor is not used in process, disable it from the IC control panel. NOTE: Make sure that the machine is always operated in a safe manner, and that it is in good mechanical condition. Make sure that the machine is firmly positioned and that there is no risk of its inclination. Operation of the machine is permitted only when all necessary protective and safety devices, e.g. guards, emergency stop devices, silencers, aspirators etc. are in place and in full operating condition. Continued on the following page...
10/2007
5-89-EN
LT106 INSTRUCTION MANUAL 5-9
CHAPTER 5 - OPERATION
6. Lift the walls of the feeder to the up position, if they have been lowered to the transport position. a. Lift the side walls to the up position. b. Lift the end wall to the up position. c. Install the safety wedges to the locking position. Hit the wedges in with a hammer and tight the wedges on their place with locking nuts.
Lowers
NOTE: You cannot rise the side walls unless hydraulic hand valve switch 3 in the hydraulic control panel is switched to position “1”. It is strictly prohibited to use the process when the side walls are lowered. Continued on the following page...
Rises Figure 5.16 Riser wall control valves
B
A A
C
Figure 5.17 Driving the riser walls to the up position
5-10
LT106 INSTRUCTION MANUAL
5-89-EN
10/2007
CHAPTER 5 - OPERATION
7. If the unit is equipped with an extended dicharge conveyor, proceed as follows. a. Activate the hand valves from the hydraulic cabin’s electric control box. b. Release the transport lockings. Lift the conveyor slightly to allow the removal of the locking pins. c. Turn the drive end of the conveyor into the crushing position. d. Reinstall the locking pins. e. Reset the trip wire switches. Adjust tightness if necessary. f. Secure the side rubber position at both joints.
Figure 5.18 Transport position
g. Deactivate the hand valve selector switch. When preparing the conveyor for transport, a. Activate the hand valves from the hydraulic cabin’s electric control box. b. Remove the locking pins (crushing position). Lift the conveyor slightly to ease the removal of the locking pins. c. Lower the conveyor drive head into the transport position. d. Mount the transport lockings. e. Deactivate the hand valve selector switch. Figure 5.19 Crushing postion
IMPORTANT! Observe great care when driving the unit onto the low bed due to the reduced ground clearance at the conveyor end.
IMPORTANT! Continued on the following page...
The LT must be on an even ground, before the discharge conveyor can be folded.
10/2007
5-89-EN
LT106 INSTRUCTION MANUAL 5-11
CHAPTER 5 - OPERATION
8. Check that there is no uncrushed material left in the crusher. 9. Make sure that the whole length of the tracks is consistently on the ground in order to avoid excess vibration and swinging. 10. Check the spirit levels in the inner walls of equipment cabin to ensure that the LT is in the horizontal position.
NOTE: If the unit is equipped with a screen module, lower the screen module support legs down. Refer to screen module instruction manual.
Figure 5.20 Make sure that the crushing site is steady enough.
Figure 5.21 The spirit levels in equipment cabin
5-12
LT106 INSTRUCTION MANUAL
5-89-EN
10/2007
CHAPTER 5 - OPERATION
5.4.6 By-pass chute Location of the by-pass chute hatch. The material flow that passes below the feeder grizzlies can be directed towards the main conveyor (fig. 5.22) or towards the optional side conveyor (fig. 5.23). With the optional screen deck, materials larger than the mesh openings can be directed towards the main conveyor (fig. 5.24). Turn the lever to change the direction of the material flow. When using the centre position, lock the lever in place using a bolt. Figure 5.24 The flow of materials has been screened and directed either to the side conveyor (pass-through) or to the main conveyor.
Figure 5.22 The chute has been directed towards the main conveyor.
Figure 5.23 The chute has been directed towards the side conveyor.
10/2007
5-89-EN
LT106 INSTRUCTION MANUAL 5-13
CHAPTER 5 - OPERATION
5.4.7 Crusher speed selection NOTE: The feeder starts automatically when the process is started and stops when the process is stopped. If the hydraulic temperature of the unit is extremely cold (-5oC/23oF), the system will ask to carry out a cold start of the process. The feeder will not start until the temperature of the oil has reached a certain temperature.
The IC system of the Lokotrack controls the crusher speed. The crusher can run either on target speed or with a stabile fixed speed.
5.4.7.1 Target speed When the target speed is set on the IC system, the crusher tries to maintain the desired speed value by adjusting the control current to the crusher pump. Refer to the IC system manual for more details.
When the process is running and the feeder is in automatic mode, the IC controller adjusts the feeder speed according to the crusher and other device operations in the LT. The IC controller tries to keep the best and equal material flow to the crusher to prevent overfilling.
5.4.7.2 Stabile fixed speed When the target speed function is disabled the fixed control current can be used to drive the crusher. With this way of control, the IC system keeps the control current stabile all the time. Therefore it does not effect to the increasing and decreasing loads, which alter the speed of the crusher.
5.4.8 Feed control The feeder can be stopped and restarted again during the crushing process. The “feeder start” and “stop” buttons are located in the remote control box on the service platform. If the machine is equipped with a radio control feature (optional), the feeder can be started and stopped using the radio control feature. To stop and restart the feeder do the following: 1. Stop the feeder during the crushing process by pressing the "feeder stop" button. 2. Restart the feeder after it has stopped completely by pressing the "feeder start" button.
In order to stabilise the feed rate, the feeder always starts at minimum speed regardless of the speed setting. After a while the speed changes to the set value. In order to control the capacity, the feeder speed can be adjusted using the feeder speed +/- switch, but only in feeder manual mode. The switch is located in the control box on the service platform. The speed can also be adjusted by using the optional radio controller. NOTE: When the process is running, the automatic control controls the stopping of the feeder. The feeder will stop if the speed of the crusher decreases or the level indicator (optional) of the crusher indicates an alarm. NOTE: If the feeder speed is too high, stones may fall over the flanks of the hopper. NOTE: Radio control will by-pass the feeder controls located in the remote control box on the service platform. The best capacity can be reached by having the feeder remain running for as long as possible. An overfilled feeder will reduce the capacity and cause unnecessary wear.
5-14
LT106 INSTRUCTION MANUAL
5-89-EN
10/2007
CHAPTER 5 - OPERATION
5.4.8.1 Feeder Automatic Control The feeder control mode can be either manual or automatic. The selection is done in the feeder parameter F5. Refer to the IC Instruction Manual for the parameter change. If manual speed is selected, feeder speed is controlled by a remote control housing or radio control. If the crusher operation pressure or speed exceeds the preset alarm values, feeder speed will automatically be reduced in prior to stop. It is recommended to use manual speed when the unit is followed with a secondary stage crushing or a screen. Feed rate does not fluctuate as much as with automatic feeder speed. It is recommended to use automatic feeder speed when material throughput fluctuation does not interfere the following process, eg. recycling. With automatic feeder speed the throughput of the crusher can be maximized.
5.4.10 Clearing of the jammed main conveyor NOTE: Never try to clear the blockage with excavator. If the conveyor stops, follow these instructions: –
Stop the process immediately.
–
Clear the jammed main conveyor as well as possible. When most of the material is removed, the main conveyor can be started by using a manual lever in the hydraulic valve manifold.
NOTE: Do NOT use this method if the rock is too big to pass under the magnetic separator! Use the hook to remove iron bars and wires. Be very careful not to hurt yourself. Never use hook when the machine is running.
5.4.8.2 Feed Material Refer to the C-Jaw instruction manual for the feed material.
5.4.9 Crusher setting The crusher setting is the most important crusher parameter since it determines the crusher's capacity as well as the top size of the crusher product. It is therefore indispensable for everyone to understand how the crusher setting is measured.
5.4.11 Removal of the steel Always stop the machine (feeder, crusher, conveyors and engine) before removing metal from it. Make sure that the machine can not be started when removing metal from it.
Refer to the C-Jaw instruction manual for setting measurement
10/2007
5-89-EN
LT106 INSTRUCTION MANUAL 5-15
CHAPTER 5 - OPERATION
5.4.12 Crushing site The unit should be located near the material pile to make loading easy and quick. Shape the feed material pile with a wheel loader or excavator so that it is distributed over a small area and piled high enough for easy loading (fig. 5.25).
The place where the crusher is to be located must be even. The machine must not be allowed to sway. The surface below the crusher must be levelled and evened out. Spread some fine-grained material on the ground, distributing it evenly (fig. 5.27). Next, harden the underlying ground by driving the unit back and forth over the site (fig. 5.28).
Figure 5.25 First shape the material pile
The location of the discharge pile must be chosen so that it doesn't cause any danger to workers or passers-by. Make sure that there is enough space for the discharge pile, the discharge machinery (wheel loader or excavator) and the lorry (fig. 5.26).
Figure 5.27 Spread some fine-grained material on the ground and even it out.
Figure 5.28 Strengthen the underlying ground by driving the unit back and forth over it. Figure 5.26 General measures taken on the site.
5-16
LT106 INSTRUCTION MANUAL
5-89-EN
10/2007
CHAPTER 5 - OPERATION
During the crushing process, make sure that the unit is in horizontal position. The maximum inclination allowance is 1 degree in lateral direction and 2 degrees in longitudinal direction (fig. 5.29 and fig. 5.30). For purposes of maintenance, it is recommended that you dig a hole under the unit (fig. 5.31).
Figure 5.29 The maximum lateral inclination permitted during the crushing process is 1 degree.
Figure 5.30 The maximum longitudinal inclination permitted during the crushing process is 2 degrees.
Figure 5.31 Dig a hole under the unit for maintenance purposes.
10/2007
5-89-EN
LT106 INSTRUCTION MANUAL 5-17
CHAPTER 5 - OPERATION
5.4.13 Feeding measures
If the feed material contains metals, someone should stand next to the feeder and remove the metal pieces before they are able to enter the crusher.
5.4.13.1 Loading Equipment The unit can be loaded with the help of either an excavator or a wheel loader.
• •
LOADING USING AN EXCAVATOR
The unit can be loaded from the side or the rear. Find a suitable loading site and move the excavator bucket to its loading position. Then drive the unit into a suitable position below the excavator bucket. The operator of the excavator must have full visibility to the upper part of the feeder (fig. 5.32).
LOADING USING A WHEEL LOADER
The unit can only be loaded from the rear. The maximum bucket width is 2400 mm (95") for standard-size hoppers. In the case of 6 m3 hoppers, the maximum bucket width is 3200 mm (126"). If required, use the feed material to make a loading ramp to ease access to the feeder. Drive the unit as close to the pile as possible to make loading quick and easy. NOTE: The feeder has two basic applications: a. stabilising the feed rate b. separating the fine material before it enters the jaw crusher. If the feeder is too full, it will not separate the fine material, which in turn will result in decreased operating capacity. NOTE: Do not drive the excavator bucket into the material or try to force the material into the jaw cavity.
Figure 5.32 The operator of the excavator must have full visibility to the upper part of the feeder.
NOTE: Keep feed gate closed during operation.
Load the material into the rear end of the feeder, on top of the solid base (fig. 5.33). WARNING! When the impactor crusher is fed from rear, the crusher rotor might shoot the feed material directly backwards if e.g. the protective chains / rubbers are worn.
Figure 5.33 Load the material into the rear of the feeder, on top of the solid base.
5-18
LT106 INSTRUCTION MANUAL
5-89-EN
10/2007
CHAPTER 5 - OPERATION
5.4.14 Recycling In recycling applications the metal objects should be removed from the feed before entering the crusher. Maximum alloved diameter of the steel Ø16 mm. Maximum allowed length of the steel in the feed 1,0 m. The most efficient way is to prepare the feed material and remove all the metal from it before loading it to the LT106. The optional magnetic separator can be used for the removal of small metal objects.
Figure 5.34 Removal of metal objects during the crushing of recyclable materials.
WARNING! The crusher rotor can shoot material backwards if the protective curtains have worn. Keep the protective curtains in appropriate condition.
10/2007
5-89-EN
LT106 INSTRUCTION MANUAL 5-19
CHAPTER 5 - OPERATION
5.5 STARTING THE CRUSHING PROCESS 1. After a cold start, let the engine idle for a few minutes or until it has warmed up. 2. Make sure that there is nobody on top of or near the LT. Warn everyone in the vicinity.
4
3. Start the process with the button (2) on the control panel. Monitor the messages appearing on the display screen of the process control system (4).
1 2
3
4. When the equipment has started up, proceed with the crushing. The crushing parameters are adjusted via the process control system. Further instructions are provided in the separate instruction manual for IC-system.
Figure 5.35 Starting from the control center
5.6 DURING RUNNING WARNING! Shut down the crusher before climbing on top of the machine. Blockages, etc. must be cleared with the engine shut down. When the LT is running, observe the normal function of the machine parts. If abnormalities occur (loud noises, strong odors, components that heat up intensively, etc.), the equipment must be shut down and the cause determined immediately. Any error messages concerning the operation of the machine will appear on the process control system screen. If the machine gives an alarm or shuts down, check the messages on the display screen first.
5-20
LT106 INSTRUCTION MANUAL
5-89-EN
10/2007
CHAPTER 5 - OPERATION
5.7 MOVING ON THE CRUSHING SITE
5.9 SHUTTING DOWN THE ENGINE
1. Stop feeding the material and let the fed material pass through the crusher and the conveyors.
IMPORTANT!
2. Stop the process by pressing the button (3) on the control panel. 3. Wait for the crusher and the conveyors to stop (If the unit is equipped with a screen module, lift the module support legs up before moving. Refer to screen module instruction manual). 4. Drive the equipment as instructed in section 6.2.
5.8 STOPPING THE CRUSHING Stop the crushing process by pressing the button (3) on the control panel. WARNING! The crusher may rotate for several minutes after the crushing process has been stopped.
Do not shut down the engine before the crusher has stopped completely. Let the engine idle without load for a few minutes before shut-down to allow the temperature to settle. It helps avoid ‘after-boiling’ of the coolant and cool the supercharger, which extends the operating life of the engine and reduces operating failures. Shut down the engine by turning the key switch (1) to the “0” position. WARNING! After the engine has been shut down, some pressure remains in the hydraulic system and in the cooling system of the engine. Let the machine cool down sufficiently before opening the pressurized components, and always make sure that the system is pressure-free before performing any servicing or checks.
1 3
Figure 5.36 Shut-down from the control center.
10/2007
5-89-EN
LT106 INSTRUCTION MANUAL 5-21
CHAPTER 5 - OPERATION
5.10 CONNECTING LOKOTRACK UNITS (INTERLOCK) Consecutively operating LT crushing units can be interlocked with connection cables. In that case the interlocked Lokotracks are transmitting information between units. E.g. an overload, a material level alarm or a mulfunction stops the feeder of the previous LT. The connection box for the primary unit is located under the feeder, and the connection box for the secondary unit under the main control box. See figure 5.37.
1
1
1
Figure 5.37 The Interlock connections of the LT
5-22
LT106 INSTRUCTION MANUAL
5-89-EN
10/2007
CHAPTER 5 - OPERATION
5.11 USING THE PROCESS CONTROL SYSTEM (IC)
1
The LT is equipped with an IC process control system which controls and monitors the functions of the unit. The display screen of the system has been installed in the control center located in the equipment cabin, on the right side of the LT.
5
Use your fingertips to operate the panel. NOTE: Do not use a screwdriver or other pointed objects to press the buttons or the display. It might damage the surface of the display or the buttons. Do not use protective gloves when pressing the buttons, for you might accidentally press several buttons at the same time.
4 3
2 Figure 5.38 Control panel of the process control system (UCD), main menu
(1) The LCD screen displays information and settings relevant to the current mode of the machine. (2) The function keys 1-5 are used to control the system, to select information for display and to change settings. These keys have different functions in different operating modes. (3) The key icons indicate the key functions available at the moment. (4) The status bar of the system displays general information, such as the fuel level and time. (5) The main display shows information on the function that has been selected. Further information about using the system is provided in the IC instruction manual.
The INFORMATION key gives you more information about the current mode of the LT The HELP key gives you more instructions for using the functions displayed on the screen
The OPTIONS key allows you to customize the settings of the functions The SETTINGS key allows you to set crushing parameters and to control the manual drive functions The DIAGNOSTICS key allows you to view diagnostics, troubleshooting and log information Figure 5.39 The most important key icons of the process control system
10/2007
5-89-EN
LT106 INSTRUCTION MANUAL 5-23
CHAPTER 5 - OPERATION
5.12 LEVEL DETECTOR AMPLIFIER The amplifier is located inside the control panel. Factory default settings: Telco on: 2 sec Telco off: 1 sec Sensitivity: 45%
Switch positions: Long/short operation: Short (right position) Dark/light function: Dark (left position) Indicator/diagnostic lights: Green led - Power on Yellow led - Relay output activated Red led (LT or LR) - Sensor fault indicator NOTE: If LT or LR is lit, the level sensor wire harness must be replaced.
1 2 3 4
6
5 7 Reference 1 2 3 4
Description Telco on: 0 - 10 sec Telco off: 0 - 10 sec Sensitivity: 0 - 100% Long/short operation
Reference 5 6 7
Description Dark/light function Sensor diagnostic light Sensor diagnostic light
Figure 5-40 Level detector amplifier
5-24
LT106 INSTRUCTION MANUAL
5-89-EN
10/2007
CHAPTER 5 - OPERATION
5.13 ENGINE PREHEATER (OPTIONAL) The LT can be equipped with a fuel-operated engine preheater. The preheater facilitates the startup of the engine and reduces wear. When the outside temperature is below +5 °C (+41 °F), the preheater should be used for at least 20 minutes, and if the temperature is below –10 °C (14 °F), the period should be at least 40 minutes.
1
The preheater control panel is located in the equipment cabin on the right side of the machine, next to the main control panel.
2
5.13.1 Setting the day of the week and the time Press the time setting key (3) for 3 seconds (the time will start to flash) and set the correct time using the arrow keys. Wait a moment for the day of the week to start flashing on the screen. Set the time of the week using the arrow keys.
Memory location number Alarm indicator Day of the week Time display
5.13.2 Timer use The timer allows you to program the daily start of the heating in seven-day periods. You can program three different starting times for every day of the week, one of which is displayed at a time. The selector switch (2) must be turned to the left position when using the timer.
Heater on
Activating the timer use Turn the selector switch (2) to the left position. Press the program selecting key (4) until the memory location of the desired starting time appears on the screen.
3
Disabling the timer Press the clock key (3) briefly (the time disappears from the screen). Setting the heating period Keep the left arrow key (6) pressed for 3 seconds (the numeric value will flash). Set the heating period with the arrow keys, between 10 - 120 minutes. During the heating, it is only possible to change the duration of the current period with the arrow keys (the time is not saved in the memory), with the final time being between 1 - 120 minutes. The heating period cannot be set when the preheater is in ignition mode (immediately after the heater has started).
10/2007
5-89-EN
4
5
6
Setting the time Program selection Forced start / stop Arrow keys Figure 5.41 Preheater control panel
LT106 INSTRUCTION MANUAL 5-25
CHAPTER 5 - OPERATION
Setting the starting time Press the program selecting key (4) once; the memory location number will appear on screen. Set the starting time for heating using the arrow keys (6). Wait a moment for the day of the week to appear on the screen. Set the correct time of the week using the arrow keys. You can change the starting times saved in other memory locations by pressing the program selecting key again.
1
Deleting a starting time
2
Press the program selecting key (4) until the memory location of the desired starting time appears on the screen. Wait a moment. Press the program selecting key until only the time is displayed on the screen.
Memory location number Alarm indicator
5.13.3 Forced start (manual run)
Day of the week
When using forced start, the preheater starts immediately. Turn the selecting switch (2) to the right and keep the key for forced start (5) pressed for a while until the heater starts. Shut down the heater by pressing the key again.
Time display Heater on
NOTE: Preheater use consumes battery power. If the preheater is used for long periods consecutively, battery charge level may weaken to such an extent that the charge is not sufficient for starting the engine.
3
If the preheater will not start, check the battery charge level and the fuel level in the tank.
4
5
6
Setting the time Program selection
Further instructions on using the preheater are provided in the instruction manual of the heater.
Forced start / stop Arrow keys
5-26
LT106 INSTRUCTION MANUAL
5-89-EN
10/2007
MOVING AND TRANSPORTING
CHAPTER
6
6.1 GENERAL Because of the size and weight of the equipment, special attention must be paid when moving the LT. Always make sure that nobody is on top of or near the LT. Use always approved lifting equipment with adequate capacity when preparing for a transport.
IMPORTANT! The hydraulic oil temperature must be observed during longer moves. The temperature may be a maximum of 90 °C. Oil that is too hot might damage the sealings.
WARNING!
NOTE!
Make sure that the lighting is appropriate at the site or near the LT.
Longer moves (more than 100 m) must be driven with the feeder end of the machine first, when the driving gear comes after the track. In that case, the lower end of the track remains tight, because the ground supports the track and it does not bend down. This helps to prevent the chain from jumping over the driving wheel teeth.
MAXIMUM INCLINATIONS Sideways 5° Lengthwise 15 °
NOTE! WARNING! Make sure that there is nobody on top of or near the LT.
When driving on a sloping surface or onto a trailer truck, the automation may stop the LT if the hydraulic fluid or the coolant level is too low. If the machine stops unexpectedly, check the fluid levels.
IMPORTANT! NOTE!
Make sure that –
the driving route is smooth enough
–
differences in altitude or inclinations do not prevent driving
The track drive does not function if the selector switch of the hydraulic functions has been switched ON.
WARNING! In case the surface is slippery or icy, make sure that the sanding is sufficient enough to prevent the unpredictable movement of the LT.
10/2006 INSTRUCTION MANUAL
6-100-EN
LT95(S)/105(S)/116(S)/1213(S)/1110(S)
6-1
CHAPTER 6 - MOVING AND TRANSPORTING
6.2 MOVING ON THE SITE WARNING! When moving the machine, pay attention to the light pole and exhaust pipe length. They may exceed the height of the other parts of the machine. Avoid power lines, bridges, branches and other work site obstacles.
1
Internal moves on the work site can usually be performed by track drive. 1. Make sure that the load bearing capacity of the ground is at least 20,000 kg/m2 (4100 lbs/ft2). 2. Start the engine as instructed in section 5. 3. Connect the drive control box to one of the alternative cable connectors (1) (fig. 6.1). If the machine is equipped with an optional radio remote control box, switch on the radio control preselection from the main control board (2) (fig. 6.2), when driving with the radio control.
Figure 6.1 Connecting the drive control box
2
4. Adjust the engine speed with the switch in the drive control box to the desired speed between idle and max rpm. Figure 6.2 Radio control preselection on the main control board
5. Drive the machine to the desired area using the manual levers on the drive control box, or by the radio control (if equipped).
WARNING! The drive control box must be disconnected from the unit immediately after driving. The drive control box is allowed to be lifted and held only from its handles. Do not pull the box from the cable or drag or move it otherwise. Figure 6.3 Driving the equipment with the help of the manual levers on the drive control box
6-2
LT95(S)/105(S)/116(S)/1213(S)/1110(S)
6-100-EN
INSTRUCTION MANUAL 10/2006
CHAPTER 6 - MOVING AND TRANSPORTING
6. The driving speed can be changed by adjusting the engine speed with a switch located in the drive control box. Note: the machine does not move if the engine speed is too low. Driving speed range Slow driving Normal driving Fast driving
Engine speed idle...1200 1200...1900 1900...
7. In the case the ground is soft , drive the tracks backwards and forwards few times in order to make the ground more compact before placing the LT on a new crushing site. 8. If you do not proceed with crushing after moving the machine, shut down the engine as instructed in section 5. NOTE! When the radio control use is switched on, you cannot use the cable drive control box.
6.2.1 Some hints for turning the LT: –
the LT turns easier when driven forward with the minimum power required.
–
the LT turns easier on hard than soft ground.
–
If the LT cannot be turned when driving uphill, drive a short way downhill and turn the unit at the same time.
–
By driving the center of one of the track onto a small rise, rock, or similar, it becomes easier to turn towards the lifted side.
–
Always select an appropriate surface for turning the LT. Only attempt to turn the LT in a location where the turning is easiest.
–
When turning on soft ground, change the direction gradually.
–
Avoid turning the unit completely at one time, so that material does not accumulate on the sides of the tracks.
IMPORTANT! If driving on uneven ground or with the LT connected to Lokolinks, you have to exercise special caution when driving the unit. Always note the ground clearance of the machine and the irregularities of the ground. IMPORTANT! Avoid turning the machine in situations when the traction force is on the upper section of the chain track. The chain track may loosen as the tension spring inside the track frame cannot hold the pressure any longer, which might cause the track chain to jump over the sprocket.
10/2006 INSTRUCTION MANUAL
6-100-EN
LT95(S)/105(S)/116(S)/1213(S)/1110(S)
6-3
CHAPTER 6 - MOVING AND TRANSPORTING
6.3 TRANSPORT FROM ONE SITE TO ANOTHER When the LT is transported on public roads, note that it is a special transport which may need transportation permits. Check the local regulations, for they vary in each country. The feeder side walls, side conveyors, light mast, stairs etc. must be placed in transport position. Refer section 6.3.2. The screen unit (if equipped) must be placed in transport position . See section for screen module.
6.3.1 Transport equipment needed –
a trailer truck for transporting the LT
–
a trailer truck for transporting the side conveyor
IMPORTANT! PRIOR TO TRANSPORT MAKE SURE THAT •
THE COMPONENTS THAT EXCEED THE FREE TRANSPORT HEIGHT AND WIDTH HAVE BEEN REMOVED
•
THE LOAD IS APPROPRIATELY FASTENED
•
ALL THE LATCHES OF THE HATCHES AND THE ENGINE COVER ARE LOCKED
6-4
LT95(S)/105(S)/116(S)/1213(S)/1110(S)
6-100-EN
INSTRUCTION MANUAL 10/2006
CHAPTER 6 - MOVING AND TRANSPORTING
6.3.2 Preparing for a transport WARNING! Make sure that the process has stopped, and there has not been left material into the LT.
•
Drive the side conveyor into transport position. See figure 6.4.
•
Open the safety wedges of the feed hopper walls and lower the walls to the down position. Lower first the rear wall and then the side walls. See figure 6.5. Figure 6.4 Turn the side conveyor up
Figure 6.5 Lower the feed hopper walls
WARNING! WARNING! Stay out of the turning feed hopper wall. Check visually from the ground, that the hinge pins of the feed hopper walls are properly positioned and there are no damage in the lugs of the cylinders. Make sure the condition of the feed hopper extensions. Check also that the extensions are properly fastened.
10/2006 INSTRUCTION MANUAL
6-100-EN
Do not extend the feed hopper extension, or mount any additional extensions. WARNING! Make sure that there has not been left material or loose parts into the feed hopper.
LT95(S)/105(S)/116(S)/1213(S)/1110(S)
6-5
CHAPTER 6 - MOVING AND TRANSPORTING
•
•
Lower the upper part of the main conveyor to the down position, if there is a risk of exceeding the transportation height. See section 7.
•
Disassemble the dust removal unit, if the transport height is exceeded. WARNING! The machines equipped with discharge hopper, dust encapsulation or other device exceeding transport height must be disassembled safely.
Fasten the conveyor locking (if equipped). WARNING! Make sure that there has not been left material on to the conveyor. Do not go under the conveyor.
WARNING! Always use approved lifting equipment with adequate capacity.
WARNING!
Stay away under the lifted load.
If the machine is equipped with a hoist of the impact crusher, make always sure that the hoist is locked into the transport position.
•
Lower the light pole. WARNING! Make sure that the LT is not located underneath the electric power lines when preparing for a transport.
•
Drive the hydraulic hammer(if equipped) into the transport position. Lock the hammer with a locking bar. WARNING! Make sure that there is no one in the danger area, when the hammer is prepared for a transport. Beware, that the hydraulic hammer or the boom don’t hit the hydraulic hoses, or the hydraulic hoses of the hammer or the boom don’t hit the other parts of the machine.
6-6
LT95(S)/105(S)/116(S)/1213(S)/1110(S)
6-100-EN
INSTRUCTION MANUAL 10/2006
CHAPTER 6 - MOVING AND TRANSPORTING
6.4 DRIVING ONTO/OFF A TRAILER TRUCK The LT must be driven onto and off the truck trailer with extreme precaution. Slow down the driving speed from the driving panel by decreasing the engine speed.
The ramp must have as low a gradiant as possible (rise max.1:4), when the LT is driven onto the truck trailer. Refer to the picture below, but remember that the picture is for reference only, and not necessary from your machine.
WARNING!
WARNING!
Drive the unit onto/off the truck trailer with great care.
Make sure that the ramp is properly positioned and in perfect technical order.
Make sure that there is nobody in the danger area. When driving the unit onto/off the truck trailer, always make sure that no component of the Lokotrack hits the truck tractor. Also make sure, that the load is not on top of the truck tractor’s cabin and does not cause any danger to the trailer truck’s driver especially if the conveyor end is in front.
Shut down the engine as instructed in section 5.9.
Figure 6.6 Driving the unit onto a truck trailer
NOTE! The actual weight of the unit can be calculated by adding the weight of the optional equipment to the weight of the basic unit. Check the actual weight of the unit from the transport drawing.
10/2006 INSTRUCTION MANUAL
6-100-EN
NOTE! The weights are indicative. Actual weights may vary due to manufacturing tolerances.
LT95(S)/105(S)/116(S)/1213(S)/1110(S)
6-7
CHAPTER 6 - MOVING AND TRANSPORTING
Make sure that the load is properly fastened. Refer to the figure below. Discharge end
Loading end
Figure 6.7 Fastening the LT
Make sure that the truck trailer is wide enough for the Lokotrack, and most of the track’s width is on the truck trailer on both sides. Refer to the figure below.
Figure 6.8 LT on the trailer truck
6-8
LT95(S)/105(S)/116(S)/1213(S)/1110(S)
6-100-EN
INSTRUCTION MANUAL 10/2006
CRUSHING
CHAPTER
7
7.1 CRUSHING LOCATION The LT106 should be located near the material pile to make loading easy and fast. Shape the feed material pile with the wheel loader or excavator so that it is in small area and high enough for easy loading (Figure 7.1). The location of the discharge pile must be chosen so that it doesn't cause any danger to workers or passers-by. Ensure that there is enough space for the discharge pile, discharge machinery (a wheel loader or excavator) and a lorry (Figure 7.2).
Figure 7.3 Spread some fine material on the ground, then rub it smooth.
Figure 7.1 First shape the material pile
Figure 7.2 General measures taken on the site.
07/07
The location where the crusher is to be placed must be even. The machine must not be allowed to sway. The surface below the crusher must be levelled and evened out. Spread some fine-grained material on the ground, distributing it evenly (Figure 7.3). Next, harden the underlying ground by driving the LT106 back and forth over the site (Figure 7.4).
7-85-EN
Figure 7.4 Strenghten the underlying ground by driving the LT106 back and forth over it.
LOKOTRACK LT106 INSTRUCTION MANUAL
7-1
CHAPTER 7 - CRUSHING
While crushing, make sure the LT106 is in horizontal position. The maximum inclination allowance is 1 degree in lateral direction and 2 degrees longitudinal direction (Figure 7.5 and Figure 7.6).
For purposes of maintenance it is recommended that you dig a hole under the LT106 unit (Figure 7.7).
Figure 7.7 Dig a hole under the LT106 for purposes of maintenance.
Figure 7.5 The maximum lateral inclination permitted during the crushing process is 1 degree.
Figure 7.6 The maximum longitudinal inclination permitted during the crushing process is 2 degrees.
7-2
LOKOTRACK LT106 INSTRUCTION MANUAL
7-85-EN
07/07
CHAPTER 7 - CRUSHING
7.2 FEEDING MEASURES LOADING EQUIPMENT The LT106 can be loaded with the help of either an excavator or a wheel loader. LOADING USING AN EXCAVATOR The LT106 can be loaded from the side or the rear. Find a suitable loading site and move the excavator bucket to its loading position. Then drive the LT106 into a suitable position below the excavator bucket. The operator of the excavator must have full visibility to the upper part of the feeder (Figure 7.8). Load the material into the rear end of the feeder, on top of the solid base (Figure 7.9).
Figure 7.8 The operator of the excavator must have full visibility to the upper part of the feeder.
If the feed material contains metals, someone should stand next to the feeder and remove the metal pieces before they are able to enter the crusher. LOADING USING A WHEEL LOADER The LT106 can only be loaded from the rear. Maximum bucket width is 3200 mm (126"). If required, use the feed material to make a loading ramp to ease access to the feeder. Drive the LT106 as close to the pile as possible to make loading quick and easy. NOTE: The feeder has two basic applications: stabilising the feed rate and separating the fine material before it enters the jaw crusher. If the feeder is too full, it will not separate the fine material, which in turn will result in decreased operating capacity.
Figure 7.9 Load the material into the rear end of the feeder on top of the solid base.
CAUTION! Do not hit the excavator bucket into the material or try to force the material into the jaw cavity.
07/07
7-85-EN
LOKOTRACK LT106 INSTRUCTION MANUAL
7-3
CHAPTER 7 - CRUSHING
7.3 DISCHARGE ARRANGEMENT ALTERNATIVES –
Wheel loader
–
Stack conveyor
–
Additional process
–
Lokotrack (secondary)
Check the height and volume of the discharge pile. Do not let the pile grow so high that it reaches the the conveyor. The distance between the pile and the conveyor must always be at least 200 mm (9") (Figure 7.10). When discharging with the help of the wheel loader, be careful not to damage the conveyor. Discharge from the side, do not push the material under the LT106 unit.
Figure 7.10 The distance (h) between the pile and the conveyor must always be at least 200 mm (9").
The material emitted from the vibrating chute can be directed to either the main conveyor or the side conveyor with the help of the control plate.
7-4
LOKOTRACK LT106 INSTRUCTION MANUAL
7-85-EN
07/07
CHAPTER 7 - CRUSHING
7.4 CRUSHING Release the transport locks from the side conveyor (optional). Turn the side conveyor down with the help of the controls located in the hydraulic valve section (Figure 7.11 and Figure 7.12).
Figure 7.11 Turn the side conveyor down with the help of the control levers.
Figure 7.12 Conveyor control switches: 1) Side conveyor up/down, 2) Side conveyor in/out, 3) Main conveyor folding. NOTE: The control switch for manual valves, refer to Chapter 3.9
07/07
7-85-EN
LOKOTRACK LT106 INSTRUCTION MANUAL
7-5
CHAPTER 7 - CRUSHING
NOTE: A lifting instrument, such as a rope or chain, that is used to lift a single side wall, will not be strong enough to lift the entire LT106 unit.
Turn up the side walls of the feed hopper and lock them in place with the help of the wedges (Figure 7.13).
When the side wall is lifted vertically against the joint hinge, the mass of the entire LT106 may apply to the lifting instrument.
Figure 7.13 Turn up the side walls of the feed hopper. NOTE: Do not stand in side of the frame when mounting the wedge on it's place
If the additional side walls of the unit are not lifted with hydraulic cylinders, be extremely careful when lifting or lowering them. In this case, the side walls must be lifted and lowered using a crane. WARNING! Make sure that there is no-one below the side walls, or too near them, as it may cause an accident risk.
When lifting the side walls, first lift the side wall to its uppermost position with the crane (phase 1) and position the wedges. When positioning the wedges, the crane must not make any corrective measures. If the wedge cannot be fitted in its place, the mechanic must move away from the side wall and give new instructions to the crane attendant. After this, place the wedge first at the crusher end (phase 2) and then at the feeding end (phase 3). Once the wedges are fitted in their positions, make sure that they are tightly in their positions by hammering them. Finally, secure them with screws or chains. Lifting or lowering the side walls must in no circumstances be done with the help of an excavator. The order of lifting the walls: first, lift both side walls, then the back side wall. After lifting the back side wall, position and lock its wedge as well. To lower the walls, perform the steps above in reverse order. Before removing the wedges, first set and tighten the lifting ropes of the crane. Do not perform any corrective measures during the operation. NOTE: If the side walls are lifted with the help of a hydraulic cylinder, they are lifted in the same order as explained above. Lift and lock one side wall at a time, as explained above. When positioning the wedges, do not lift or lower anything.
Figure 7.14 Turn the rear wall of the feed hopper upwards.
7-6
LOKOTRACK LT106 INSTRUCTION MANUAL
7-85-EN
07/07
CHAPTER 7 - CRUSHING
Turn the light pole up (Figure 7.15). Make sure that the crusher is always operated in a safe manner and that it is in good mechanical condition. Make sure that the crusher is securely stationed so that there is no risk of its inclination.
starting the machine, caution everybody in its vicinity that you are about to start the crusher.
Operation of the crusher is only permitted, when all necessary protective and safety devices, e.g. guards, emergency stop devices, silencers, aspirators etc. are in place and in full operating condition. Before starting the crushing process, make sure that no-one is on, next to or under the crusher. Before
Figure 7.15 Turn the light pole up
07/07
7-85-EN
LOKOTRACK LT106 INSTRUCTION MANUAL
7-7
CHAPTER 7 - CRUSHING
Starting the crushing process
Refer to the Crusher Instruction Manual for further information on the crushing process.
Before starting the crushing process, always make sure that the crusher cavity is empty. If there is material on the cavity, clear the cavity as instructed in Chapter 7.8 .
WARNING!
When the crushing process has started, the RPM speed of the diesel engine cannot be adjusted by the operator before the crushing process has been stopped again. Initiate the crushing process by pressing “Process ON” -button (ref 4.1 and 4.2) NOTE: When starting the crushing process, the automatic control function takes care of starting the devices, delays, monitoring any possible problems and adjusting the RPM level of the diesel engine. The initiation of the crushing process takes about one minute after the process button has been pressed. –
Connect the water supply (if needed).
–
Turn on the lights if required.
In case of emergency press the "Emergency stop"-button to stop the LT106. Do not attempt to crush stones that are too large to fit inside the cavity. Having to reposition rocks wastes time, reduces capacity, and imposes unnecessary loads on the crusher. You can stop the feeder and crusher in order to safely remove uncrushable objects from the feeder. Both the crusher and the feeder can be restarted from the remote control box located in the service platform. CAUTION! Clay, wood and any non-stone-based materials must be prevented from entering the crusher. This may overload and damage the crusher. Also make sure that no explosives are allowed to enter the crusher.
Stop the crushing process by pressing the "Process OFF” -button. NOTE: When stopping the crushing process, the automatic control function takes care of turning off the equipment, delays, monitoring any possible problems and adjusting the RPM level of the diesel engine. The termination of the crushing process takes approximately 1 minute. 1. Process options eg. side conveyor, magnet separator or hydraulic PTO must be selected before the process start. Process options are editable during the process. 2. You can stop the feeder and crusher in order to safely remove uncrushable objects from the feeder. Crusher and feeder can be restarted from the service platform. Load some material into the feed hopper while the vibrating chute is running. For further instructions, refer to Chapter 7.6 . When loading with the help of a wheel loader, the feed hopper must be almost empty before any more material can be loaded into it. When loading with the help of an excavator, more than one bucketful can be loaded in to the hopper at a time.
7-8
LOKOTRACK LT106 INSTRUCTION MANUAL
7-85-EN
07/07
CHAPTER 7 - CRUSHING
Figure 7.16 "Emergency stop" - buttons (for more information, refer to 5.5)
NOTE: The side conveyor must not be switched on if it is in transport position
Figure 7.17 Do not switch the side conveyor on while it is in a transport position.
07/07
7-85-EN
LOKOTRACK LT106 INSTRUCTION MANUAL
7-9
CHAPTER 7 - CRUSHING
7.5 BY-PASS CHUTE Location of the by-pass chute hatch. The material flow that passes below the feeder grizzlies can be directed towards the main conveyor (Figure 7.18) or towards the optional side conveyor (Figure 7.19) .With the optional screen deck, materials larger than the mesh can be directed towards the main conveyor. (Figure 7.20). Turn the lever to change the direction of the material flow. When using the centre position, lock the lever in place using a bolt.
Figure 7.20 The flow of materials has been screened and directed either to the side conveyor (pass-through) or to the main conveyor.
Figure 7.18 The chute has been directed towards the main conveyor.
Figure 7.19 The chute has been directed towards the side conveyor.
7-10
LOKOTRACK LT106 INSTRUCTION MANUAL
7-85-EN
07/07
CHAPTER 7 - CRUSHING
7.6 FEED CONTROL The feeder can be stopped and restarted again during the crushing process. The “feeder start” and “stop” buttons are located in the remote control box on the service platform. If the machine is equipped with a radio control feature (optional), the feeder can be started and stopped using the radio control feature.
The best capacity can be reached by having the feeder remain running for as long as possible.
To stop and restart the feeder do the following: 1. Stop the feeder during the crushing process by pressing the "feeder stop" button. 2. Restart the feeder after it has stopped completely by pressing the "feeder start" button. NOTE: The feeder starts automatically when the process is started and stops when the process is stopped. If the hydraulic temperature of the unit is extremely cold (10oC/14oF), the system will ask to carry out a cold start of the process. The feeder will not start until the temperature of the oil has reached a certain temperature. In order to stabilise the feed rate, the feeder always starts at minimum speed regardless of the speed setting. After a while the speed changes to the set value. In order to control the capacity, the feeder speed can be adjusted using the crusher speed +/-switch. The switch is located in the control box on the service platform. NOTE: When the process is running, the automatic control takes care of stopping of restarting the feeder. The feeder will stop if the speed of the crusher decreases or the level indicator (optional) of the crusher indicates an alarm. DANGER! If the feeder speed is too high, stones may fall over the flanks of the hopper.
NOTE: Radio control will by-pass the feeder controls located in the control box on the service platform.
07/07
7-85-EN
LOKOTRACK LT106 INSTRUCTION MANUAL
7-11
CHAPTER 7 - CRUSHING
7.7 MINIMUM SETTING The hardness of the feed material will effect the minimum setting. Refer to the C-Jaw instruction manual for the setting ranges.
7.7.1 FEED MATERIAL Feed sizes depending on the material in question: Concrete 0...550 mm (22"). Concrete with rebars 0...550 mm(22"), the maximum length of the rebars 500 mm(20") and max. diameter is 20 mm(3/4"). Construction rubble (mixed, including fines) 0...550 mm(22"). Bricks 0...550 mm(22"). Figure 7.22 Measurement of the material dimensions.
Rock 0...550 mm(22"). Asphalt 0...550 mm(22") (only if the temperature is below +10º C(50º F) and the bitumen content is low). Slag 0...550 mm(22"). The size of the material is measured as illustrated in figure 7.7.1.
7.7.2 SETTING ADJUSTMENT Manual setting adjustment: refer to the C-Jaw Instruction Manual for instructions on setting adjustment. Hydraulic setting adjustment: Settings can be adjusted only when the crusher is in the maintenance/adjustment mode.
Figure 7.21 Setting adjustment
–
10: opens the setting
–
11: closes the setting.
–
6: crusher stop-button: crusher in maintenance/adjustment mode.
The process does not have to be stopped completely when changing settings. Process is restarted with the crusher start button (7) and the feeder start button (3), see Chapter 4.3 .
7-12
LOKOTRACK LT106 INSTRUCTION MANUAL
7-85-EN
07/07
CHAPTER 7 - CRUSHING
7.8 CLEARING OF THE BLOCKAGE CAUTION! Never try to clear the blockage with an excavator. If the process is initiated with material in the cavity, the crusher tries to start with slow ramp and if the rock is strong enough to prevent crusher from starting, the alarm # 3 (“Crusher pressure rising too fast on start”) will be shown in the display. The process will be fully activated but the feeder and the crusher will not function. You can swing the crusher clockwise and counter clockwise with the buttons 8 and 9 (Figure 7.23) of the remote control box, located on the service platform. When the cavity is clear, switch on the crusher using the “Crusher start” -button (# 7, Figure 7.23). Start the feeder. Figure 7.23 Remote control
7.9 REMOVAL OF THE STEEL WARNING! Always stop the machine (feeder, crusher, conveyors and engine) before removing metal from it. Make sure that it can not be started during removing metal from it.
WARNING! Use a hook to remove iron bars and wires. Be very careful not to hurt yourself. Never use a hook when the machine is running.
07/07
7-85-EN
LOKOTRACK LT106 INSTRUCTION MANUAL
7-13
CHAPTER 7 - CRUSHING
7.10 RECYCLING In carrying out recycling processes with the crusher, all metal objects should be removed from the feed before they enter the crusher.
The optional magnetic separator can be used for the removal of small metal objects. The maximum diameter allowance for steel objects entering the crusher is 20 mm. The maximum length allowance is 0,5m.
The most efficient method is to prepare the feed material for the process and remove all the metal pieces from it before loading it to the LT106. Someone should stand next to the feeder and remove the metal pieces. Be very careful when touching the feed material. The feeder must be stopped when removing larger objects. Never climb on top of the feeder.
Figure 7.24 Removal of metal objects during the crushing of recyclable materials.
7.11 OPTIONAL EQUIPMENT LEVEL INDICATOR
INTERMEDIATE CABLE FOR SECONDARY UNIT
The purpose of the level indicator is to control the feed material level that enters the crusher. The indicator stops the feed process and emits a light signal when the material level is too high. The indicator resets itself automatically.
The LT106 unit is equipped with a 6-pin socket allowing information flow between the primary and the secondary unit. The socket has three different functions:
Keep the level indicator clean to ensure that it functions proper function.
Pins 1&2: When connected, LT106 gets information on the connection of the secondary unit..
Refer to the IC500 Instruction Manual for further information on switching the level indicator to ON or OFF position. HYDRAULIC OUTPUT
Pins 3&4: Feeder ON/OFF information (secondary feed/emergency functions can be connected to this). Normally open contact required. Pins 5&6: For the level sensor of the secondary unit. Normally closed contact required.
The hydraulic output can be set ON/OFF permanently or ON with the process. Refer to the IC500 Instruction Manual for further information on how to select the hydraulic output.
7-14
LOKOTRACK LT106 INSTRUCTION MANUAL
7-85-EN
07/07
CHAPTER 7 - CRUSHING
7.12 RADIO CONTROL BOX
(OPTIONAL)
11
2
1
3
a)
4
6
7
9 10
5
8
b) * The directions right and left are defined from the direction of travel of the material from the feeder side perspective.
Reference Description 1 Drive control, left track * (function a) 2 Drive control, right track * Main switch for the radio control box 3 (on/off) (not shown in the picture) 4 5
6
Sound signal button
Reference Description 7 Adjusting the feeder speed +/8 Changing the radio frequency ** 9 10
Control box mode selection a) track drive (orange symbols) b) conveyor control (white symbols) - Adjusting the engine speed +/(function a) - Feeder on/off (function b)
11
Radio control on (green signal light) Weak battery power (red signal light) Remote stop (crushing, hydraulic operations and the engine are stopped)
Figure 7-25 Drive control box
**When changing the frequency, hold the horn button (4) down and press the radio frequency button (8) to find a correct channel.
07/07
(Push the button as many times as many channels you need to change to)
7-85-EN
LOKOTRACK LT106 INSTRUCTION MANUAL
7-15
CHAPTER 7 - CRUSHING
This Page Left Intentionally Blank.
7-16
LOKOTRACK LT106 INSTRUCTION MANUAL
7-85-EN
07/07
LUBRICANT RECOMMENDATION 8.1 GENERAL
CHAPTER
•
This section contains information and instructions on several alternative and optional equipment. Normally Lokotracks have only some of them. Before maintaining and servicing, find out which alternative and optional equipment your Lokotrack has.
ELF –
•
•
•
•
See further instruction in your feeder/screen manual.
–
Oil designation to DIN 51517, part 3: CLP 220.
•
–
ISO viscosity to DIN 51519: ISO - VG 220.
•
–
Kinematic viscosity at 40°C(104ÉF): Min. 198 mm2/s (cSt). Max. 242 mm2/s (cSt).
–
FZG test A /8,3/90 to DIN 51354, p. 2: Min. breakdown load stage 12.
Mobilgear 630, SHC 220
PANOLIN –
8.4 TRACK GEAR
Q8 Goya 220, El Greco 220
MOBIL –
•
Lamora 220
KUWAIT –
8.3 FEEDER / SCREEN
Renolin AWD 220
KLÜBER –
See further instruction in your crusher manual.
Giran L 220
FUCHS –
8.2 CRUSHER
Reductelf SP 220, Elf Epona Z 220
FINA –
•
8
EP Gear Synth 220
TEXACO –
Syngear 220
TOTAL –
Varter EP 220
8.5 ENGINE Allowed oil grades are: 10W30 and 15W40 (refer to the C-9 Operation and Maintenance Manual).
Recommended brands are e.g.:
OIL GRADE PLUG
•
Engine is equipped with oil grade plug. (refer to the C-9 Operation and Maintenance Manual).
•
AGIP –
Blasia 220ARAL
–
Degol BG 220
Oil Grade
1
10W30
2
15W40
Alphasyn T 220, Aplha ZN 220
DEA –
07/07
Enersyn HTX 220
Plug
CASTROL –
•
Gear RSX 220
BP –
•
OIL GRADE DETECTION
AVIA –
•
Factory filled oil type: 10W30 (plug position 1).
Trion EP 220, Intor HCLP 220
8-49-EN
LOKOTRACK LT106 INSTRUCTION MANUAL
8-1
CHAPTER 8 - LUBRICANT RECOMMENDATION
8.6 HYDRAULICS
In summer time e.g. in hot climate conditions, when the ambient temperature exceeds +35ºC(95ºF), the use of a special hydraulic oil of ISO VG 68 class is recommended. The max. allowable operating temperature with this oil type is about +90ºC(194ºF) and min. allowable starting temperature is about -10ºC (14ºF).
Basic requirements for the hydraulic oil quality: –
viscosity index should be min. 150
–
min. viscosity 16 cSt at operating temperature
–
max. viscosity 1000 cSt at starting temperature
Attached some examples of oil brands meeting these requirements:
Unless otherwise mentioned, the factory fill oil is a special hydraulic oil of ISO VG 46 class. The max. allowable operating temperature with this oil type is about +80ºC (176ºF) and min. allowable starting temperature is about -20ºC(-4ºF), which makes it suitable for use all year round in most operating conditions.
–
BP Energol SHF 68
–
Mobil DTE 16
–
Teboil Tebo Hydraulic Oil 68
Oil amount is 520 litres (140 gal).
Attached some examples of oil brands meeting these requirements: –
BP Energol SHF 46
–
Esso Univis N 46
–
Shell Tellus Oil T 46
–
Teboil Tebo Hydraulic Oil 46
–
Mobil DTE 15
8.7 GREASE The grease must be NLGI EP 2 Type. Grease containing Molybdenum additives in NOT recommented.
In winter time e.g. in cold climate conditions, when the operating temperature of the oil stays below +60ºC (140ºF), the use of a special hydraulic oil of ISO VG 32 class is recommended. The max. allowable operating temperature with this oil type is about +65ºC (149ºF) and min. allowable starting temperature is about -30ºC (22ºF). Attached some examples of oil brands meeting these requirements:
8-2
–
BP Energol SHF 32
–
Esso Univis N 32
–
Mobil DTE 13
–
Shell Tellus Oil T 32
–
Teboil Tebo Hydraulic Oil 32 S
LOKOTRACK LT106 INSTRUCTION MANUAL
8-49-EN
07/07
CHAPTER 8 - LUBRICANT RECOMMENDATION
8.8 FILLING VOLUMES
LT106 AMOUNT
TYPE
Hydraulics
520 l / 140 gal
ISO VG 46
Final drive
4,5 l / 1,2 gal
ISO VG 220
Fuel tank
600 l / 160 gal
Feeder vibr. unit
4 l / 1 gal
ISO VG 150
CATERPILLAR C9
07/07
Engine oil
28 l / 7,5 gal
Water
36 l / 9,5 gal
8-49-EN
LOKOTRACK LT106 INSTRUCTION MANUAL
8-3
CHAPTER 8 - LUBRICANT RECOMMENDATION
This Page Left Intentionally Blank.
8-4
LOKOTRACK LT106 INSTRUCTION MANUAL
8-49-EN
07/07
MAINTENANCE
CHAPTER
DIESEL ENGINE Change engine oil Change the engine oil filter Drain water from fuel Change the primary fuel filter Change the fine fuel filter Check the service indicator of the air filter. Change the cartridge if necessary. Change the safety cartridge every third time See the engine operating manual for other maintenance. JAW CRUSHER Check V-belt tension. Check the tightness of the jaw bolts daily during the first 40 operating hours after jaw installation. Then weekly. Check the tightness of cheek plate bolts. Check the side guide plates and the protection rubber of the toggle plate. Lubricate crusher drive jack shaft 10g/40h/bearing Check wear on the jaw plates.
When needed
Every 12 months 2000-2200 h
Every 6 months 1000-1200 h
Daily 8-16 h
Carry out periodical maintenance according to given operating hours rather than given period.
Monthly 200-250 h
NOTE: Grease lubrification specification NLGI EP 2.
Weekly 40-50 h
9.1 PERIODICAL MAINTENANCE
9
X X X X X X X
X X
X
X X X X
75oC/
Check the sound, temperature (max. 167oF) and grease flow in the eccentric bearings. Lubricate eccentric shaft bearings. Check wear on the cheek plates. Check toggle plate for aligment, straightness and cracks. Check toggle seats, clean as necessary. Check the tightness of the mounting bolts of the labyrinth covers and the frame bearings. Check the tightness of the frame tie rods. Check the mounting of the flywheel. Check the tightness of the frame mounting bolts on the side plates. Check the bearings on the eccentric shaft.
07/07
X X X X X X X X X X
9-39-EN
LOKOTRACK LT106 INSTRUCTION MANUAL
9-1
Check for any wear on the contact surfaces of the pitman and front frame. Check rubber damper condition of the jaw crusher Mounting of the crusher no horizontal movement. Check the locking mechanism. Check for any wear on the contact surfaces between the side plates and cheek plates. MECHANICAL SETTING ADJUSTMENT Lubricate the cap nuts of the setting adjustment device. Check the rubber covers. AUTOMATIC LUBRICATING DEVICE Check operation and grease amount (add grease if necessary) VIBRATOR UNIT Oil change (1000h) Check oil level Replace breather FEEDER Clean vibration unit from outside. Check tightness of vibration unit joints. Check the wires/hoses. Check tightness of screen deck mountig bolts CONVEYORS Lubricate the bearings of head and tail pulleys. 5g/40h/per bearing Check the belt tension. HYDRAULICS Check oil level Check the oil temperature (max 90ºC / 194ºF). Check the fixing bolts of all components. Check pipes and hoses.
X X X
X X
X
X* X
X X
X X X X
X X X X X X X
Change the hydraulic oil filters Clean the hydraulic tank Check the breather of the hydraulic tank. Replace every 6 months
LOKOTRACK LT106 INSTRUCTION MANUAL
When needed
X
Change hydraulic oil
9-2
Every 12 months 2000-2200 h
Every 6 months 1000-1200 h
Monthly 200-250 h
Weekly 40-50 h
Daily 8-16 h
CHAPTER 9 - MAINTENANCE
X X X
9-39-EN
X
07/07
FINAL DRIVE Check oil level. Change oil BATTERY Check fluid level. Check the cleanliness of the battery terminals. TRACKS Check tension of track chains. Check tightness of track bolts. MAGNETIC SEPARATOR Lubricate the bearings. 3g/40h/Bear. Check the belt tension. FUEL TANK Breather replacement Fuel fill pump filter replacement (optional) *
When needed
Every 12 months 2000-2200 h
Every 6 months 1000-1200 h
Monthly 200-250 h
Weekly 40-50 h
Daily 8-16 h
CHAPTER 9 - MAINTENANCE
X X X X
X X X X X X
First oil change
07/07
9-39-EN
LOKOTRACK LT106 INSTRUCTION MANUAL
9-3
CHAPTER 9 - MAINTENANCE
9.2 RUNNING-IN
9.2.1 HYDRAULIC ADJUSTMENTS
Carry out the maintenance during running-in period as follows.
All components are set to operate at optimal speed. If adjustments is needed it is allowed only for Metso Minerals authorized persons.
200-250 h –
Change the engine oil (Note the warranty policy of the CAT engine!).
–
Replace the engine oil filters.
–
Replace the filters of the hydraulic oil.
–
Replace the breather of the hydraulic oil tank.
–
Change the vibrator’s oil
9.3 FINAL DRIVE Change final drive oil after first 150 operating hours. After that every 1500 operating hours. Oil amount is 4.5l (1.2 gal). Oil quality is ISO VG 220.
Crusher See the Crusher instruction manual for further information.
9-4
LOKOTRACK LT106 INSTRUCTION MANUAL
9-39-EN
07/07
CHAPTER 9 - MAINTENANCE
9.4 FUEL LEVEL The fuel level can be checked from the fuel amount indicator in the display (figure 9.1). Fuel tank capasity 600l (160gal).
9.5 CRUSHER SPACER REMOVAL & ASSEMBLY / TOGGLE PLATE CHANGE Please refer to the C106 manual.
NOTE: The system will inform about a low fuel amount by a display alarm, but it will not prevent the machine from running out of fuel.
Figure 9.1 Checking the fuel level
07/07
9-39-EN
LOKOTRACK LT106 INSTRUCTION MANUAL
9-5
CHAPTER 9 - MAINTENANCE
9.6 TRACKS Tension –
–
Frame Check that the track chains are properly tensioned (figure 9.2). Adjust as necessary. Measure in the middle of main pulley and idler. To tension tracks pump more grease into regulating cylinder with a grease gun. Correspondingly, the tracks are loosened by letting grease flow out through the opened grease nipple and moving the Lokotrack if needed.
Check the welded structure for cracks or weld failures, and carry out any necessary repairs as soon as possible. Track shoe bolt torque –
With lubricant: 304-358 Nm / 224-264 ft/Lb
–
Without lubricant:365-430 Nm / 269-317 ft/Lb
Check track shoes for damage.
Figure 9.2 Check that the track chains are properly tensioned. The correct deflection (X) is 25 mm (1")
9.7 ADDING FLUIDS 9.7.1 Adding hydraulic fluid Adding hydraulic oil: •
open the oil addition plug in the top of the return filter
•
add oil through the return filter in order to prevent impurities from entering the hydraulic system
•
the correct hydraulic oil level is in the middle of the upper sight glass
NOTE: The unit must be in operating and horizontal position when the hydraulic oil level inspection is carried out.
9-6
LOKOTRACK LT106 INSTRUCTION MANUAL
9-39-EN
07/07
CHAPTER 9 - MAINTENANCE
9.7.2 Adding Engine Fluids Add the engine oil through plug 2. Check the amount of oil with dipstick 1 (see chp 8.8 Filling volumes).
Callout Description 1 Engine oil dipstick 2 Engine oil plug (addition)
Callout Description 3 Engine coolant water expansion tank
Figure 9.3 Adding engine fluids
07/07
9-39-EN
LOKOTRACK LT106 INSTRUCTION MANUAL
9-7
CHAPTER 9 - MAINTENANCE
9.7.3 Removing Engine / Hydraulic Fluids
9.8 ENGINE FILTER CHANGE INFORMATION
Observe the following instructions: –
remove the plug
9.8.1 Replacing the Engine Fuel Filters
–
open the valve
Engine fuel filters must be replaced every 200 h of engine running hours or at least once a year.
Make sure that the drain pan will be able to hold all the fluid (See 8.8 Filling volumes).
For more information, refer to the Caterpillar C-9 Operation Manual.
9.8.2 Replacing the Engine Oil Filter Engine oil filter must be replaced every 200 h of engine running hours or at least once a year
9.8.3 Engine Air Filter Change The condition of the filter must be observed every 8h of operation. Air filter is a three stage filter : – Precleaner. –
Primary cartridge
–
Safety cartridge
Filter assembly contains an indicator. If the indicator shows red the primary filter must be replaced. Replace the safety cartridge (fig. 9.5) in every third primary filter replacement.
Callout Description 1 Coolant valve (under the cooler) 2 Engine oil 3 Hydraulic oil Figure 9.4 Draining engine fluids
Figure 9.5
9-8
LOKOTRACK LT106 INSTRUCTION MANUAL
9-39-EN
07/07
CHAPTER 9 - MAINTENANCE
Figure 9.6 Undo the filter housing latches to remove the cover.
Figure 9.8 Install new cartridges on their place (always check that the replacement filter size is correct. If the replacement filter is shorter than original it might cause a serious engine damage).
Figure 9.7 Draw the primary cartridge out from it's place. If needed draw the safety cartridge out from it's place. Figure 9.9 Close the air filter housing cover correctly on it's place and make sure that all latches are properly closed.
07/07
9-39-EN
LOKOTRACK LT106 INSTRUCTION MANUAL
9-9
CHAPTER 9 - MAINTENANCE
9.8.4 Fuel tank Breather change.
9.9.1 Crusher Drive Pump Filter Change
Breather is located side by the engine cover (fig. 9.6). Breather is a spin on type. Breather must be replaced every 2000 hours or once a year.
Filter location: The filter locates on the pump itself. Filter is a spin-on-type replaceable filter. The crusher drive pump is the hydraulic pump closer the engine.
Figure 9.10 Fuel tank breather
Figure 9.11 Crusher drive pump filter
Replacement information:
9.9 REPLACING THE HYDRAULIC OIL FILTERS First hydraulic oil filter change should take place at 1000 h of engine operation. Before startup of the unit the filter replacement is not necessary as the filters are renewed after the test run. Hydraulic filters: –
Cursher drive pump filter
–
Device pump pressure filter
–
Device pump return oil filter
–
Hydraulic tank breather
Work must be carried out when the engine is stopped and main switch in off position. Close the suction valves under the hydraulic tank. Undo the filter by turning the filter in counter clock wise. Disposel the used hydraulic filter according to the country legislation. Lubricate the O-ring of the new filter. Spin the new filter to the hand tightness and turn 30 ° (1/12 of the round ) to secure filter installation. Filter must be replaced every 2000 h of engine operation or whenever the filter condition indicator is alarming.
9.9.2 Device Pump Circuit Pressure Filter Change Filter location : Filter is mounted on the frame at left side of the unit. Filter is replaceable element inside the spin on type housing. Replacement information:
9-10
LOKOTRACK LT106 INSTRUCTION MANUAL
9-39-EN
07/07
CHAPTER 9 - MAINTENANCE
Work must be carried out when the engine is stopped and main switch in off position. Close the suction valves, located under the hydraulic tank. Undo the filter by turning the filter in counter clock wise. Dispose the used hydraulic filter according to country legislation
Figure 9.14 Lubricate the O-ring of the housing and spin the housing carefully on it's place Tighten the housing with 40 - 50 Nm torque.
Filter must be replaced every 1000 h of engine operation or whenever the filter condition indicator is alarming.
Figure 9.12 Undo the filter housing by turning the housing counter clockwise with 41 mm wrench.
9.9.3 Device Pump Circuit Return Oil Filter Change Filter location : Filter is mounted to the hydraulic tank. Filter is a replaceable element, under a cover. Replacement information: Work must be carried out when the engine is stopped and main switch in off position.Close the suction valves, located under the hydraulic tank.
Figure 9.13 Remove the filter element from the housing and install a new element to the filter support.
Figure 9.15 Undo the cover of the return filter. Open the four nuts ( 13 mm wrench ) and remove the cover.
07/07
9-39-EN
LOKOTRACK LT106 INSTRUCTION MANUAL
9-11
CHAPTER 9 - MAINTENANCE
Figure 9.16 Be careful when doing this as there is a spring under the cover. Figure 9.19 Clean the magnets before installing a new filter element (fig. 9.20). Use 20 - 25 Nm torque when securing the filter element. Insert the filter assembly on its place and close the cover.
Figure 9.17 Pull the filter assembly out from the filter housing.
Figure 9.20 Observe the O-ring condition and lubricate it before installation. Use 15 Nm torque for the cover mounting nuts.
Figure 9.18 Open the filter assembly by opening the 36 mm lock nut. Remove the filter element.
9-12
LOKOTRACK LT106 INSTRUCTION MANUAL
Filter must be replaced every 1000 h of engine operation or whenever the filter condition indicator is alarming. If the device pump pressure filter must be replaced due to alarm the return filter must be replaced at the same time.
9-39-EN
07/07
SERVICE INSTRUCTIONS
CHAPTER
10.1 GENERAL Only skilled and experienced mechanics must be allowed to service the plant. In any work related to the operation, adaptation to manufacture, conversion or adjustment of the LT and its safety equipment, as well as to inspection, maintenance and repair, observe starting and stopping procedures in accordance with the Instruction Manual and any indications relating to maintenance work! Secure extensively, as far as necessary, the area of maintenance works! In case the LT is completely switched off during maintenance and repair works, it must be safeguarded against unexpected switching-on. Lock-up main starting equipment, draw off keys and affix a hazard pictorial at the main switch. Smoking and any open flame is prohibited in the immediate area of the machine when refuelling or servicing the fuel system.
10
Service facilities must be kept clean. Oil and water can make floors slippery and highly dangerous. Avoid severely soiled clothing, they can be a fire hazard. Keep the LT and equipment free from oil spillage and dust. A clean machine reduces the fire risk and simplifies visual checks for components requiring attention. Be careful when using pressure cleaning equipment. Even low pressures and temperatures can damage wire insulation. Check wiring for signs of abrasion damage or kinks. This can cause short circuits and fire. Check hydraulic hoses for abrasion damage or kinks. Never weld or grind containers of inflammable liquids. Always have a fire extinguisher on hand when carrying out welding or grinding operations. Notify the location and use of fire extinguishers.
IMPORTANT!
10.2 BATTERY MAINTENANCE
In case of fire:
10.2.1 Fluid level check
–
Move the LT away from the dangerous area
–
Stop the engine
–
Turn off the main switch
–
Start fire fighting and give the alarm if necessary.
The fluid level in the batteries must be checked every 100 operating hours (figure 10.2.1). The level should be approximately 10 mm(1/4") above the plates. Add clean distilled water as required. Monitoring the fluid consumption will give an indication of the charge of the battery, but a separate test of the specific gravity of the acid will confirm the state of charge. If the fluid consumption is high it is possible for the alternator charging rate to be too high.
Diesel fuel is flammable - do not use as cleaning fluid. Use solvents of accepted quality only. Always stop the engine during maintenance unless it is mentioned in the instruction manual to keep the engine running. Do not check for leaks with a bare hand, use suitable cleaning cloth. Never adjust any hydraulic valve beyond the pressure recommended by the manufacturer. Always ensure adequate ventilation when running the engine in a confined area. Remember that some solvent qualities may cause skin irritation and may be extremely inflammable. Avoid breathing of solvent fumes.
07/07
10-28-EN
Figure 10.2.1 Check battery fluid level every 100 operating hours. Add clean distilled water in the accumulator as required
LOKOTRACK LT106 INSTRUCTION MANUAL
10-1
CHAPTER 10 - SERVICE INSTRUCTIONS
10.2.2 Battery check
10.2.3 Cleaning batteries, terminals and cables
The level of charge in the battery must be checked regularly using a hydrometer. Do not make this check immediately after adding any distilled water to the battery; the water and acid will be more evenly mixed after some charging has taken place. The specific gravity of a fully charged battery is approximately 1.28, and if only half-charged the reading will be about 1.2. These values relate to a battery temperature around +20ºC(68ºF).
Batteries and terminals must be cleaned at least once per year. The terminals and the cable ends should be cleaned with the special tools which will restore the contact area to the right form and size. After cleaning, the terminals and cable ends should be liberally covered with petroleum jelly to protect against oxidation. Check also the fastening of: battery earth cables to the main frame, engine starter cables, and electrical connections for the alternator. Clean and tighten as necessary. Keep battery cases clean and dry.
Batteries must always be maintained as far as possible at full charge. If the charge is allowed to remain low, the plates will become sulphated reducing the capacity and efficiency of the whole battery. Remember that a half-charged battery will freeze at a temperature of -25ºC(-13ºF) and a flat one at only -10ºC(14ºF).
10.3 OTHER ELECTRICAL EQUIPMENT 10.3.1 Charging circuit
Never use an open flame when checking the acid level of a battery. The gases given off by the chemical reaction during the recharging process are highly inflammable. The liquid used in lead-acid batteries is dilute sulf acid. This acid is corrosive, will cause severe burns to exposed skin and will damage clothing. Be very careful when handling a battery.
–
Check and tighten connections regularly.
–
The alternator requires only periodic attention.
NOTE: It is important to strictly follow the instructions for protecting the alternator: –
Do not remove battery cables or any other connections in the charging circuit while the engine is running.
–
Never start the engine if any wire in the charging circuit is disconnected or loose.
–
Whenever the batteries are charged using an external source, the earth lead to the frame must be disconnected from the battery. When reconnecting batteries, using jumper leads or a charger, be sure to identify the correct polarities.
–
Always disconnect the batteries when servicing the electrical equipment of the LT.
–
Do not cause a short circuit in any part of the system, nor take a test reading with an instrument with low internal resistance.
Always wear protection glasses and gloves while handling and maintaining.
NOTE: If auxiliary batteries are used to assist engine start, make sure that:
10-2
LOKOTRACK LT106 INSTRUCTION MANUAL
10-28-EN
–
batteries have the same voltage
–
the correct poles are connected
07/07
CHAPTER 10 - SERVICE INSTRUCTIONS
10.3.2 Starter circuit Normally the starter circuit requires little attention, but all components should be kept clean and electrical connections tight. The batteries are an essential part of the electrical system and are required to be kept fully charged, clean and topped up properly to maintain the acid level. Battery cables must also be checked for tightness and kept clean and greased.
10.3.3 Fuse List
IMPORTANT! Use only fuses with required size as oversize fuse can damage components in the electrical circuit.
Fuse ID 1F01
Fuse Size 10A
1F02
20A
1F03 1F04 1F05 1F06 1F07
10A 10A 15A 10A 10A
Description Control key Control fuse, secondary main Options Power for I/O-modules Optional water pump Radio control Not in use
Table 10-1 Fuse location in the control panel
Fuse ID 2F01 2F02 2F03 2F04 2F05 2F06 2F07
Fuse Size 30A 50A 10A 10A 10A 15A 10A
2F08
15A
2F09 2F10 2F11 2F12 2F13 2F14 2F15
15A 15A 15A 8A 8A 8A 10A
Description Control main fuse Start motor pilot Not in use Engine + bat Switched Optional drive lights Work lights Engine control Service light sockets + optional engine pre-heater Fuel cooler Oil cooler S- models Not in use Engine Engine Engine Engine
Table 10-2 Fuse location in the electrical panel next to the hydraulic tank
Fuse ID 2F20 2F21
Fuse Size 100A 100A
2F22
20A
2F23
10A
Description Main fuse Engine grid heater Engine control main fuse Main switch
Table 10-3 Fuse location next to the main switch
Fuse ID 3F01 3F02
Fuse Size 10A 20A
Description Screen module Fuel pump
Table 10-4 Fuse location in the electrical panel next to the hydraulic valves
07/07
10-28-EN
LOKOTRACK LT106 INSTRUCTION MANUAL
10-3
CHAPTER 10 - SERVICE INSTRUCTIONS
10.4 WELDING
10.6 CRUSHER SPEED SENSOR
If any welding is to be done on the machine, care must be taken to protect sensitive electrical equipment.
FUNCTION
–
Stop the engine.
The crusher is equipped with a speed sensor. The sensor controls the pitman rotation and gives one impulse per one pitman revolution.
–
Turn the main switch OFF.
MOUNTING
–
Disconnect the earth lead to the batteries.
–
Fasten the earth cable of the welding apparatus as close to the part to be welded, as possible and make sure that no welding current is able to pass through any bearings or electrical equipment.
The sensor is mounted at the back side of the pitman, close to the eccentric shaft. To locate the sensor, lift the rubber cover behind the pitman.
–
Disconnect engine wire harness sockets.
–
Disconnect control module sockets.
10.5 PRESSURE ACCUMULATOR
The sensor is mounted on its support with a plastic clamp. The correct distance from the sensor end to the pitman is 3-5 mm. (The minimum distance while the crusher is running). When replacing the sensor there is no need to adjust the sensor itself. Sensor has a LED-indicator. The function can be controlled from this led indicator. Possible reasons if the speed sensor is causing an alarm:
NOTE: Before removing / repairing any components from the hydraulic setting control circuit release the pre-charge pressure by opening the SHUT off VALVE. Make sure that the pressure gauge above accumulator indicates NO pressure. Make sure that the security valve of the gauge is open.
10-4
LOKOTRACK LT106 INSTRUCTION MANUAL
10-28-EN
–
Chocked fuel filter
–
Chocked air filter
–
V-belts are loose - slipping
–
The setting too small for the crushed material
–
Cavity worn out.
–
Hydraulic drive component failure
07/07
Symbol Identification
APPENDIX
A
1.General symbols
1. On/Start
2. Off/Stop
3. Connecting
4. Disconnecting
5. Increase
6. Decrease
7. Stepless adjustable movement
8. Warning
9. Warning: pressurized
10. Warning: electric danger
11. Grease lubrication point
12. Oil lubrication point
13. Running hours
14. Lifting point
15. Horn
16. Level
07/00
APPENDIX A
APPENDIX A - SYMBOL IDENTIFICATION
1.General symbols
17. Belt conveyor
18. Feeding
20. Check
2. Electric symbols
1. Remote control
21. Max. temperature
3. Lights
2. Battery charging indicator
1. Work light
2. Driving lights
4. Engine
1. Engine emergency stop
-2
2. Stopping of engine
3. Engine running speed
APPENDIX A
4. Combustion engine
07/00
APPENDIX A - SYMBOL IDENTIFICATION
4. Engine
5. Starting of engine
5. Fuel
1. Fuel volume
2. Fuel pressure
3. Fuel filter
5. Fuel refill
07/00
APPENDIX A
4. Fuel shut-off
APPENDIX A - SYMBOL IDENTIFICATION
6. Engine oil
1. Oil level
2. Oil refill
3. Oil pressure
4. Oil temperature
5. Oil filter
7. Cooler system
1. Coolant refill
-4
2. Coolant level indicator
3. Coolant pressure
APPENDIX A
4. Coolant temperature
07/00
APPENDIX A - SYMBOL IDENTIFICATION
8. Transmission oil
1. Oil refill
2. Oil level indicator
5. Oil filter
6. Testing point: oil pressure
3. Oil pressure
4. Oil temperature
9. Hydraulic oil
1. Hydraulic oil refill
07/00
2. Hydraulic oil level
3. Hydraulic oil pressure
APPENDIX A
4. Hydraulic oil temperature
APPENDIX A - SYMBOL IDENTIFICATION
9. Hydraulic oil
5. Hydraulic oil filter
6. Pressure testing
7. Shut-off valve
10. Air
1. Air intake
2. Air pressure
3. Air filter
11. Symbols not included in the ISO standard
1. Tensioning of power 2. Tightening of nuts and transmission belt bolts
-6
3. Remove / install transport locking
APPENDIX A
07/00
ADDITIONAL INFORMATION
CHAPTER
GUARDS AND PROTECTION DEVICES –
Belt drives are guarded.
–
The feed opening to the crusher is guarded.
–
Conveyor head and tail drum nip points are guarded.
–
Conveyors are equipped with emergency stop cables and safety switches or valves.
–
Emergency stop buttons are provided on the remote control box and service platform and in the electrical centre and cabin.
6
STORAGE OF THE MACHINES The machine must be stored in a dry and covered area. DISPOSAL OF THE MACHINE Whenever a machine is taken out of use, being dismantled or disposed of, all hazardous materials, such as oils, battery acids, fuels etc. must be carefully removed first to eliminate any danger to life and the environment. The hazardous materials must be removed to a suitable waste collection plant for disposal or recycling. Dispose of the machine so that there is no danger to life or the environment.
EMERGENCY STOP If a dangerous situation occurs, pull the nearest emergency stop cable or push an emergency stop button. After pulling an emergency stop cable, the trip switch will remain engaged and a signal light will show. To reset, push the button in the switch. To reset an emergency stop button, pull the red button to its outer position. Before restarting the machine ensure the area is clear around the unit and that no one will be endangered by your action. Start the machine according to the instruction manual. DISPOSAL OF WASTE Waste materials, such as oil, battery acids and cleaning fluids etc. must be removed carefully using suitable containers to prevent any hazard to people, animals or environment. The hazardous material must be removed to a suitable waste collection plant for disposal or recycling. FIRE The Manufacturer has not provided this machine with a fire extinguisher, and recommends that the user equips the machine with an extinguisher of a type approved by his local authorities. Inflammable materials used in the construction and use of this machine include: diesel and lubricating oils, conveyor belting and skirts, electrical cables and fittings, etc.
1/95
12-00-EN
A-1
This Page Left Intentionally Blank.
6-2
A-1
12-00-EN
1/95
NOISE LEVELS
SECTION
0
Noise levels in excess of 85 dBA around the LT unit while running are shown in the diagram below. Ear protection must be worn in this area.
03/03
LOKOTRACK LT INSTRUCTION MANUAL 0-1
SECTION 0 - NOISE LEVELS
This Page Left Intentionally Blank.
0-2
LOKOTRACK LT INSTRUCTION MANUAL
03/03
RECYCLING
CHAPTER
0
If the machine is used for recycling, pay attention to the following: 1. Preprocessing of the feed material Break the feed material small enough and cut the metal bars to the length of 0.5 - 1 metres depending on the machine. Too long bars may damage the conveyor belt. 2. Feeding the material Remove the metal objects from the feed, if possible. At least remove the loose metal. The metal objects larger than the crusher setting must not enter the crusher. When removing the metal objects be very careful. Never go to the feeder when the machine is running. Observe the feed material. Never let uncrushable objects enter the crusher. 3. Block removal Be very careful when clearing the blocking. Stop the machine and use safety valve or switch during clearing.
02/06
CHAPTER 0 - RECYCLING
This Page Left Intentionally Blank.
0-2
02/06
SAFETY PLATES ANSI
10/04
APPENDIX
0
SAFETY PLATES ANSI 0-17
APPENDIX 0 - SAFETY PLATES ANSI
0-18
SAFETY PLATES ANSI
10/04
APPENDIX 0 - SAFETY PLATES ANSI
10/04
SAFETY PLATES ANSI 0-19
APPENDIX 0 - SAFETY PLATES ANSI
0-20
SAFETY PLATES ANSI
10/04
APPENDIX 0 - SAFETY PLATES ANSI
10/04
SAFETY PLATES ANSI 0-21
APPENDIX 0 - SAFETY PLATES ANSI
0-22
SAFETY PLATES ANSI
10/04
APPENDIX 0 - SAFETY PLATES ANSI
10/04
SAFETY PLATES ANSI 0-23
APPENDIX 0 - SAFETY PLATES ANSI
0-24
SAFETY PLATES ANSI
10/04
Factory test run in Metso Minerals (Tampere) Oy This document is only valid for products manufactured in Tampere, Finland. The machine has been test-run – i.e., its operation has been checked and adjusted to meet the requirements of the product specifications. During the test run, diesel fuel was used. This fuel may have in many countries a lowduty/tax or even duty/tax-free status and which may be categorised as red fuel in your country. There is this fuel left in the fuel tank and it may be subject to restrictions for use in certain countries.
NORDBERG C SERIES JAW CRUSHERS INSTRUCTION MANUAL 140588-EN
NORDBERG C SERIES JAW CRUSHERS
CHAPTER
0
This manual is valid for the Nordberg C Series Jaw Crushers manufactured by Metso Minerals. These crushers are high capacity jaw crushers, intented to be used in primary crushing applications.
Because of the continuous development of the products, the manufacturer reserves a right to alter the technical specifications written in this manual, without any advance information. This is the first edition published in April 2003 in Tampere, Finland .
Metso Minerals (Tampere) Oy P.O. Box 306 FIN-33101 Tampere Finland Tel. +358 (0)20 484 142 Fax +358 (0)20 484 143
EN
140588-0_K
NORDBERG C SERIES JAW CRUSHERS 0-1
CHAPTER 0 - NORDBERG C SERIES JAW CRUSHERS
This Page Left Intentionally Blank.
0-2
NORDBERG C SERIES JAW CRUSHERS
140588-0_K
EN
Nordberg C Series Jaw Crushers
Table of Contents NORDBERG C SERIES JAW CRUSHERS PREFACE 1.1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
SAFETY 2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.1.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.2 Warning signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.2.1 Warning sign codes and texts (ANSI). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2.2.2 Warning sign codes and texts (ISO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
GENERAL CRUSHER INFORMATION 3.1 CRUSHER TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 CRUSHER COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.3 SPARE PARTS BOOK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.4 ORDERING PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.5 ESTIMATING CRUSHER CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.6 ESTIMATING CRUSHER PRODUCT GRADATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3.7 CRUSHER SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3.8 CRUSHER SETTING LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 3.9 OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3.9.1 Intermediate Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3.9.2 Protection Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3.9.3 Conveyor Belt Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 3.9.4 Hydraulic Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 3.9.5 Automatic Lubrication Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
OPERATING INSTRUCTIONS 4.1 PREPARATIONS BEFORE STARTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.2 STARTING THE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.3 STOPPING THE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Nordberg C Series Jaw Crushers
Table of Contents 4.4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.4.1 Oversized Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.4.2 Tramp Iron/Uncrushables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.4.3 Packing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.5 RE-STARTING A CRUSHER STALLED UNDER LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.6 CRUSHER SETTING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.6.1 Mechanical Wedge Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.6.2 HYDRAULIC WEDGE SETTING ADJUSTMENT (OPTIONAL) . . . . . . . . . . . . . . . . . . . 4-6 4.6.3 ACTIVE SETTING CONTROL ADJUSTMENT (OPTIONAL). . . . . . . . . . . . . . . . . . . . . 4-8 4.7 TOGGLE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 4.8 SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 4.9 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
MAINTENANCE 5.1 SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.1.1 Spacer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.1.2 Spacer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5.2 TOGGLE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 5.2.1 Replacing the Toggle Plate And Toggle Seats (with wedge setting adjustment) . . . . . . 5-5 5.2.2 Replacing the Toggle Plate And Toggle Seats with Active Setting Control . . . . . . . . . . 5-7 5.3 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 5.3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 5.3.2 Grease Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 5.3.3 Eccentric Shaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 5.3.4 Eccentric Shaft Bearing Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 5.3.5 Jack-shaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 5.3.6 Jack-shaft Bearing Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 5.3.7 Thrust Bearing And Cap Nut Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 5.3.8 Electric Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 5.3.9 Toggle Seats And Toggle Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 5.3.10Setting Adjustment Wedges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 5.4 INSTRUCTIONS FOR LIFTING A JAW CRUSHER WHEN REPLACING CRUSHER SUPPORT BRACKET DAMPERS5-18 5.5 HYDRAULIC SETTING ADJUSTMENT POWER UNIT (OPTIONAL). . . . . . . . . . . . . . . . 5-20 5.5.1 Checking oil level and temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 5.5.2 Changing oil and filter (Figure 5.10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 5.5.3 Oil recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 5.5.4 Bleeding the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Nordberg C Series Jaw Crushers
Table of Contents 5.6 PERIODICAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 5.6.1 Daily maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 5.6.2 Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 5.6.3 Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 5.6.4 Twice a Year. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 5.6.5 Regularly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 5.7 MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 5.8 BOLT TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
REPLACEMENT OF WEAR PARTS 6.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.2 JAW SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.3 JAW WORK HARDENING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.4 CHEEK PLATE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.4.1 Cheek Plate Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.4.2 Cheek Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6.5 CHANGING OR ROTATING THE JAWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 6.5.1 One Piece Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 6.5.2 TWO-PIECE JAW REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 6.6 PITMAN EYE PROTECTION PLATE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 6.7 FEED HOPPER LINER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 6.8 TOGGLE PLATE SEAT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Nordberg C Series Jaw Crushers
Table of Contents APPENDIX
1. 2. 3. 4. 5. 6. 7. 8. 9.
SAFETY, OPERATING AND MAINTENANCE INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . .A-1 Purpose of the jaw-lifting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Storage of the jaw-lifting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Safe use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Commissioning and operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 The jaw-lifting tool verification before first use and in service . . . . . . . . . . . . . . . . . . . .A-1 Handling the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3 Operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
APPENDIX
1. 2. 3. 4. 5. 6. 7. 8. 9.
SAFETY, OPERATING AND MAINTENANCE INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . .B-1 Purpose of the cheek plate lifting tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Storage of the cheek plate lifting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Safe use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Commissioning and operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2 The cheek plate lifting tool verification before first use and in service . . . . . . . . . . . . . .B-2 Handling the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3 Operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
PREFACE
CHAPTER
1
1.1 FOREWORD
1.2 SAFETY
This instruction manual provides guidance for first time operators of the crusher as well as technical procedures as a reference for the experienced crusher operator. Read, study, and keep it for future reference.
BASIC RULES REGARDING SAFETY IN AND AROUND A CRUSHING PLANT ARE OUTLINED IN THE SECTION ENTITLED "SAFETY."
The instructions given are for the operation and basic maintenance procedures only, as this instruction book is not a repair manual. Should maintenance procedures not covered in this manual be required, contact Metso Minerals. Illustrations and instructions guide the operator through correct procedures for checking, operating and maintaining the crusher and its accessories. Operating techniques outlined in this manual are basic. Operating skills and additional techniques will develop through experience as the operator gains knowledge of the crusher and its capabilities.
OPERATOR SAFETY AND THE SAFETY OF OTHERS DEPEND UPON REASONABLE CARE AND JUDGEMENT IN THE OPERATION OF THIS CRUSHER. A CAREFUL OPERATOR IS GOOD INSURANCE AGAINST AN ACCIDENT. MOST ACCIDENTS, NO MATTER WHERE THEY OCCUR, ARE CAUSED BY FAILURE TO OBSERVE AND FOLLOW SIMPLE FUNDAMENTAL RULES OR PRECAUTIONS. FOR THIS REASON RECOGNIZING HAZARDS AND TAKING STEPS TO AVOID THEM CAN PREVENT MOST ACCIDENTS. REGARDLESS OF THE CARE USED IN THE DESIGN AND CONSTRUCTION OF THIS TYPE OF EQUIPMENT, THERE ARE CONDITIONS THAT CANNOT BE COMPLETELY SAFEGUARDED AGAINST WITHOUT INTERFERING WITH REASONABLE ACCESSIBILITY AND EFFICIENT OPERATION. WARNINGS ARE INCLUDED IN THIS INSTRUCTION MANUAL TO HIGHLIGHT THESE CONDITIONS.
Continuing improvement and advancement of product design may result in changes to your new machine that may not be included in this publication. As required, each publication is reviewed and revised to update and include appropriate changes in the later editions. The descriptions and specifications in this manual were in effect at the time this manual was approved for printing. Metso Minerals reserves the right to discontinue models at any time and to change specifications and designs, without notice and without incurring obligation. Whenever a question arises concerning your crusher, or this publication, please consult your Metso Minerals representative for the latest available information.
EN
140588-1_K
NORDBERG C SERIES INSTRUCTION MANUAL 1-1
CHAPTER 1 - PREFACE
This Page Left Intentionally Blank.
1-2
NORDBERG C-SERIES INSTRUCTION MANUAL
140588-1_K
EN
SAFETY
CHAPTER
2.1 GENERAL The instructions of the safety guide, these safety instructions and other manuals and safety labels for the equipment must be read, understood and used by each person who works with this equipment.
2
This manual uses the alert symbol, with words such as DANGER, WARNING or CAUTION, to alert you and other Crushing Plant personnel of actions or conditions that pose a potential safety hazard, with an attending risk of personal injury (including death) or property damage. The machine also displays safety signs, labels and tags at appropriate points to show safety risks that may exist.
WARNING! In addition to these unit-specific safety instructions, the operators of this equipment must also read the safety guide with instructions for general operational safety.
DANGER
The following symbol is used in this manual and on the machine to call attention to instructions, which will help prevent machine related injuries.
WARNING
When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.
CAUTION Sign
Figure 2.1 Alert Symbol
Description
Immediate hazards or unsafe practices DANGER that will result in severe personal injury or death. Hazards or unsafe practices that could WARNING result in severe personal injury or death Hazards or unsafe practices that could CAUTION result in minor personal injury or equipment damage Figure 2.2 Danger, warning, caution signs and their meaning
EN
140588-2_K
NORDBERG C SERIES INSTRUCTION MANUAL 2-1
CHAPTER 2 - SAFETY
2.1.1 General safety instructions
5. It is prohibited to stay in the danger area during the crushing process. The crushing material may be thrown into a few meters distance from the crusher. Always use helmet and safety glasses.
WARNING! Before performing any maintenance or repair work, make sure that the crusher is stopped and locked out.
6. Do not look into the jaw cavity during crushing. Material may be thrown from the crusher during crushing and cause injuries. Always use a helmet and safety glasses.
LOCKOUT PROCEDURE of the Lokotrack installed crushers
7. Because the crusher is installed on rubber dampers, it moves during crushing. This movement causes a crushing danger. Never put your hands or feet between the moving parts and the structure of the crusher during crushing. The movement may be as much as ± 10mm.
1. Switch off engine 2. Remove the ignition key and keep it on person during lockout 3. Place appropriate maintenance warning signs (TAG OUT)
8. Clearing a jammed cavity is extremely dangerous. Do not attempt to clear the cavity until the crusher has stopped completely.
LOCKOUT PROCEDURE of the electrical motor driven crushers
9. The crusher does not stop immediately after the motor has been turned off. Make sure that the crusher has stopped completely before opening any covers, performing any maintenance, or adjusting the crusher.
1. Switch off motor 2. Lock the main switch of the motor with a padlock or make sure in some other way that the engine cannot be started
10. The crushing plant and auxiliary equipment such as chutes, transfer stations, screens, etc. can create dust and, if not contained, the dust can escape into the air. Metso Minerals highly recommends that dust protective devices such as an appropriate respirator be worn by anyone exposed to airborne dust to prevent its inhalation. It is the responsibility of the Owner and Operator to determine the necessity and adequacy of protective devices and warnings, to provide them, and to ensure that they are used and followed!
3. Lock the main switch of the hydraulic adjustment power unit (if delivered) with padlock 4. Keep the keys on person during lockout 5. Place appropriate maintenance warning signs (TAG OUT). 1. Ignoring the safety instructions or the warning signs increases the risk of the severe injury or death.
11. The noise level is dangerously high near the crusher. All personnel working near the crusher must wear hearing protection. The noise level is typically about 102-110 dB next to the crusher during crushing.
2. Nordberg C series jaw crushers has been designed for safe operation when used by professional staff in the operating situations included in this instruction manual. All other service and repair procedures must be performed by specially trained personnel or authorized Metso service staff.
12. Before performing any maintenance or repair work, make sure that the crusher is stopped and locked out.
3. Never operate the crusher without proper covers and safety devices. 4. Before starting the crusher make sure that no one is near the crusher.
2-2
NORDBERG C SERIES INSTRUCTION MANUAL
13. The surfaces of the crusher may become hot during crushing. Hot surfaces can cause severe burn injuries. Make sure that the
140588-2_K
EN
CHAPTER 2 - SAFETY
surfaces have cooled before performing any maintenance work. 14. Before changing any wear parts of the crusher, read chapter 6: Replacement of wear parts and appendixes A and B carefully. 15. Before lifting any wear parts, check the weight of the component and ensure that lifting equipment being used is adequate to lift the weight. In addition, familiarize yourself with all the special tools provided with the crusher specifically for replacing the wear parts. 16. Read the instructions regarding the lifting tools and replacing wear parts carefully before replacing any wear parts. Make sure that the parts are adequately supported before lifting. Never go under a hanging part. The lifting tools delivered with the crusher are designed to be used only with original Metso Minerals wear parts. 17. The spring of the mechanical setting adjustment may accumulate significant amount of energy. Follow the instructions strictly and be extremely accurate when adjusting the spring. Never release the protective plate. 18. The pressure accumulator of the hydraulical setting adjustment may be charged only by a professional. If the pressure accumulator is charged incorrectly, it may explode. Do not charge the accumulator yourself. Release the pressure from the hydraulic system according to instructions before any maintenance to the system. 19. Keep the warning signs clean. Replace illegible and damaged signs before starting the crusher. Make sure that the warning signs are not hidden from sight when installing the crusher. If a part with a warning sign is replaced, make sure that the new part also has the required warning signs.
EN
140588-2_K
NORDBERG C SERIES INSTRUCTION MANUAL 2-3
CHAPTER 2 - SAFETY
2.2 WARNING SIGNS The warning signs attached to the equipment must always be kept readable and clean. Damaged or loose signs must be replaced at once before starting the crusher. Make sure that the warning signs are not covered during installation. If a part of the crusher attached a warning sign are replaced, always make sure that the warning signs needed are included in a new part.
IMPORTANT! There are two different sets of warning signs depending on the delivery country. You can check which set of warning signs is used on your machine from the side of the machine or the spare part manual.
Figure 2.3 The locations of the warning signs
The number and exact locations of the warning signs may vary according to options (for example, guards).
IMPORTANT!
The warning signs 1, 2, 3, and 4 are located on both sides of the crusher.
Warning signs 1, 2, 3 and 4 are not attached on crushers installed in Lokotracks or Nordwheelers.
The warning signs 3 are delivered only if the crusher delivery includes the drive guards. The warning sign 5 is delivered only with crushers that have a mechanical setting adjustment. The warning signs 6, 7, and 9 are delivered only with crushers that have a hydraulical setting adjustment.
2-4
NORDBERG C SERIES INSTRUCTION MANUAL
140588-2_K
EN
CHAPTER 2 - SAFETY
1
2
4
3
7
6
5
8 9
Figure 2.4 Warning signs (ANSI)
EN
140588-2_K
NORDBERG C SERIES INSTRUCTION MANUAL 2-5
CHAPTER 2 - SAFETY
2.2.1 Warning sign codes and texts (ANSI) 1. MM0229994 WARNING Read and understand instruction manual before using or maintaining this machine. Failure to follow operating instructions may result in death or serious injury. DANGER Lung disease hazard. Dust protection required. WARNING Risk of eye injury. Use of eye protection required. CAUTION Risk of head injury. Use of a helmet required. CAUTION Hazardous noise level. Use of ear protection required. 2. MM0229995 DANGER Moving parts can crush and cut. Do not insert tools in the crusher cavity when the motor is running. WARNING Material can fall out. do not stand in the vicinity of the crusher when the motor is running.
5. MM0229998 DANGER Spring in compression. Read and understand instruction manual before adjusting or servicing. Do NOT remove this protection plate. 6. MM0230002 WARNING Servicing while pressurized can cause severe injury. Lock out source and relieve pressure before servicing. 7. MM0230006 CAUTION Hot surface. Contact with skin may cause burns. Do not touch. 8. MM0230004 CAUTION Hot surface. Contact with skin may cause burns. Do not touch. 9. MM0230447 WARNING Pressurized device. Only authorized personnel should service this dev ice. See instruction manual for safety information.
3. MM0229997 WARNING Exposed moving parts can cause severe injury. Do not open drive guard before machine is completely stopped. 4. MM0229996 WARNING Exposed moving parts can cause severe injury. Do NOT operate this machine without proper guards.
2-6
NORDBERG C SERIES INSTRUCTION MANUAL
140588-2_K
EN
CHAPTER 2 - SAFETY
1
3 4
2
6
5
7
8
9
Figure 2.5 Warning signs (ISO)
EN
140588-2_K
NORDBERG C SERIES INSTRUCTION MANUAL 2-7
CHAPTER 2 - SAFETY
2.2.2 Warning sign codes and texts (ISO) 1. MM0250258 WARNING Read and understand instruction manual before using or maintaining this machine. Failure to follow operating instructions may result in death or serious injury. DANGER Lung disease hazard. Dust protection required. WARNING Risk of eye injury. Use of eye protection required. CAUTION Risk of head injury. Use of a helmet required. CAUTION Hazardous noise level. Use of ear protection required. 2. MM0250251 DANGER Moving parts can crush and cut. Do not insert tools in the crusher cavity when the motor is running. WARNING Material can fall out. do not stand in the vicinity of the crusher when the motor is running.
5. MM0250242 DANGER Spring in compression. Read and understand instruction manual before adjusting or servicing. Do NOT remove this protection plate. 6. MM0250241 WARNING Servicing while pressurized can cause severe injury. Lock out source and relieve pressure before servicing. 7. MM0250239 CAUTION Hot surface. Contact with skin may cause burns. Do not touch. 8. MM0251117 CAUTION Hot surface. Contact with skin may cause burns. Do not touch. 9. MM0250104 WARNING Pressurized device. Only authorized personnel should service this device. See instruction manual for safety information.
3. MM0250244 WARNING Exposed moving parts can cause severe injury. Do not open drive guard before machine is completely stopped. 4. MM0250244 WARNING Exposed moving parts can cause severe injury. Do NOT operate this machine without proper guards.
2-8
NORDBERG C SERIES INSTRUCTION MANUAL
140588-2_K
EN
CHAPTER 2 - SAFETY
This Page Left Intentionally Blank.
EN
140588-2_K
NORDBERG C SERIES INSTRUCTION MANUAL 2-9
GENERAL CRUSHER INFORMATION
CHAPTER
3
3.1 CRUSHER TERMINOLOGY Throughout this instruction manual, technical terms are used to describe the crusher, its components and its operation. These terms are defined herein with the intent of avoiding any confusion or misunderstanding.
Callout 1 2 3 4
Description Feed opening depth Moving jaw Stationary jaw Closed side setting (c.s.s)
Callout Description 5 Stroke 6 Nip angle 7 Feed opening width
Figure 3.1 Jaw crusher terminology
Feed: The raw material to be crushed, such as the rock type (limestone, basalt, granite, etc.) or man-made materials such as concrete and asphalt. The feed size is typically denoted in terms of a size distribution or based on an average top (maximum) size. Product size: The size of the material after it has been crushed. Similarly to the feed size, the product size is typically denoted in terms of a size
EN
distribution or based on an average top (maximum) size. Capacity: The output of the crusher in tons per hour. Feed Opening: The opening where the feed material is fed into the crusher. The feed opening has two dimensions: a width and a depth. The feed opening depth is a critical dimension because it dictates the maximum feed size a given jaw crusher model can accept.
140588-3_K
NORDBERG C SERIES INSTRUCTION MANUAL 3-1
CHAPTER 3 - GENERAL CRUSHER INFORMATION
Maximum Recommended Feed Size: As a general guideline, the maximum average recommended feed size should be about 80% of the feed opening depth. Such measures will ensure that any bridging events resulting from oversized feed are kept to a minimum. A rock hammer is recommended for applications where the maximum feed size is regularly close to the feed opening depth.
Feed Opening
C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200
mm 800 X 510 930 X 600 1000 X 760 1060 X 700 1100 X 850 1150 X 800 1380 X 760 1250 X 950 1400 X 1070 1400 X 1100 1600 X 1200 2000 X 1500
inch 20 X 32 24 X 37 30 X 40 28 X 42 34 X 44 32 X 45 30 X 54 37 X 49 42 X 55 43 X 55 47 X 63 59 X 79
Stroke: The difference between the maximum and minimum distances at the bottom of the fixed and moving jaws during one revolution of the eccentric shaft.
Maximum Rec. Feed Size mm 408 480 608 560 680 610 608 760 856 880 960 1200
inch 16 19 24 22 27 24 24 30 34 35 38 47
Table 3-1 Maximum recommended feed sizes
Nip Angle: The angle between the fixed and moving jaws. The nip angle is often referred to as the "bite" angle as well. Jaws: The members that perform the crushing are commonly referred to as jaws. The jaws consist of a stationary and moving jaw, and depending on the model each one of these may consist of either 1 or 2 pieces. Different jaw profiles are available for different applications. Discharge Setting: The shortest distance between the bottom of the fixed and moving jaws as measured at the point where the jaws are at their closest relationship during their work cycle (i.e. the closed side setting, or c.s.s.). The method in which the setting is measured varies depending on the jaw profile. These differences are explained in detail in the CRUSHER SETTING section.
3-2
NORDBERG C SERIES INSTRUCTION MANUAL
140588-3_K
EN
CHAPTER 3 - GENERAL CRUSHER INFORMATION
3.2 CRUSHER COMPONENTS
Callout 1 2 3 4 5 6 7 8 9 10 11
Description Front frame Upper wedge Filling wedge Jaw bolt Disc spring package Cheek plate, upper Fixed jaw, upper Moving jaw, upper Center wedges Cheek plate, lower Fixed jaw, lower
Callout 12 13 14 15 16 17 18 19 20 21 22
Description Moving jaw, lower Frame bolt Fixed wedge Pitman eye protection plate Flywheel Eccentric shaft Pitman bearing Pitman Frame connecting rods Side plate Toggle seat
Figure 3.2 Jaw crusher main components
EN
140588-3_K
NORDBERG C SERIES INSTRUCTION MANUAL 3-3
CHAPTER 3 - GENERAL CRUSHER INFORMATION
Callout 1 2 3 4 5 6 7
Description Rear frame Adjustment wedges Spacer Toggle seat holder Toggle seat Locking nuts with thrust bearing Tension spring
Callout 8 9 10 11 12 13 14 15
Description Tension rod Toggle plate Piston rod Piston Pressure relief valve Pressure accumulator Tension cylinder Cylinder cover
Figure 3.3 Jaw crusher rear frame components
3-4
NORDBERG C SERIES INSTRUCTION MANUAL
140588-3_K
EN
CHAPTER 3 - GENERAL CRUSHER INFORMATION
3.5 ESTIMATING CRUSHER CAPACITY
3.3 SPARE PARTS BOOK A Spare Parts Book containing various assembly drawings pertaining to your crusher will be sent immediately after the crusher has been shipped. This book illustrates each and every part used in the assembly of the machine and is to be used when ordering spare or replacement parts.
3.4 ORDERING PARTS Metso Minerals endeavors to carry an ample supply of parts in stock to provide prompt and efficient service on all orders for repairs and replacements. To avoid delay and the possibility of incorrect parts being furnished, the following information should be given:
The capacity of the crusher depends on factors such as the type of feed (material type, size distribution, fracture characteristics, moisture content, etc.), type of operation (feed availability, feed arrangement) and discharge setting. To obtain an estimate of the capacity, refer to the following capacity table. These capacities are based on results obtained in actual practice with hard granite that has a bulk density of 1.6 t/m3 (100 lb/ft3), and are where the feed has been properly graded so that bridging does not take place. To obtain more accurate capacity estimates specific to your actual crushing application, contact your local Metso Minerals sales representative to request a computer simulation of your circuit's operating condition
1. Crusher size. 2. The serial number of the crusher which is stamped on the crusher nameplate. The serial number is also on the cover of the spare parts books. 3. Complete name and part code number as shown in the Spare Parts Book. 4. Exact quantity of each part ordered. 5. Complete shipping instructions. If your crusher Spare Parts Books have been lost, destroyed or misplaced, an additional set can be ordered. For proper operation, only genuine factory parts should be installed. These are guaranteed as to accuracy, workmanship and material. Using pirate parts may put your safety and that of your crusher at risk. Make sure you completely understand your crusher's Warranty conditions at all times.
EN
140588-3_K
NORDBERG C SERIES INSTRUCTION MANUAL 3-5
CHAPTER 3 - GENERAL CRUSHER INFORMATION
c.s .s .
C80
C96
C100
C106
C110
C116
C125
C140
C145
C160
C200 C3054
M tph M tph M tph M tph M tph M tph M tph M tph M tph M tph M tph M tph mm
in
40
Stph
Stph
Stph
Stph
Stph
Stph
150
171
190
175
Stph
Stph
Stph
Stph
Stph
Stph
65 1-5/8"
50
70 80
2"
90
2-3/8"
105
135
115
140
60
95
70 2-3/4" 80 3-1/8" 90 3-1/2" 100 4" 125 5" 150 6" 175 7" 200 8"
120 240
125
155
165
187
210
190
265
130
160
170
193
210
195
270
145
175
190
215
235
220
295
150
180
190
220
235
220
295
165
200
210
242
260
240
165
200
215
242
255
245
290
325
180
220
235
270
285
270
320
355
210
250
265
308
310
305
250
385
400
230
275
290
336
345
335
385
425
440
250
300
315
369
370
360
410
455
470
325
390 430 520
460
275
330
350
407
405
400
455
500
520
575
290
350
370
429
425
425
470
520
540
595
760
530
320
385
405
473
470
465
520
575
595
655
840
585
420
490
480
530
590
610
675
855
600
465
539
530
585
650
670
740
940
660
590
655
680
750
945
650
725
750
825
1045
650
725
750
825
1040
720
800
825
910
1145
820
900
1130
900
995
1250
225 9" 250 10" 275 11" 300 12"
510
980
1225
1080
1350
Table 3-2 Nominal jaw crusher capacities
3-6
NORDBERG C SERIES INSTRUCTION MANUAL
140588-3_K
EN
CHAPTER 3 - GENERAL CRUSHER INFORMATION
3.6 ESTIMATING CRUSHER PRODUCT GRADATION
These product gradations are based on results obtained in actual practice with hard granite. To obtain more accurate product gradation estimates, contact your local Metso Minerals sales representative to request a computer simulation of your circuit's operating conditions.
The crusher's product gradation depends on the same factors that affect capacity. The following figure gives an indication of the product gradation as a function of the closed side setting (c.s.s.).
1"
2"
4"
8"
16"
100
90 css
40 50
70
100 130 160 200 250
300
80
Percentage passing, weight %
70
60
50
40
30
20
10
0 1
10
100
1000
Product size
Figure 3.4 Crusher product gradation
EN
140588-3_K
NORDBERG C SERIES INSTRUCTION MANUAL 3-7
CHAPTER 3 - GENERAL CRUSHER INFORMATION
3.7 CRUSHER SETTING The Crusher setting is the most important Crusher parameter since it determines the Crusher's capacity as well as the top size of the Crusher product. It is therefore indispensable for everyone to understand how the Crusher setting is measured. The discharge setting is the shortest distance between the bottoms of the fixed and moving jaws during their work cycle. This distance is referred to as the closed side setting (c.s.s.), and it is a calculated distance as the Crusher setting is typically measured when the Crusher is at rest. The largest distance between the bottoms of the fixed and moving jaws is referred to as the open side setting (o.s.s.), and it is typically a distance that is directly measured when the Crusher is at rest.
The Crusher setting is measured in three different ways, first referring to the tooth groove (bottom) or crown (top) of the stationary jaw and then to the tooth groove (bottom) or crown (top) of the movable jaw. Thus, the setting is always measured from the Stationary (bottom or top) to the Movable jaw (bottom or top). The three alternatives are shown in Table 3-3. The measurement type depends on the profile as well as on the Crusher model. This information is also found in the Crusher Spare Parts Book.
Measurement Type 1 2 3
Reading Sequence (Jaws) Stationary Bottom Top Top
to to to to
Movable Top Top Bottom
Table 3-3 Measurement types
Figure 3.5 Crusher setting measurement
3-8
NORDBERG C SERIES INSTRUCTION MANUAL
140588-3_K
EN
CHAPTER 3 - GENERAL CRUSHER INFORMATION
For example, the setting of the C125, equipped with Quarry jaws, is measured from Top to Top (Type 2). However, with Standard jaws, the setting is measured from Bottom to Top (Type 1). IMPORTANT! The Crusher setting must always be measured in a straight line at the bottom of the crushing cavity. Measure the setting always from the least worn area.
Example Crusher: C140 Stroke: 42 mm (15/8” ) (Table 3-4) Jaw Profile: Quarry (top to top) O.S.S.: 230 mm (9") C.S.S.: 230 – 42 = 188 mm (9" – 1 5/8" = 7 3/8")
It is easiest to measure the setting when the Crusher is at rest with a device such as a block of wood of known dimensions (several blocks should be available if more than one setting is typically used). The distance measured this way is larger than the closed side setting (c.s.s.) because the pitman always stops at its lowest point. This value is close (±2mm/±0.08") to the open side setting (o.s.s.). As previously mentioned, the closed side setting is calculated by deducting the stroke from the open side setting (Table 3-4).
Model C80 C96 C100 C106
Stroke mm Inch 24 1 32 1¼ 32 1¼ 13/8 34
C110
36
17/16
C116 C3054
37 32
C125
41
1½ 1¼ 15/8
C140
41
15/8
C145
41
15/8
C160
41
15/8
C200
50
2
Table 3-4 Dimension (stroke) to be deducted from the open side setting (o.s.s.) to calculate the closed side setting (c.s.s.).
Dimension (stroke) to be deducted from the open side setting (o.s.s.) to calculate the closed side setting (c.s.s.).
EN
140588-3_K
NORDBERG C SERIES INSTRUCTION MANUAL 3-9
CHAPTER 3 - GENERAL CRUSHER INFORMATION
Figure 3.6 Measuring the setting
NOTE: The C.S.S does not have to be calculated if the user knows the Crusher setting limits in terms of the O.S.S. The C.S.S. is typically calculated because Crusher capacity is always denoted in terms of the C.S.S. only.
3.8 CRUSHER SETTING LIMITS All C-Series Crusher models have a maximum possible setting as well as a minimum allowed setting, and it is very important that the user understands why these are important to keep these in mind at all times. The maximum possible setting is simply the maximum setting that the Crusher is physically able to accommodate. Typically, such setting is indicated with new jaws, and the setting actually depends on the jaw profile as well as on whether a spacer is being used or not. This information is always found in the Crusher Spare Parts Book.
3-10
NORDBERG C SERIES INSTRUCTION MANUAL
The minimum allowed setting (c.s.s. or o.s.s.) is the minimum setting at which the Crusher can be used when the Crusher is operated according to Metso Minerals' recommendations. The minimum allowed setting is very important as it takes into account the design and operation limits of the Crusher. Not respecting these recommendations can lead to a poor utilization of the jaws (high scrap rate) as well as a shortened Crusher life. The minimum allowed setting varies depending on whether the application is a normal rock application (Normal), or a recycling application (Special), when materials such as concrete, asphalt and bricks are being crushed. Note that the minimum allowed setting does not depend on the jaw profile (it is always the same for a specific Crusher model). See Table 3-5.
140588-3_K
EN
CHAPTER 3 - GENERAL CRUSHER INFORMATION
Crusher model
C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200
CSS Hard rock Soft Rock (>150 Mpa) (<150 MPa) Recycling (> 22 000 psi) (<22 000 psi) mm
mm
mm
40 60 70 70 70 70 70 100 130 125 150 175
30 45 60 50 60 60 60 N.A N.A N.A N.A N.A
20 25 45 25 45 45 45 N.A N.A N.A N.A N.A
Stroke mm
24 32 32 32 36 37 32 39 42 36 39 50
CSS Crusher model
C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200
Hard rock Soft Rock (>150 Mpa) (<150 MPa) Recycling (> 22 000 psi) (<22 000 psi) in in in 1 5/8 1 2/8 7/8 2 4/8 1 7/8 1 2 7/8 2 4/8 1 7/8 2 7/8 2 1 2 7/8 2 4/8 1 7/8 2 6/8 2 3/8 1 6/8 2 7/8 2 4/8 1 7/8 4 1/8 N.A N.A 5 2/8 N.A N.A 5 1/8 N.A N.A 6 1/8 N.A N.A 7 1/8 N.A N.A
Stroke in
1 1 2/8 1 2/8 1 2/8 1 4/8 1 4/8 1 2/8 1 5/8 1 6/8 1 4/8 1 5/8 2
OSS Hard rock Soft Rock (>150 Mpa) (<150 MPa) Recycling (> 22 000 psi) (<22 000 psi) mm
mm
mm
64 92 102 102 106 107 102 139 172 161 189 225
54 77 92 82 96 97 92 N.A N.A N.A N.A N.A
44 57 77 57 81 82 77 N.A N.A N.A N.A N.A
OSS Hard rock Soft Rock (>150 Mpa) (<150 MPa) Recycling (> 22 000 psi) (<22 000 psi) in in in 2 5/8 2 2/8 1 6/8 3 6/8 3 1/8 2 3/8 4 1/8 3 6/8 3 1/8 4 1/8 3 3/8 2 3/8 4 3/8 3 7/8 3 2/8 4 2/8 3 7/8 3 2/8 4 1/8 3 6/8 3 1/8 5 5/8 N.A N.A 7 N.A N.A 6 5/8 N.A N.A 7 6/8 N.A N.A 9 1/8 N.A N.A
Table 3-5 Minimum allowed settings for hard rock, soft rock and recycling applications.
EN
140588-3_K
NORDBERG C SERIES INSTRUCTION MANUAL 3-11
CHAPTER 3 - GENERAL CRUSHER INFORMATION
To increase the length of the crushing zone (and thus increase the life of the jaw dies) when the feed material is consistently smaller than the crusher's input capacity.
WARNING! The minimum allowed setting of a Crusher must be respected at all times unless otherwise indicated by Metso Minerals. Not respecting these recommendations can lead to a poor utilization of the jaws (high scrap rate) as well as to a shortened Crusher life. Moreover, operating the Crusher at settings smaller than allowed will void the Crusher's warranty.
The intermediate plate is not available for all models. Moreover, multiple plate thicknesses are available with certain models. Before ordering intermediate plate consult Metso Minerals if it fits to your application.
3.9.2 Protection Plates
WARNING!
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 minimum recommended setting) and/or when the rock to be crushed is very hard (very low crushability). Of course, these can be used at any time for added protection.
The maximum size of tramp iron (rebars, excavator teeth, etc.) must be smaller than the Crusher closed side setting (c.s.s.).
3.9 OPTIONS
NOTE: The front frame protection plate is not used when an intermediate plate is used.
Following options can be installed on Crusher after start-up.
Protection plates are not available options with all C-Series crusher models. IMPORTANT!
3.9.1 Intermediate Plate Fitting an intermediate (backing) plate behind the fixed jaw reduces the nip angle of the crusher. The intermediate plate reduces the feed opening and the setting range by approximately the same amount as its thickness. However the intermediate plate does not, under normal circumstances, allow the user to use a smaller setting than the minimum recommended setting.
When using protection plates, different bottom retaining wedges must be used. NOTE: Excessive replacement of the protection plates indicated a feed problem. Contact Metso Minerals if such is the case with your Crusher.
If available with the specific C-Series jaw crusher model, an intermediate plate may be used for the following reasons: To improve the nip angle (by decreasing the nip angle) when crushing slippery material (material that is difficult to bite).
3-12
NORDBERG C SERIES INSTRUCTION MANUAL
140588-3_K
EN
CHAPTER 3 - GENERAL CRUSHER INFORMATION
Callout Description 1 Front frame protection plate
Callout Description 2 Pitman protection plate
Figure 3.7 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 can damage the belt.
EN
140588-3_K
NORDBERG C SERIES INSTRUCTION MANUAL 3-13
CHAPTER 3 - GENERAL CRUSHER INFORMATION
3.9.5 Automatic Lubrication Unit The lubrication system automatically lubricates the four (4) eccentric shaft bearings in accordance with the recommendations provided by the factory. Refer to Chapter 5.3 and Installation Manual Chapter 6.5.
Callout 1 2 3 4 5 6 7 8 9
Description Protector plate Support holder Eye screw Split pin Washer Washer Hex screw Hex nut Joint pin
Figure 3.8 Conveyor belt protector
3.9.4 Hydraulic Setting Adjustment A Crusher equipped with mechanical setting adjustment can be retrofitted with the hydraulic setting adjustment. Refer to Chapter 4.6.2.
3-14
NORDBERG C SERIES INSTRUCTION MANUAL
140588-3_K
EN
OPERATING INSTRUCTIONS
CHAPTER
4.1 PREPARATIONS BEFORE STARTING
4
This is a brief outline of the control logic sequence that is required to start the Crusher. Other measures may be taken in accordance with local conditions.
Good inspection habits will do much to insure years of successful operation of the Crusher. Do not rely on memory alone to regulate required periodic maintenance, keep an accurate written record. Regularly performing pre-start and maintenance inspections will pay off in the way of eliminating costly down time and prolonging the life of the Crusher. Before starting the Crusher, perform the following operations: 1. Make a final inspection of the Crusher to be certain that no tools or mechanical obstructions are on the Crusher, that all joints and fasteners are properly tightened, that no leaks are apparent and that there is no 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 the area whose safety may be endangered. Walk around the Crusher and ensure that there is nobody on, by or below the Crusher. Warn everybody in the vicinity before starting.
Figure 4.1 Starting and stopping sequence
4.3 STOPPING THE CRUSHER To stop the Crusher, proceed as follows:
4.2 STARTING THE CRUSHER 1. Stop the feeder. An electric motor or diesel engine drives the Crusher. Starting the Crusher merely amounts to starting the motor or engine according to the manufacturers' instructions. Do not introduce any feed to the Crusher during starting. To start the Crusher, proceed as follows:
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
1. Start the discharge conveyor. 2. Start the electric motor or diesel engine. If a slip 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 (page 11). 3. Start the feeder.
EN
140588-4_K
NORDBERG C SERIES INSTRUCTION MANUAL 4-1
CHAPTER 4 - OPERATING INSTRUCTIONS
4.4 OPERATION WARNING! Feed the material to the Crusher evenly in accordance with the feed arrangement recommendations. Note that the Crusher operates most efficiently when the crushing cavity is two-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.
Lift or turn the rocks in the cavity only when the Crusher is stopped. Do not try to clear the blocked crushing cavity when the Crusher is running. Be always very careful when clearing the cavity. Never use a crowbar to turn oversized feed.
WARNING! Never use explosives to clear a blocked crushing cavity. Make sure no explosives enter the Crusher The oversized rock can be lifted out of the cavity with 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 blocked feed.
4.4.2 Tramp Iron/Uncrushables Uncrushable ("tramp iron") material larger than the Crusher's c.s.s., such as excavator teeth, should be prevented from entering the Crusher by installing a magnetic separator. Uncrushable material larger than the c.s.s will cause the toggle plate to buckle, and will impose unnecessary stresses on the Crusher.
Figure 4.2 Recommended filling ratio
Refer to the WEAR PARTS section for operating instructions pertaining to wear parts.
If tramp iron enters and stays in the Crusher, stop the feeder and Crusher immediately. Empty the cavity and remove the tramp iron. If necessary increase the Crusher setting to remove the tramp iron.
4.4.1 Oversized Feed Avoid trying to crush oversized feed (feed too large for the cavity). Having to reposition rock wastes time, reduces capacity and imposes unnecessary loads on the Crusher. Therefore attention must be paid to the size of feed. A stationary grizzly is a suitable alternative for limiting oversized feed. A hydraulic hammer can be used for breaking oversized material and is recommended if such problems are foreseen.
4-2
NORDBERG C SERIES INSTRUCTION MANUAL
140588-4_K
WARNING! Always inspect the toggle plate, tension rod and spring (or hydraulic cylinder) for possible damage.
EN
CHAPTER 4 - OPERATING INSTRUCTIONS
4.5 RE-STARTING A CRUSHER STALLED UNDER LOAD
4.4.3 Packing The Crusher should never be operated when the feed is packing in the crushing cavity (i.e. when the feed packs in such a way that it cannot be reduced in size), as this results in a drastic reduction of the Crusher lifetime.
A stalled Crusher MUST be treated as possibly being jammed and therefore a potential hazard. Clear the plant area of all personnel. Notify the manager or his deputy of a stalled Crusher situation immediately.
WARNING! WARNING!
Never operate the Crusher when the feed is packing in the cavity. This will result in a drastic reduction of the Crusher lifetime.
Any inspection of the crushing cavity must be carried out from underneath the Crusher, not from above. Tramp iron could be ejected from the crushing cavity. Serious personal injury can result.
When packing occurs, the: 1. Crusher speed slows down.
Find out why the Crusher stalled. If, after careful examination, there appears to be no electrical or mechanical reason why the Crusher has stalled, it would indicate that the Crusher is jammed by the ingress of foreign matter and is in a hazardous state.
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 the feed opening width).
If a Crusher stalls under load any stored energy within a mechanism due to tramp material can be reduced to insignificant level by ensuring that the jaws are moved to the open position. After that start the 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 tramp metal must be removed from the Crusher manually.
3. The material is very brittle and readily breaks into fines (material characteristics).
WARNING! Always note the position of the gib keys to determine if the crusher is "at rest" or if there is potential energy remaining in the flywheels.
4. Wet feed material. 5. Incorrect jaws. To prevent packing, all possible causes must be addressed. If, however, the causes cannot be eliminated, the material level in the Crusher cavity must be lowered and/or the Crusher setting must be increased.
EN
140588-4_K
NORDBERG C SERIES INSTRUCTION MANUAL 4-3
CHAPTER 4 - OPERATING INSTRUCTIONS
4.6 CRUSHER SETTING ADJUSTMENT The setting adjustment of C Series Jaw Crushers is done either by means of moving two wedges against or away from each other or optionally with a active setting control.
WARNING! Turning the cap nuts should be made with the ratchet provided with the Crusher. NO HYDRAULIC OR PNEUMATIC WRENCH MAY BE USED
4.6.1 Mechanical Wedge Setting Adjustment The movement of the wedges changes the effective thickness "s" of the wedge pair, which in turn increases or decreases the Crusher setting, respectively. 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 setting adjustment (option), refer to chapter 4.6.2. The main components of the device are the adjusting wedges, cap nut(s) (2) and locking pipe(s) (3). Changing the setting requires the use of the ratchet delivered with the Crusher (special tool) to turn the cap nuts.
WARNING! The wedges are self-restraining and their surfaces must not be lubricated. It may overload the adjusting mechanism. To change the setting, the locking nuts of the tension rod must be loosened, and then the cap nuts must be turned clockwise or counterclockwise to increase or decrease the Crusher setting, respectively. A single complete rotation of one cap nut has a net effect on the Crusher setting as indicated in Table 4-1. Turning both cup nuts one complete rotation in the same relative direction will thus change the Crusher setting by twice as what is indicated in Table 4-1.
Model C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200
4
Callout 1 2 3 4
Description Adjusting wedges Cap nut Locking pipe Rubber bellow
Figure 4.3 Mechanical setting adjustment
4-4
NORDBERG C SERIES INSTRUCTION MANUAL
Change in Setting mm (in) 2.3 (0.09) 2.2 (0.09) 2.3 (0.09) 2.2 (0.09) 2.0 (0.08) 2.3 (0.09) 2.3 (0.09) 1.7 (0.07) 2.3 (0.09) 2.5 (0.10) 2.2 (0.09) 3.2 (0.12)
Table 4-1 Average change in setting per cap nut rotation
To calculate how many rotations the cap nuts must be turned to change the Crusher setting, simply
140588-4_K
EN
CHAPTER 4 - OPERATING INSTRUCTIONS
divide the desired setting change amount by the appropriate value in Table 4-1 and the quantity of cap nuts.
8. Start the Crusher and listen if the toggle plate knocks. If it knocks, contact Metso Minerals.
Required Rotations = (Desired Setting Change)/(Crusher Change in Setting)
9. Start crushing.
Round the result to the nearest higher number. WARNING! Example:
Always tighten and loosen the spring from the side. Never remove the protection plate
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 total rotations => 3 rotations per cap nut 3/8" / 0.07" / rotation = 5.35 => 6 total rotations => 3 rotations per cap nut
4.6.1.1 Decreasing the Crusher Setting The Crusher setting can only be adjusted while the crusher is at rest. 1. Stop crushing, then stop the Crusher. Figure 4.4 Mechanical wedge setting adjustment
2. Determine how much the setting must be decreased and calculate how many rotations the cap nuts must be turned. 3. Loosen the locking nuts of the tension spring (Figure 4.4). Be careful not to drop the 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 adjusted equally so that their position in relation to the Crusher remains the same. If you have to change the setting remarkably, turn the cap nuts for a while and loosen the spring locking nuts again if necessary. There are washers fastened to the rear end of the adjusting wedges. When decreasing the setting, push the wedges only until these washers are against the guide plates. 6. Lock the pipes with the pin.
C80 C96 C100 C106 C110 C116
Tension Spring Length L mm (in.) 310 (12 ¼") 385 (15 ¼”) 370 (14 ½") 365 (14 ¼") 365 (14 ¼") 365 (14 ¼")
C3054
440 (17 1/3")
C125 C140 C145 C160 C200
425 (16 ¾") 540 (21 ¼") 540 (21 ¼") 540 (21 ¼") 540 (21 ¼")
Model
Table 4-2 Tension Spring Operating Length
7. Adjust the spring length according to Table 4-2 (see Figure 4.4).
EN
140588-4_K
NORDBERG C SERIES INSTRUCTION MANUAL 4-5
CHAPTER 4 - OPERATING INSTRUCTIONS
4.6.2 HYDRAULIC WEDGE SETTING ADJUSTMENT (OPTIONAL)
4.6.1.2 Increasing the Crusher Setting The Crusher setting can only be adjusted while the crusher is at rest.
IMPORTANT! The hydraulic setting adjustment system in the Lokotrack is different from the system shown here. See details in the Lokotrack manual.
1. Stop crushing, then stop the Crusher. 2. Determine how much the setting must be increased and calculate how many rotations the cap nuts must be turned.
Hydraulic wedge setting adjustment enables remote setting adjustments that are much quicker and simpler as setting adjustments are made remotely by operating a control panel.
3. Loosen the locking nuts of the tension spring (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 sure that both wedges are adjusted equally so that their position in relation to the Crusher remains the same. Be careful not to drop the toggle plate as the spring gets loose. 6. Lock the pipes with the pin. 7. Adjust the spring length according to Table 4-2 (Figure 4.4). 8. Start the Crusher and listen if the toggle plate knocks. If it knocks, contact Metso Minerals. 9. Start crushing.
Figure 4.5 Hydraulic wedge setting adjustment
WARNING! Always tighten and loosen the spring from the side. Never remove the protection plate
The system is powered with an independent hydraulic unit, or it can be connected to a large hydraulic system, as in the Lokotrack. The hydraulic oil pressure forces the wedges either towards or apart from each other, therefore decreasing or increasing the setting, respectively. Setting can be adjusted while the Crusher is at rest or idling. If adjustment of setting is done during crushing lifetime of crusher components is shorter. For detailed information, refer to the Installation Manual, Chp. 4.7 Installing the Hydraulic Unit.
4-6
NORDBERG C SERIES INSTRUCTION MANUAL
140588-4_K
EN
CHAPTER 4 - OPERATING INSTRUCTIONS
4.6.2.1 Oil heater The hydraulic setting adjustment power unit is equipped with a hydraulic oil heater. The heater’s thermostat is set to switch the heater on when the oil temperature is below 35°C (95°F). The heater can be switched on/off from the control panel (7, Figure 4.6). Use the heater for about 30 minutes before setting adjustment when the oil temperature is below 0°C (32°F).
4.6.2.2 Decreasing the setting Turn the setting adjustment switch 6 (located in the control panel) to the "decrease" position. Observe the wedge movement. Time relay in control panel will stop the adjusting after 6 sec. To adjust the setting more you have to turn the switch back to "neutral" position and again to "decrease" position. IMPORTANT! Do not let the jaws hit each other. Adjust the setting in several stages. Check the setting between adjustments, see the minimum setting in chapter General Crusher Information. After adjustment, check the pressure value in the tension cylinder.
Callout 1 2 3 4 5 6 7
Description Main switch ON Running ON Hydraulic pump Setting (1 Decrease, 2 Increase) Oil heating
Figure 4.6 Setting adjustment control panel
4.6.2.3 Increasing the setting Turn the setting adjustment switch 6 (located in the control panel) to the "increase" position. Observe the wedge movement. Setting adjustment may stop if the pressure in the tension cylinder decreases. To adjust the setting more you have to turn the switch back to "neutral" position and again to "increase" position. When the setting is increased, the pressure in the adjusting cylinder will rise automatically and the wedges will stop for a moment. After adjustment, check the pressure value in the tension cylinder.
EN
140588-4_K
NORDBERG C SERIES INSTRUCTION MANUAL 4-7
CHAPTER 4 - OPERATING INSTRUCTIONS
4.6.3 ACTIVE SETTING CONTROL ADJUSTMENT (OPTIONAL) IMPORTANT! The active setting control works as a safety device only in the adjustment range of the cylinders. If the uncrashable object is larger than the maximum setting, the toggle plate collapses through elastic buckling. (See chapter 4.7)
Active setting control adjustment is used in basically the same way as the hydraulic wedge setting adjustment. The system is powered with an independent hydraulic unit, or it can be connected to a large hydraulic system, as in the Lokotrack. The hydraulic oil pressure moves the cylinder, which increases or decreases the setting.
4.6.3.1 Oil heater
Setting can be adjusted while the Crusher is at rest or idling. If adjustment of setting is done during crushing lifetime of crusher components is shorter.
The hydraulic setting adjustment power unit is equipped with a hydraulic oil heater. The heater’s thermostat is set to switch the heater on when the oil temperature is below 35°C (95°F). The heater can be switched on/off from the control panel (7, Figure 4.6). Use the heater for about 30 minutes before setting adjustment when the oil temperature is below 0°C (32°F).
4.6.3.2 Decreasing the setting Turn the setting adjustment switch 6 (located in the control panel) to the "decrease" position. Time relay in control panel will stop the adjusting after 6 sec. To adjust the setting more you have to turn the switch back to "neutral" position and again to "decrease" position.
IMPORTANT! Figure 4.7 Active setting control
Do not let the jaws hit each other.
The active setting control also functions as a safety device. If there are any uncrushable objects in the jaw cavity, the pressure in the cylinders rises. When the pressure rises over a pre-set value, the pressure relief valves open and let the piston move backwards. The crusher setting opens and the uncrushable material can exit the jaw cavity.
Adjust the setting in several stages. Check the setting between adjustments, see the minimum setting in chapter General Crusher Information.
In a Lokotrack, after the uncrushable material has left the cavity, the setting returns to where it was.
4.6.3.3 Increasing the setting
After adjustment, check the pressure value in the tension cylinder.
Turn the setting adjustment switch 6 (located in the control panel) to the "increase" position. Observe the wedge movement. After adjustment, check the pressure value in the tension cylinder.
4-8
NORDBERG C SERIES INSTRUCTION MANUAL
140588-4_K
EN
CHAPTER 4 - OPERATING INSTRUCTIONS
4.7 TOGGLE PLATE WARNING! For spontaneous overloading or uncrushable objects that are larger than the Crusher setting, such as excavator bucket teeth, the Crusher is equipped with a toggle plate that serves as a safety device. In the event of overloading, the toggle plate collapses through elastic buckling, frequently preventing damage to more costly parts.
Do not lubricate the toggle seats, toggle plate or toggle plate ends. This area of the crusher is designed to operate without lubrication.
WARNING! Always use original Metso Minerals toggle plates. Toggle plate design and manufacturing is more complicated than most people think. Using a toggle plate that is not manufactured by Metso Minerals will put the Crusher at risk and will void the Crusher's warranty.
IMPORTANT! Note that the toggle plate is designed to buckle when overload events occur in the lower half of the crushing cavity. The toggle plate will not buckle if the crusher is overloaded due to oversized feed or an inadequate feed arrangement. Thus, in these cases, certain crusher components such as the eccentric shaft, flywheels, bearings and bearing housings will be unnecessarily loaded.
Check the condition of the seats and protection rubber regularly during weekly maintenance. They must be kept clear of dust and dirt. If dust has entered 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 these areas and contaminate seat surfaces.
IMPORTANT! Although the toggle plate is designed to protect the more expensive Crusher components, certain overload events are often so violent in nature that it is possible for other components such as the tension spring, tension rod and tension spring bracket to fail when the toggle plate buckles
Toggle plate and seat installation and removal described in Maintenance chapter.
IMPORTANT! Toggle plate is not protecting crusher components of fatigue damages when crusher is continuously overloaded with smaller setting than allowed by Metso Minerals’ The function of the toggle seats is based upon a rolling concept against the roll-shaped surfaces with different radii against each other. Therefore the toggle seats should be kept dry and must not be lubricated.
EN
140588-4_K
NORDBERG C SERIES INSTRUCTION MANUAL 4-9
CHAPTER 4 - OPERATING INSTRUCTIONS
4.8 SPACER
with settings smaller than the minimum allowed settings (see the Crusher Setting section).
A spacer may be placed between the lower adjusting wedge and the toggle seat holder (not applicable to all models and models with the active setting control). The use of the spacer makes it possible to use two different Crusher setting ranges, but its use does not permit that the Crusher is used
Callout 1 Spacer
Qualitatively, the use of the spacer reduces both the Crusher's minimum and maximum setting. Refer to the Crusher parts book for details concerning the effect of the spacer on the Crusher setting range for a specific jaw profile. Spacer installation and removal instructions can be found in Maintenance chapter.
Description
Figure 4-8 Spacer
4-10
NORDBERG C SERIES INSTRUCTION MANUAL
140588-4_K
EN
CHAPTER 4 - OPERATING INSTRUCTIONS
4.9 TROUBLESHOOTING
PROBLEM CAUSE Toggle plate falls out of Feed material is too large. seat. Tension spring too loose. Material fed directly onto the upper pitman cover.
REMEDY Feed the Crusher with proper size material. Make sure the feed hopper's rear wall is properly designed. Tighten the tension spring. Material must be fed into the crushing chamber without hitting the upper pitman cover. Make sure the feed hopper's rear wall is properly designed.
Tension cylinder hydraulic pressure too low.
Check the pressure.
Toggle plate seating surfaces wear prematurely.
Tension spring too loose.
Tighten the tension spring.
Toggle plate breaks (buckles).
Feed material is too small. Feed the Crusher with proper size material.
Feed hopper has loosening or breaking bolts.
Jaw bolts loosening or breaking.
Insufficient capacity.
Stalled Crusher.
Tramp iron or other uncrushable material caught near the bottom of the crushing chamber. Toggle plate not installed correctly. Feed material is being crushed too high in the chamber. Bolt fastener not applied to the feed hopper bolts. Incorrect jaws installed.
When installing the toggle plate, inspect the toggle seats for good condition and smooth, even surfaces. RESTRICT FEED! Feed to keep the chamber 2/3 full with proper size material for greatest efficiency. Apply bolt fastener. Use Metso Minerals jaws.
Jaws installed incorrectly.
Re-install the jaws.
Feed too large. Wrong direction of flywheel rotation. Incorrect speed. Discharge setting too small. Jaws worn excessively. Loose jaws.
Check for proper feed size. Make sure the flywheels turn in the correct direction. Check for proper speed. Increase the discharge setting. Replace the jaws. Tighten the jaw bolts.
Wrong jaw profile.
Consult your Metso Minerals representative.
Large rock or tramp iron jammed in the crushing chamber. Discharge setting is too small.
Remove stuck material. DO NOT USE EXPLOSIVES TO CLEAR A STALLED CRUSHER!
Power failure.
EN
Empty the crushing chamber to remove tramp iron or other uncrushable material.
Each Crusher has a minimum recommended setting. DO NOT use a smaller setting unless authorized by Metso Minerals. Check all fuses in the motor electrical control panel.
140588-4_K
NORDBERG C SERIES INSTRUCTION MANUAL 4-11
CHAPTER 4 - OPERATING INSTRUCTIONS
PROBLEM
Excessive vibration.
CAUSE Motor failure. Damaged and/or loose V-belts. Wrong speed. Flywheels loose.
REMEDY Check the motor. Check the condition of the V-belts. Operate the Crusher at the recommended speed. Tighten the flywheels properly. Weld the bolts together with plates to prevent them from coming loose. Remount the flywheel with the appropriate keyway (gibkey).
Flywheel aligned with the wrong keyway (gibkey) during assembly.
Bearings too hot.
Counterweights incorrectly installed. Bearings damaged.
Consult your Metso Minerals representative. Consult your Metso Minerals representative.
Too much or insufficient grease.
Use correct quantity of grease for each bearing. Seat a schedule for greasing of the bearings. Incorrect crusher speed. Check the Crusher's speed. Crusher operating at a Each Crusher has a minimum recommended setting. DO NOT use a smaller setting unless authorized by smaller setting than Metso Minerals. recommended.
Crusher speed varies.
A "knocking" is heard while operating.
Crusher not level. Feeding the Crusher with very fine material. Damaged and/or loose V-belts. Inadequate plant voltage level. Tension spring too loose.
Check or re-level the Crusher. Feed the Crusher with proper size material. Check the condition of the V-belts. Check the plant's voltage level. Tighten the tension spring.
Toggle plate improperly seated. Loose jaws. Jaws hitting each other.
Movement of the jaws.
Check the toggle plate and seats for wear. Tighten the jaw bolts. Check the Crusher's discharge setting.
Tension cylinder hydraulic pressure too low.
Check the pressure.
Loose jaws. Inadequate clearance.
Tighten the jaw bolts. Check that the clearance between the upper and lower jaws is between 5-8 mm (3/16-5/16").
Centralizing lug worn out.
Repair the lug.
Adjusting wedges don´t Wedge surfaces worn. move The seals are leaking. Active setting control: The setting opens by itself. There is no uncrushable material in the cavity. Feed material is too small.
4-12
NORDBERG C SERIES INSTRUCTION MANUAL
Drop a couple of small stones to cavity to decrease friction between wedges. Check the possible oil leaks. Contact your Metso Minerals representative.
Feed the crusher with proper size material.
140588-4_K
EN
MAINTENANCE
CHAPTER
5
5.1 SPACER A spacer is only used in crushers with wedge setting adjustment.
WARNING! Before performing any maintenance or repair work, make sure that the crusher is stopped and locked out.
A spacer may be placed between the lower adjusting wedge and toggle seat holder (Figure 5.1). Use of the spacer makes it possible to use two different crusher setting ranges. Never use a setting smaller than the minimum allowed setting even using the spacer.
LOCKOUT PROCEDURE of the Lokotrack installed crushers
After installing or removing the spacer the crusher setting must be adjusted (also when using hydraulic setting adjustment).
1. Switch off engine 2. Remove the ignition key and keep it on person during lockout
Before you operate the machine make sure that there is no clearance between the upper and lower wedge. When using the spacer make sure there is no clearance between the spacer and adjusting wedges.
3. Place appropriate maintenance warning signs (TAG OUT) LOCKOUT PROCEDURE of the electrical motor driven crushers 1. Switch off motor
IMPORTANT!
2. Lock the main switch of the motor with a padlock or make sure in some other way that the engine cannot be started
After installing or removing the spacer the Crusher setting and the spring tension must be adjusted.
3. Lock the main switch of the hydraulic adjustment power unit (if delivered) with padlock 4. Keep the keys on person during lockout 5. Place appropriate maintenance warning signs (TAG OUT).
Figure 5.1 Spacer makes it possible to use two different crusher setting ranges
EN
140588-5_K
NORDBERG C SERIES INSTRUCTION MANUAL 5-1
CHAPTER 5 - MAINTENANCE
5.1.1 Spacer Installation 1. Open the crusher’s setting to maximum
2b. Mechanical setting: Loosen the tension spring in order to be able to move the pitman.
2. a. Hydraulic setting:
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 to support the ends or hooks of the come-along. Make sure that both ends (or hooks) are properly secured.
In the valve unit, release the hydraulic pressure from the return cylinder by turning the knob of the shut-off valve (1) counter-clockwise. You can check the pressure level from the pressure gauge (2).
4. Inch the come-along until the lower adjustment wedge touches the washers (or the jaws contact each other). IMPORTANT! Be careful not to drop the toggle plate.
5-2
NORDBERG C SERIES INSTRUCTION MANUAL
140588-5_K
EN
CHAPTER 5 - MAINTENANCE
valve 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! After installing or removing the spacer the Crusher setting and the spring tension must be adjusted
5. Insert the spacer between the front wedge and toggle seat holder by inserting the spacer through the side plate hole. WARNING! Always tighten and loosen the spring from the side. Never remove the protection plate
6. Release the pitman and remove the come-along and shackles. 7. a. Hydraulic setting: Pressurize the return cylinder by turning the knob of the shut-off valve clockwise in the
EN
140588-5_K
NORDBERG C SERIES INSTRUCTION MANUAL 5-3
CHAPTER 5 - MAINTENANCE
5.1.2 Spacer Removal 1. When removing the spacer pull the setting adjustment wedges as far out as possible. Secure the wedges so that they do not slide down when spacer is being removed.
2. Make sure that the toggle plate does not fall down.
5-4
NORDBERG C SERIES INSTRUCTION MANUAL
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 the spacer. Then pull the spacer out.
140588-5_K
EN
CHAPTER 5 - MAINTENANCE
5.2 TOGGLE PLATE
6. Support the lower setting adjustment wedge to its position by using a proper sling. Make sure that the sling is properly tensioned.
5.2.1 Replacing the Toggle Plate And Toggle Seats (with wedge setting adjustment) If the toggle plate has to be replaced, it is recommended that the following steps be followed: 1. Open the crusher's setting to maximum.
5_9_1_3
7. a. Hydraulic setting:
5_9_1_1
In the valve unit, release the hydraulic pressure from the return cylinder by turning the knob of the shut-off valve (1, fig below) counterclockwise. You can check the pressure level from the pressure gauge (2, fig below).
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 the toggle plate lifting tool (3, fig below) and upper end for example to the eyebolt of the pitman (4, fig below).
5_9_1_2
5. Tension the come-along so that the toggle plate does not drop.
EN
140588-5_K
NORDBERG C SERIES INSTRUCTION MANUAL 5-5
CHAPTER 5 - MAINTENANCE
7 b. Mechanical setting: Remove the locking nuts of the tension spring (fig below).
13. Replace the toggle seats if they are damaged. 14. Install the new toggle plate and release the pitman.
WARNING!
15. Remove lower adjusting wedge support.
Always tighten and loosen the spring from the side. Never remove the protection plate
16. a. Hydraulic setting: Attach the return cylinder to the pitman and pressurize the hydraulic return cylinder 16 b. Mechanical setting: Attach the tension rod to the pitman and fasten the locking nuts of the tension spring. Adjust the tension spring length according to Table 5.1 17. Remove the toggle plate lifting tool.
5_9_1_5
8. a. Hydraulic setting: Unfasten the return cylinder from the pitman. 8 b. Mechanical setting: 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 to support the ends or hooks of the come-along. Make sure that both ends (or hooks) are properly secured (fig below).
5_9_1_6
10. Inch the come-along until the toggle plate is loose.
Callout 1 2 3 4
Description Lifting tool Chain block Protection rubber Chain block Figure 5.2
11. Lower the toggle plate on to the discharge conveyor belt and take it out. 12. Check the condition of the toggle seats and other related components.
5-6
NORDBERG C SERIES INSTRUCTION MANUAL
140588-5_K
EN
CHAPTER 5 - MAINTENANCE
Model C80 C96 C100 C106 C110 C116
Tension Spring Length L mm inch 310 12 ¼ 385 15 ¼ 370 14 ½ 365 14 ¼ 365 14 ¼ 365 14 ¼
C3054
440
17 1/3
C125 C140 C145 C160 C200
425 540 540 540 540
16 ¾ 21 ¼ 21 ¼ 21 ¼ 21 ¼
5_9_1_2
5. Tension the come-along so that the toggle plate does not drop.
Table 5.1 Tension spring operating length
6. Ensure that the pistons cannot move. 5.2.2 Replacing the Toggle Plate And Toggle Seats with Active Setting Control If the toggle plate has to be replaced, it is recommended that the following steps be followed:
7. In the valve unit, release the hydraulic pressure from the return cylinder by turning the knob of the shut-off valve (1, fig below) counterclockwise. You can check the pressure level from the pressure gauge (2, fig below).
1. Open the crusher's setting to maximum.
5_9_1_4
5_9_1_1
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 the toggle plate lifting tool (3, fig below) and upper end for example to the eyebolt of the pitman (4, fig below).
EN
140588-5_K
NORDBERG C SERIES INSTRUCTION MANUAL 5-7
CHAPTER 5 - MAINTENANCE
16. Attach the return cylinder to the pitman and pressurize the hydraulic return cylinder 17. Remove the toggle plate lifting tool.
8. Unfasten the tension cylinder 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 shackles to support the ends or hooks of the come-along. Make sure that both ends (or hooks) are properly secured (fig below).
5_9_1_6
10. Inch the come-along until the toggle plate is loose. 11. Lower the toggle plate on to the discharge conveyor belt and take it out. 12. Check the condition of the toggle seats and other related components. 13. Replace the toggle seats if they are damaged. 14. Install the new toggle plate and release the pitman. 15. Release the pistons.
5-8
NORDBERG C SERIES INSTRUCTION MANUAL
140588-5_K
EN
CHAPTER 5 - MAINTENANCE
5.3 LUBRICATION WARNING! 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 the instructions provided in this chapter diligently.
Do not use grease types containing molybdenum or calcium as their solid components cause additional wear in the bearings and thus decrease bearing lifetime.
5.3.2 Grease Specifications
WARNING!
For lubrication points, lithium-based multi-purpose grease with the following characteristics is required:
C Series crushers are not designed to operate at temperatures lower than -30ºC/-22ºF. Should operating temperatures be lower than -30ºC/-22ºF, contact Metso Minerals.
•
NLGI-class of 2
•
Minimum viscosity of the base oil must be 160 mm2/s (cSt) in +40ºC/104ºF with a minimum viscosity-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 must contain EP-additives.
Metso Minerals does not recommend that different brands of grease are mixed. When in doubt, please contact Metso Minerals.
Some of the recommended lithium based grease brands are as follows. Other grease brands with similar characteristics may be used as well.
Brand CASTROL BP ESSO GULF MOBIL SHELL SKF
Type APS 2 Energrease LS-EP 2 Beacon EP 2 Gulfcrown Grease EP 2 Mobilux EP 2 Alvania Grease EP 2 LG EP 2
Table 5.2 Recommended grease brands
EN
140588-5_K
NORDBERG C SERIES INSTRUCTION MANUAL 5-9
CHAPTER 5 - MAINTENANCE
5.3.3 Eccentric Shaft Bearings Lubrication of the jaw crusher spherical roller bearings is accomplished by using a manual type grease gun or an automatic lubricating system through four grease fittings. Refer to Figure 5.3 and Figure 5.4.
Some crushers are equipped with the distributor unit with grease nipple (figure 5.5). Through that nipple, grease is distributed to all four bearings. NOTE: When adding grease, make sure that the amount of grease is adequate for four bearings. Refer to Table 5.4.
Figure 5.3 Lubrication of jaw crusher spherical roller bearings with grease gun
5-10
NORDBERG C SERIES INSTRUCTION MANUAL
140588-5_K
EN
CHAPTER 5 - MAINTENANCE
Callout 1 Pump unit
Description
Callout Description 2 Distributor unit
Figure 5.4 Lubrication of jaw crusher spherical roller bearings using automatic lubricating system
EN
140588-5_K
NORDBERG C SERIES INSTRUCTION MANUAL 5-11
CHAPTER 5 - MAINTENANCE
Callout Description 1 Grease nipple
Callout Description 2 Distributor unit
Figure 5.5 Distributor unit with grease nipple
During operation there is always a very slight working of the grease out through the pitman and frame bearings and adjacent labyrinth seals. Movement of the grease out of the bearing and the adhering of grease outside the seal, protects the bearing and seal from foreign particles. By observation of this grease working action, the operator will soon be able to estimate the amount and frequency of bearing grease requirements. The amount of grease required and the length of time between greasings will vary in accordance with operating conditions.
5-12
NORDBERG C SERIES INSTRUCTION MANUAL
Before greasing the bearings, thoroughly clean the area around each grease fitting before removing the cover from the fitting. If the grease gun method of lubrication is used, add the grease immediately after shut down while the bearings are still warm. Refer to the Lubrication Schedule in Table 5.3.
140588-5_K
EN
CHAPTER 5 - MAINTENANCE
Model
C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200
Manual Lubrication Normal Conditions Very Dusty Conditions (every 80 hours) (every 40 hours) Grease Amount/Nipple Grease Amount/ Nipple grams (oz.) grams (oz.) 60 (2.1) 30 (1.1) 125 (4.4) 63 (2.2) 175 (6.1) 88 (3.1) 125 (4.4) 63 (2.2) 175 (6.1) 88 (3.1) 175 (6.1) 88 (3.1) 175 6.1) 88 (3.1) 250 (8.8) 125 (4.4) 300 (10.5) 150 (5.3) 300 (10.5) 150 (5.3) 400 (14) 200 (7) 500 (17.5) 250 (8.8)
Automatic Lubrication All Conditions (continous) Grease Amount g/h (oz./h) 1.1 - 1.8 (.04 - .06) 2.0 - 3.4 (.07 - .11) 2.9 - 4.8 (.1 - .17) 2.0 - 3.4 (.07 - .11) 2.9 - 4.8 (.1 - .17) 2.9 - 4.8 (.1 - .17) 2.9 - 4.8 (.1-.17) 3.9 - 6.5 (.14 - .23) 4.7 - 7.8 (.16 - .27) 4.7 - 7.8 (.16 - .27) 5.9 - 9.8 (.2 - .34) 7.7 - 12.9 (.27 - .45)
Table 5.3 Lubrication schedule of eccentric shaft bearings
Model
C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200
Manual Lubrication (distributor with grease nipple) Normal Conditions Very Dusty Conditions (every 80 hours) (every 40 hours) Grease Amount Grease Amount grams (oz.) grams (oz.) 240 (8.4) 120 (4.4) 500 (17.6) 252 (8.8) 700 (24.4) 352 (12.4) 500 (17.6) 252 (8.8) 700 (24.4) 352 (12.4) 700 (24.4) 352 (12.4) 700 (24.4) 352 (12.4) 1000 (35.2) 500 (17.6) 1200 (42) 600 (21.2) 1200 (42) 600 (21.2) 1600 (56) 800 (28) 2000 (70) 1000 (35.2)
Table 5.4 Lubrication schedule of eccentric shaft bearings (distributor with grease nipple (Figure 5.5))
WARNING! Avoid using too much grease as excessive grease will cause overheating and shorten the bearing life.
EN
140588-5_K
NORDBERG C SERIES INSTRUCTION MANUAL 5-13
CHAPTER 5 - MAINTENANCE
5.3.4 Eccentric Shaft Bearing Temperatures Bearing temperature should be checked frequently and greasing accomplished immediately if an unusual temperature rise is noted. During operation, bearings will feel warm to the touch but it should always be possible to touch them for a few seconds 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 the cause. A check should also be made, if one bearing is over 10-15°C (18-27°F) warmer than the other bearings. WARNING! C Series crushers are not designed to operate at temperatures lower than -30ºC/-22ºF. Should operating temperatures be lower than -30ºC/-22ºF, contact Metso Minerals.
WARNING! If temperature sensors are not installed on the crusher, temperature reading must be done when the crusher is at rest.
5-14
NORDBERG C SERIES INSTRUCTION MANUAL
140588-5_K
EN
CHAPTER 5 - MAINTENANCE
5.3.5 Jack-shaft Bearings When applicable, the jack-shaft bearings must be lubricated manually with a grease gun. Before greasing the bearings, thoroughly clean the area around each grease fitting before removing the cover from the fitting. If the grease gun method of
lubrication is used, add the grease immediately after shut down while the bearings are still warm. Refer to the Lubrication Schedule in Table 5.5.
Figure 5.6 Jack-shaft bearings lubrication (electric drive)
Figure 5.7 Jack-shaft bearings lubrication (hydraulic drive)
EN
140588-5_K
NORDBERG C SERIES INSTRUCTION MANUAL 5-15
CHAPTER 5 - MAINTENANCE
Model
Normal Conditions (every 80 hours) Grease Amount/Nipple grams (oz.)
C80 C96 C106 C110 C116 C3054 C125 C140 C145 C160 C200
40 (1.4) 40 (1.4) 40 (1.4) 70 (2.5) 55 (2) 55 (2) 70 (2.5) 70 (2.5) 70 (2.5) 80 (2.8) 80 (2.8)
WARNING!
Very Dusty Conditions (every 40 hours) Grease Amount/ Nipple grams (oz.) 20 (0.7) 20 (0.7) 20 (0.7) 35 (1.2) 28 (1) 28 (1) 35 (1.2) 35 (1.2) 35 (1.2) 40 (1.4) 40 (1.4)
If temperature sensors are not installed on the crusher, temperature reading must be done when the crusher is at rest.
5.3.7 Thrust Bearing And Cap Nut Bearings This only applies to crushers equipped with mechanical setting adjustment. The turning cap nut(s) and the thrust bearing must be manually lubricated in accordance with the following Lubrication Schedule (Table 5.6).
Model
Table 5.5 Lubrication schedule of jack-shaft bearings
C80 C96 C106 C110 C116 C3054 C125 C140 C145 C160 C200
WARNING! Avoid using too much grease as excessive grease will cause overheating and shorten the bearing life.
5.3.6 Jack-shaft Bearing Temperatures Bearing temperature should be checked frequently and greasing accomplished immediately if an unusual temperature rise is noted. During operation, bearings will feel warm to the touch but it should always be possible to touch them for a few seconds 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 the cause.
5-16
NORDBERG C SERIES INSTRUCTION MANUAL
Thrust Bearings Cap Nut(s) Grease Grease Amount/ Amount/Nipple Nipple grams (oz.) grams (oz.) n/a 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0,7) 20 (0,7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7)
Table 5.6 Lubrication schedule of thrust bearings
5.3.8 Electric Drive Motor For instructions, refer to the motor documentation that has been provided with the crusher.
140588-5_K
EN
CHAPTER 5 - MAINTENANCE
5.3.9 Toggle Seats And Toggle Plate
WARNING! Do not lubricate the toggle seats, toggle plate or toggle plate ends. This area of the crusher is designed to operate without lubrication
Figure 5.8 Do not lubricate the toggle seats, toggle plate or toggle plate ends
EN
140588-5_K
NORDBERG C SERIES INSTRUCTION MANUAL 5-17
CHAPTER 5 - MAINTENANCE
5.3.10 Setting Adjustment Wedges
5.4 INSTRUCTIONS FOR LIFTING A JAW CRUSHER WHEN REPLACING CRUSHER SUPPORT BRACKET DAMPERS
CAUTION! Do not lubricate the setting adjustment wedges. This area of the crusher is designed to operate without lubrication. Water or dust suppression spray mists must be kept away from this area of the Crusher.
Two crusher lifting brackets (if applicable) are used to lift a jaw crusher when replacing crusher support bracket dampers. The crusher is lifted one side at a time. For location of the crusher lifting bracket in relationship to the crusher, refer to Figure 5.9. 1. Loosen and remove stop block bolts and rubber dampers. 2. Fasten the lifting brackets with bolts to crusher support bracket. WARNING! Make sure that the lifting bracket bolts are properly tightened before attempting to lift the crusher. 3. Once the lifting brackets are secured to the crusher brackets, place a hydraulic jack (cylinder) under each lifting bracket. WARNING! Make sure that the jacks that were selected are capable of lifting the crusher weight. Weight of the crusher should be checked from the machine plate of the crusher. 4. Once desired height is achieved to remove worn dampers, block the crusher with timber or steel blocks. WARNING! Do not attempt to remove the worn dampers before the crusher is properly blocked. 5. Remove worn dampers and replace with new. Refer to Table 5.11. 6. Remove the blocks. 7. Simultaneously lower the crusher on the dampers. 8. Remove the jacks and crusher lifting brackets. 9. Repeat the procedure on the opposite side.
5-18
NORDBERG C SERIES INSTRUCTION MANUAL
140588-5_K
EN
CHAPTER 5 - MAINTENANCE
2 3
1 4
Callout Description 1 Lifting bracket 2
Bolt
Callout Description 3 Washer Hydraulic cylinder (not a part of the 4 delivery) Figure 5.9
EN
140588-5_K
NORDBERG C SERIES INSTRUCTION MANUAL 5-19
CHAPTER 5 - MAINTENANCE
5.5 HYDRAULIC SETTING ADJUSTMENT POWER UNIT (OPTIONAL)
Hydraulic setting adjustment system relief valve pressure settings and pressure accumulator filling pressures are shown in Table 5.9.
The hydraulic setting adjustment is powered with an independent hydraulic power unit, or it can be integrated to an extensive hydraulic system, as in the Lokotrack.
5.5.1 Checking oil level and temperature
Hydraulic power unit produces oil flow to the adjusting cylinders and keeps the correct pressure level in the tension cylinder.
Hydraulic oil level can be checked from sight glass (3) on the tank's front panel. Oil level is correct when the oil level is visible in the sight glass.
Hydraulic setting adjustment system has a dump valve, which automatically releases the tension cylinder pressure when the crusher is stopped. This helps adjustment wedges to move smoother.
The glass also houses a thermometer showing the temperature of the oil in the tank.
This function is tightly limited to take place only when the crusher is completely stopped. After the power of the crusher motor is switched off, time relay prevents valve to open until preset time (Table 5.7). This prevents pressure release while the crusher is coasting down. The pressure release while crusher is rotating will cause the drop of the toggle plate.
Model
Time relay setting (min)
C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200
2 2 2 2 2 2 2 3 3 3 4 7
Table 5.7
WARNING!
5.5.2 Changing oil and filter (Figure 5.10) Change oil and the filter in the hydraulic unit for the first time after 100 operating hours. After that the oil and the filter must be changed at 1000 hour intervals or at least twice a year. •
Stop the crusher and wait until it is completely stopped.
•
Turn off and lock out power from main switch (located in the control panel).
•
Remove cover of the hydraulic power unit.
•
Blow off the dust on the unit using pressurized air.
•
In the valve unit, release the hydraulic pressure from the tension cylinder by turning the knob of the shutoff valve (1) counterclockwise. You can check the pressure level from the pressure gauge (2). Remember to shut the pressure gauge valve after checking.
•
Drain oil by removing the drain plug (5).
•
Loosen the filter cover (4) screws.
•
Pull the cover out carefully. Observe the filter assembly when it is dismantled for the first time.
•
Pull the filter cartridge out. If possible, clean the filter base groove. Protect the filter housing from contamination when changing filter cartridges.
•
Install a new cartridge.
Only authorized personnel can adjust relief valves and refill the accumulator.
5-20
NORDBERG C SERIES INSTRUCTION MANUAL
140588-5_K
EN
CHAPTER 5 - MAINTENANCE
•
Check the seal surfaces and renew seal if necessary.
5.5.3 Oil recommendation
•
Replace the cover carefully, so that the cartridge settles into the correct position.
Oil amount in the hydraulic unit is:
•
Fill the oil tank with new oil. Oil amount is: –
40 litres (10½ gal) in all crushers other than C200
–
125 litres (33 gal) in C200
Tighten the pressure relief knob (1).
•
Turn the main switch on and check the pressure level of the tension cylinder from pressure gauge (2). Correct pressure values are shown in Table 5.9. Remember to shut the pressure gauge valve after checking. Check the oil level.
40 litres (10½ gal) in all crushers other than C200
–
125 litres (33 gal) in C200
Use only high quality hydraulic oil with good resistance to corrosion, water, air and foam. The oil must not oxidize easily. The minimum viscosity index is 100.
•
•
–
Suitable brands are listed in Table 5.8. Ambient temperature -30...+25°C (-22...+77°F) BP Bartran HV 32 ESSO Univis N 32 SHELL Tellus oil T 32 Tebo hydraulic lift TEBOIL 32 MOBIL DTE 24 CASTROL Rando HD 32
Ambient temperature -10...+60°C (+14...+140°F) Bartran HV 46 Univis N 46 Tellus oil TX 46 Tebo hydraulic lift 46 DTE 25 Rando HD 46
Table 5.8 Suitable oil brands
Figure 5.10 Hydraulic power unit
EN
140588-5_K
NORDBERG C SERIES INSTRUCTION MANUAL 5-21
CHAPTER 5 - MAINTENANCE
Model C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200
Tension cylinder lower limit bar (PSI) 80 (1160) 100 (1450) 135 (1960) 135 (1960) 135 (1960) 135 (1960) 135 (1960) 80 (1160) 135 (1960) 135 (1960) 90 (1305) 100 (1450)
Tension cylinder upper limit bar (PSI) 100 (1450) 115 (1670) 155 (2250) 155 (2250) 155 (2250) 155 (2250) 155 (2250) 100 (1450) 155 (2250) 155 (2250) 105 (1520) 120 (1740)
Pressure accumulator filling pressure bar (PSI) 70 (1015) 80 (1160) 100 (1450) 100 (1450) 100 (1450) 100 (1450) 100 (1450) 70 (1015) 100 (1450) 100 (1450) 75 (1090) 85 (1230)
Pressure relief valve bar (PSI) 120 (1740) 125 (1815) 170 (2465) 170 (2465) 170 (2465) 170 (2465) 170 (2465) 120 (1740) 170 (2465) 170 (2465) 125 (1815) 145 (2100)
Table 5.9 Tension cylinder and accumulator pressures
Model C96
Tension cylinder lower limit bar (PSI) 100 (1450)
Tension cylinder upper limit bar (PSI) 150 (2175)
Pressure accumulator filling pressure bar (PSI) 80 (1160)
Pressure relief valve bar (PSI) 170 (2465)
Table 5.10 Tension cylinder and accumulator pressures for crushers with active setting control
WARNING!
5.5.4 Bleeding the hydraulic system
Oil can splash. Air in the hydraulic system can be bled with the following procedures. When installing the adjusting cylinders, tension cylinder and pipes/hoses must be properly filled with hydraulic oil. Observe oil level during bleeding and add oil if necessary.
Use eye protection and safety gloves.
CAUTION! Read the oil supplier’s safety instructions before handling hydraulic oil. Beware of hot oil!
Recover all hydraulic oil coming out from the system during bleeding. Waste it properly. WARNING! Air in the tension cylinder may cause the toggle plate fall down.
5-22
NORDBERG C SERIES INSTRUCTION MANUAL
140588-5_K
EN
CHAPTER 5 - MAINTENANCE
Bleeding the tension cylinder when the cylinder is removed for maintenance or is new: 1. Place the tension cylinder and the pressure accumulator beside the crusher. Turn hose couplings upwards and the piston rod end of the cylinder higher than the other end.
6. Ask an assistant to turn the hydraulic power unit on and observe the oil coming out from the system. Recover the oil to a container and waste it properly. 7. Wait until the oil has no air bubbles in it and tighten the screw immediately.
2. Push the piston rod fully in. 3. Fill the cylinder, accumulator and hoses with new hydraulic oil. Prevent contamination. 4. Connect the hoses and disconnect the C-line from the hydraulic power unit (refer to the Installation Manual, fig. 4-11 and 4-12). Plug the C-line hose by the power unit. Prevent contamination. 5. Install the accumulator and the tension cylinder’s cap end to the rear frame. 6. Ask an assistant to unplug the C-line hose and pull the piston rod of the tension cylinder out enough to install it to pitman. Use a come-along if needed. The oil coming out from the C-line hose must be recovered and wasted properly. The hose must be connected to the power unit immediately after the rod is out enough. 7. Install the rod end of the tension cylinder. Bleeding the tension cylinder when the cylinder has not been removed. 1. Stop the crusher and wait until it is completely stopped. 2. Turn off the hydraulic unit power from the main switch (located in the control panel). 3. Make sure that the toggle plate does not drop (See chapter 5.2.1). 4. In the valve unit, release the hydraulic pressure from the return cylinder by turning the knob of the shutoff valve (Figure 5.10: 1) counterclockwise. You can check the pressure level from the pressure gauge (Figure 5.10: 2). Remember to shut the pressure gauge valve after checking. 5. Loosen the vent screw (Figure 5.11: 1) of the pressure accumulator carefully using a 10mm wrench. Do not turn the screw for more than 8 revolutions.
EN
Figure 5.11 Pressure accumulator vent screw
Bleeding the adjusting cylinders: 1. Stop the crusher and wait until it is completely stopped. 2. Adjust the setting to maximum. 3. Slightly loosen the hoses at the inner ends of the adjusting cylinders. Recover the oil to a container and waste it properly. 4. Turn the setting adjustment switch to the "decrease" position. Observe the oil coming from the hose. Tighten the hoses when the oil has no air bubbles in it. 5. Slightly loosen the hoses at the outer ends of the adjusting cylinders. Recover the oil to a container and waste it properly. 6. Turn the setting adjustment switch to the "decrease" position. Observe the oil coming from the hose. Tighten the hoses when the oil has no air bubbles in it. Do not let the jaws hit each other!
140588-5_K
NORDBERG C SERIES INSTRUCTION MANUAL 5-23
CHAPTER 5 - MAINTENANCE
Bleeding the active setting control cylinders: 1. Stop the crusher and wait until it is completely stopped. 2. Decrease the setting if it is increased. 3. Loosen the bleeding screws (Figure 5.10: 1). 4. Turn the setting adjustment switch to the "increase" position. Observe the oil coming from the hose. Tighten the screw when the oil has no air bubbles in it. Recover the oil to a container and waste it properly.
Figure 5.12 Active setting control vent screws
5-24
NORDBERG C SERIES INSTRUCTION MANUAL
140588-5_K
EN
CHAPTER 5 - MAINTENANCE
5.6 PERIODICAL MAINTENANCE
4. Check that the protection rubber of the toggle plate (C) is in good condition and in place.
5.6.1 Daily maintenance •
5. Check the tightness of tightening rod nuts (D). The washers must be in the level with the disc spring housing 0-0,5mm (0-0.02").
BEFORE STARTING See Figure 5.13 for reference. 1. Check the tension of the V-belts. See chapter 3.8.2 Installation Manual.
6. Clean all safety signs and ensure that they are legible.
2. Check the tightness of the jaw bolt nuts (A). The washers must be in the level with the disc spring housing 0-0,5mm (0-0.02")
7. Active setting control: Drive the setting to the minimum and to the maximum to ensure the functioning of the lubrication.
3. Check the tightness of the cheek plate bolts (B), see the tightening torque in chapter 6.1.
8. Active setting control: Check for possible oil leaks.
Figure 5.13 C80, C96, C100, C106, C110, C116, C125, C140, C145, C160, C200
EN
140588-5_K
NORDBERG C SERIES INSTRUCTION MANUAL 5-25
CHAPTER 5 - MAINTENANCE
•
5.6.4 Twice a Year
DURING OPERATION
Check the condition of the eccentric shaft bearings, using e.g. a hearing device.
Listen to the sound of the bearings and check their temperature (max. 75°C/167°F). Check for the proper outflow of grease.
Check for any wear on the seating surfaces of the pitman as well as the front frame.
Check the tension and operation of the return rod, see chapter 4.4 - 4.7 Installation Manual.
Check for any wear on the seating surfaces between the side plates and cheek plates. Check the active setting control seals for leaks. Replace the seals, if necessary.
5.6.2 Weekly Maintenance If an automatic lubrication device is not used, lubricate the eccentric shaft bearings (Figure 5.14). Before lubrication, the grease nipples must be cleaned. Under normal operating conditions add grease every 80 operating hours. Under dusty condition the frequency must be doubled (to every 40 hours). See the required grease quantity in Table 5.3.
5.6.5 Regularly Change oil and the filter in the hydraulic unit first time after 100 operating hours. After that the oil and the filter must be changed at 1000 hours intervals or at least twice a year.
Lubricate the cap nut bearings of the setting adjustment device and check their rubber bellows (mechanical setting adjustment), see Chapter 5.3.7 . Check the wear on the cheek plates. Change if necessary. Check the toggle plate for alignment, straightness and cracks. Check the toggle seats and their stopper plates. Clean or replace if necessary. Check the tightness of the frame tie bolts. Check the mounting and condition of the flywheel and the tightness of the gib keys. Check the mounting of the crusher.
5.6.3 Monthly Maintenance Check the tightness of the frame mounting bolts on the side plates. Check the rubber dampers under the crusher's mounting brackets. If any damper is damaged, it should be changed. Refer to Table 5.11.
5-26
NORDBERG C SERIES INSTRUCTION MANUAL
140588-5_K
EN
CHAPTER 5 - MAINTENANCE
Figure 5.14 Lubricate eccentric shaft bearings weekly
Model C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200
Height of the rubber damper (mm) worn, installed new, uninstalled (to be replaced) 15 11 20 14 16 12 15 11 32 25 32 25 32 25 32 25 32 25 32 25 32 25 35 26
Table 5.11 Height of the rubber damper
NOTE: The rubber dampers must be installed to the crusher when they are measured.
EN
140588-5_K
NORDBERG C SERIES INSTRUCTION MANUAL 5-27
CHAPTER 5 - MAINTENANCE
5.7 MAINTENANCE INTERVALS ITEM
Daily
Check V-belt tension. Check the tightness of jaw bolts. Check the tightness of cheek plate bolts. Check wear on the jaw plates Check the sound, temperature (max. 75°C/167°F) and grease flow in the eccentric bearings. Lubricate eccentric shaft bearings. Check wear on the cheek plates. Check toggle plate for alignment, straightness and cracks Check the toggle seats and their stopper plates. Clean or replace as necessary. Check the tightness of the mounting bolts of the labyrinth covers. Check the tightness of the frame tie rods Check the mounting and condition of the flywheel and the tightness of the gib keys. Lubricate crusher drive jackshaft (optional). Check the tightness of the frame mounting bolts on the side plates. Check the rubber dampers under the crusher's mounting brackets, and the mounting of the crusher. Check the bearings on the eccentric shaft. Check for any wear on the contact surfaces of the pitman and front frame. Check for any wear on the contact surfaces between the side plates and cheek plates. Mechanical wedge setting adjustment Check tension and operation of tension rod spring. Lubricate the cap nuts of the setting adjustment device Check the rubber covers Lubricate thrust bearing. Hydraulic wedge setting adjustment Check the pressure of the tension cylinder. Check operation and oil amount (add oil if necessary). Change oil and filter. Active setting control Drive the setting to the minimum and to the maximum to ensure the functioning of the lubrication. Check for possible oil leaks. Check the seals for leaks. Replace the seals, if necessary. Automatic lubricating device Check operation and grease amount (add grease if necessary).
X X X X
5-28
NORDBERG C SERIES INSTRUCTION MANUAL
140588-5_K
Weekly Monthly
Every 6 months
X X X X X X X X X X X X X X
X X X X X X X
X X X X
EN
CHAPTER 5 - MAINTENANCE
5.8 BOLT TORQUE VALUES NOTE: Tightening torques of the bearing housing bolts, frame tie rods and flywheel bolts must be checked from the Installation Manual. All other bolts must be tightened according to the table below. Correct pretightening is possible only with clean , unlubricated screw threads that are not surface treated. The table applies to bolts with property class 8.8.
Bolt M10 M12 M16 M20 M24 M30 M36 M42 M48 M52 M56 M64 M72 M80 M100
Nm 47 81 196 382 662 1320 2310 3700 5590 7180 8960 13460 19350 26850 53340
Torque kpm 4.8 8.3 20 39 67 135 236 378 570 733 914 1370 1970 2740 5440
ft lbs 35 60 145 285 490 975 1705 2730 4125 5295 6610 9930 14275 19805 39280
Table 5.12
EN
140588-5_K
NORDBERG C SERIES INSTRUCTION MANUAL 5-29
CHAPTER 5 - MAINTENANCE
This Page Left Intentionally Blank.
5-30
NORDBERG C SERIES INSTRUCTION MANUAL
140588-5_K
EN
REPLACEMENT OF WEAR PARTS
CHAPTER
6
WARNING!
DANGER!
Before performing any maintenance or repair work, make sure that the crusher is stopped and locked out.
Before entering into the crushing cavity, remove any loose rocks from the feed hopper and the feeder.
LOCKOUT PROCEDURE of the Lokotrack installed crushers
6.2 JAW SELECTION There are several different jaws available for the Nordberg C-Series jaw crusher. For profile details and application guidelines contact a Metso Minerals representative.
1. Switch off engine 2. Remove the ignition key and keep it on person during lockout 3. Place appropriate maintenance warning signs (TAG OUT)
The type of jaw must be selected according to the feed material and desired end product. Because of many different applications and variables, one jaw profile is capable of performing in many applications.
LOCKOUT PROCEDURE of the electrical motor driven crushers
If you are experiencing problems with your existing application or would like to improve the application, contact your Metso Minerals representative. When inquiring about the correct jaw profile, the following information must be provided:
1. Switch off motor 2. Lock the main switch of the motor with a padlock or make sure in some other way that the engine cannot be started 3. Lock the main switch of the hydraulic adjustment power unit (if delivered) with padlock
1. Feed size and gradation 2. Feed type and characteristics 3. End product gradation
4. Keep the keys on person during lockout
4. Capacity required 5. Options; intermediate plate, spacer
5. Place appropriate maintenance warning signs (TAG OUT).
6. Crusher setting
6.1 GENERAL
6.3 JAW WORK HARDENING
Before performing any maintenance or repair work, make sure that the crusher is stopped and locked out.
Because the wear and work hardening does not occur evenly in the crushing cavity, it is recommended that the following measures are taken to maximize the useful life of the jaws:
Nordberg C-Series crusher jaws are made from Manganese steel which work hardens. For different materials and applications there are different jaw profiles to obtain the best possible capacity to jaw cost ratio. Before lifting any wear parts, check the weight of the component and ensure that lifting equipment being used is adequate to lift the weight. In addition, familiarize yourself with all the special tools provided with the crusher specifically for replacing the wear parts.
EN
140588-6_K
–
When using 2-piece jaws, and to optimize the wear profile, flip the upper and lower jaws after first 50 to 200 hours. Hardness of the feed material will dictate when to rotate the jaws.
–
Flip the upper and lower jaws after every 400 to 500 operating hours (200 hours if the material is very hard) to properly work harden the jaws.
NORDBERG C SERIES INSTRUCTION MANUAL 6-1
CHAPTER 6 - REPLACEMENT OF WEAR PARTS
WARNING! The jaw lifting tools are designed by Metso to lift Metso manufactured jaws. Metso cannot be responsible for any personal injury or property damage, bodily harm, or equipment damage resulting from attempting to lift other manufacturer’s jaws. These lifting tools are sized based on the jaw being lifted. If a customer decides to purchase a one-piece jaw instead of a two-piece jaw, then a different lifting tool must be purchased to make that lift. Never attempt to lift a jaw with a lifting tool that is intended for a lighter jaw. Figure 6.1
CAUTION! 2. Lock the lifting tool.
Damage to the crusher side plates, pitman and front casting will result if the cheek plates and jaws are allowed to wear through.
WARNING! Make sure that the hoist being used is capable of lifting the cheek plate weight.
For more detailed information on lifting accessories, see appendices A and B. 3. When the lifting tool is engaged and locked to the cheek plate, remove the lock nuts (5), washers (4), and bolts (3).
6.4 CHEEK PLATE REPLACEMENT The lower cheek plates will normally wear before the upper cheek plates. When the lower cheek plates are replaced, a small shelf may form between the upper and lower cheek plate. This shelf may slow down the material movement through the crusher.
4. Lift the upper cheek plate (1) out from the crusher. 5. Follow the above procedure for removal of the lower cheek plates (2).
WARNING! 6.4.1 Cheek Plate Removal
The cheek plate lifting tools are designed by Metso to lift Metso manufactured cheek plates. Metso cannot be responsible for any personal injury or property damage, bodily harm, or equipment damage resulting from attempting to lift other manufacturer’s cheek plates.
To remove the cheek plate, refer to Figure 6.2 and proceed as follows: 1. Loosen the lock nuts approximately 12 mm (1/2”) and pull the cheek plate away from the side plate,so that the cam of the lifting tool can be rotated into the locked position. (Figure 6.1).
6-2
NORDBERG C SERIES INSTRUCTION MANUAL
140588-6_K
EN
CHAPTER 6 - REPLACEMENT OF WEAR PARTS
Callout Description 1 Cheek plate, upper 2 Cheek plate, lower 3 Bolt
Callout 4 Washer 5 Locking nut
Description
Figure 6.2 Cheek plate removal
EN
140588-6_K
NORDBERG C SERIES INSTRUCTION MANUAL 6-3
CHAPTER 6 - REPLACEMENT OF WEAR PARTS
6.4.2 Cheek Plate Assembly
Callout Description 1 Cheek plate, upper
Callout Description 2 Cheek plate, lower
Figure 6.3 Cheek plate assembly
6-4
NORDBERG C SERIES INSTRUCTION MANUAL
140588-6_K
EN
CHAPTER 6 - REPLACEMENT OF WEAR PARTS
To assemble the cheek plates, refer to Figure 6.3 and proceed as follows:
6.5 CHANGING OR ROTATING THE JAWS
1. Insert and lock the cheek plate lifting tool into the cheek plate. Refer to appendix B.
DANGER!
2. Align the lower cheek plate with the bolt holes.
Never place yourself or other personnel in a position beneath or adjacent to a jaw that is not properly secured against unintended movement.
DANGER! Make sure e.g. with a wooden block, that the cheek plate does not fall onto you. 3. Insert bolts and washers and tighten the nuts so that a 12 mm (1/2”) gap exists between the cheek plate and the side plate. 4. Unlock and remove the lifting tool by turning the lever. 5. Tighten the cheek plate bolts to torque specified in Table 6.1. Follow the above procedure to install the upper cheek plate (1).
Bolt Size C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200
M24 M24 M30 M24 M36 M24 M24 M36 M42 M42 M48 M42
DANGER! A working platform should be installed into the crushing cavity before entering.
NOTE: Metso’s customers have different preferences regarding material choice and configuration of their work platforms. As a result Metso does not sell working platforms for use with the C-Series jaw crushers. Regardless of the material or configuration of the working platform, it must rest securely in the jaw cavity, must protect the personnel against fall hazards, and must restrain the jaws to prevent unintended movement.
Torque Nm 216 216 437 216 760 216 216 760 1216 1216 1834 1216
kpm 22 22 44.5 22 77.5 22 22 77.5 124 124 187 124
ftlbs 160 160 325 160 560 160 160 560 900 900 1355 900
WARNING! It is the customer’s responsibility to provide a safe working environment for his employees, including safe working platforms.
Table 6.1 Cheek plate bolt torques.
EN
140588-6_K
NORDBERG C SERIES INSTRUCTION MANUAL 6-5
CHAPTER 6 - REPLACEMENT OF WEAR PARTS
6.5.1 One Piece Jaws
–
Remove the jaw. (Figure 6.4, b)
6.5.1.1 Removal
–
Place the jaw on wooden blocks. (Figure 6.5)
To remove the jaw, refer to Figure 6.4, Figure 6.5, and Figure 6.6 and proceed as follows:
NOTE: If the jaw is being rotated, before installation make sure that all the jaw seating surfaces are clean.
1. Stationary jaw removal DANGER! A working platform should be installed into the crushing cavity before entering. –
Insert a working platform into the crushing cavity.
–
Remove material build up from the jaw lifting holes.
–
Remove material build up between the stationary jaw and cheek plates.
–
Insert the jaw lifting tool into the lifting holes of the jaw, and lock it in place. Refer to Appendix A for additional information. DANGER! Properly retain the jaw from unintended movement before releasing the locking mechanism of the lifting tool.
–
Make sure the lifting hoist is capable of lifting the weight of the one piece jaw.
WARNING! The lifting tool’s locking mechanism must be engaged (cammed over into the locking position and secured with the butterfly screw) prior to attempting to remove any jaw locking components. Never attempt to lift a jaw without the lifting tool’s locking mechanism fully engaged and in the locked position.
6-6
–
Remove the hex nuts (10) and the jaw disc spring assembly (8).
–
Remove the jaw bolts (6), tightening wedge (4) and filling wedge (3).
–
Exit the crushing cavity and remove the working platform.
NORDBERG C SERIES INSTRUCTION MANUAL
140588-6_K
EN
CHAPTER 6 - REPLACEMENT OF WEAR PARTS
a
b
Figure 6.4
EN
140588-6_K
NORDBERG C SERIES INSTRUCTION MANUAL 6-7
CHAPTER 6 - REPLACEMENT OF WEAR PARTS
WARNING! The lifting tool’s locking mechanism must be engaged (cammed over into the locking position and secured with the butterfly screw) prior to attempting to remove any jaw locking components. Never attempt to lift a jaw without the lifting tool’s locking mechanism fully engaged and in the locked position.
Figure 6.5
2.1 Movable Jaw Removal (all jaw crusher models except C106 and C116) Figure 6.6 DANGER! A working platform should be installed into the crushing cavity before entering. –
Insert a working platform into the crushing cavity.
–
Remove material build up from the jaw lifting holes.
–
Remove any loose material from between the movable jaw and cheek plates.
–
Insert the jaw lifting tool into the lifting holes of the jaw, and lock it in place. Refer to Appendix A for additional information..
–
Remove the hex nuts (10) and jaw disc spring assembly (8) (Figure 6.6).
–
Remove the jaw bolts (7), tightening wedge (5), and filling wedge (3).
–
Exit the crusher cavity and remove the working platform.
–
Remove the jaw (2).
–
Place the jaw on wooden blocks. (Figure 6.5)
NOTE: If the jaw is being rotated, before reinstallation make sure that all the jaw seating surfaces are clean.
DANGER! Properly retain the jaw from unintended movement before releasing the locking mechanism of the lifting tool. –
6-8
Make sure that the lifting hoist is capable of lifting the weight of the one piece jaw.
NORDBERG C SERIES INSTRUCTION MANUAL
140588-6_K
EN
CHAPTER 6 - REPLACEMENT OF WEAR PARTS
c
d
Figure 6.6
2.2 Movable Jaw Removal C106 and C116 (Figure 6.7)
–
Remove any loose material from between the movable jaw and cheek plates.
–
Insert the jaw lifting tool into the lifting holes of the jaw, and lock it in place. Refer to Appendix A for additional information..
DANGER!
DANGER!
A working platform should be installed into the crushing cavity before entering. – –
EN
Insert a working platform into the crushing cavity.
Properly retain the jaw from unintended movement before releasing the locking mechanism of the lifting tool. –
Remove material build up from the jaw lifting holes.
140588-6_K
Make sure that the lifting hoist is capable of lifting the weight of the one piece jaw.
NORDBERG C SERIES INSTRUCTION MANUAL 6-9
CHAPTER 6 - REPLACEMENT OF WEAR PARTS
–
Remove the hex nuts (10) and jaw disc spring assembly (8).
–
Remove the jaw bolts (7), tightening wedge (5), and filling wedge (3).
–
Exit the crusher cavity and remove the working platform.
–
Remove the jaw (2).
–
Place the jaw on wooden blocks. (Figure 6.5)
WARNING! The lifting tool’s locking mechanism must be engaged (cammed over into the locking position and secured with the butterfly screw) prior to attempting to remove any jaw locking components. Never attempt to lift a jaw without the lifting tool’s locking mechanism fully engaged and in the locked position.
WARNING!
NOTE: If the pitman protection plate or the tightening wedge are worn, replace them when replacing the jaw.
Make sure that the pitman protection plate (11) is securely attached to the pitman so that it cannot fall.
Figure 6.7
6-10
NORDBERG C SERIES INSTRUCTION MANUAL
140588-6_K
EN
CHAPTER 6 - REPLACEMENT OF WEAR PARTS
6.5.1.2 Assembly CAUTION! Before installing new or partially worn jaws, make sure that the jaw and crusher cavity (front frame and pitman) seating surfaces are cleaned. The jaws must have metal to metal contact on all seating surfaces. (Figure 6.8).
DO NOT install jaws into the crusher if the jaw seating surfaces are not straight. Warped or distorted jaws can cause severe damage to the crusher seating surfaces. Contact your Metso Minerals representative for assistance.
Check the condition of the protection plate (if equipped). Replace if necessary.
IMPORTANT! When rotating the jaws, it is a good practice to check the seating surfaces of the jaw for straightness. This is easily accomplished with the use of a straight edge.
NOTE: If the ends of the jaws are bent in, or distorted, excess material must be removed to original shape by torching before the jaws can be installed.
The jaw can warp or deform if the jaw is not properly tightened, or is allowed to wear thin while crushing.
Figure 6.8 Checking the straightness of a jaw
EN
140588-6_K
NORDBERG C SERIES INSTRUCTION MANUAL 6-11
CHAPTER 6 - REPLACEMENT OF WEAR PARTS
Figure 6.9 Jaw seating surfaces
1. Stationary Jaw Installation (Figure 6.4)
6-12
–
Clean all jaw seating surfaces (Figure 6.9).
DANGER!
–
Insert and lock the the jaw lifting tool to the jaw according to appendix A.
A working platform should be installed into the crushing cavity before entering.
–
Install the jaw into the crushing cavity, making sure that the jaw seating surface makes full contact with the lower wedge.
NORDBERG C SERIES INSTRUCTION MANUAL
–
140588-6_K
Insert the working platform into the crushing cavity.
EN
CHAPTER 6 - REPLACEMENT OF WEAR PARTS
– WARNING!
Insert the working platform into the crushing cavity. WARNING!
Properly retain the jaw from unintended movement before releasing the locking mechanism of the lifting tool.
Properly retain the jaw from unintended movement before releasing the locking mechanism of the lifting tool.
–
Install the filling wedge (3), tightening wedge (4) and jaw bolts (6).
–
–
Install the disc spring assembly (8). Make sure that the disc spring stack up is according to Figure 6.17.
Install the filling wedge (3), tightening wedge (5) and jaw bolts (7).
–
Tighten the spring assembly per Chapter 5.6 , and lock with double hex nuts (10).
Install the disc spring assembly (8). Make sure that the disc spring stack up is according to Figure 6.17.
–
Tighten the spring assembly per Chapter 5.6 , and lock with double hex nuts (10).
–
Remove the jaw lifting tool.
–
Remove the working platform.
–
–
Remove the jaw lifting tool.
–
Remove the working platform.
IMPORTANT! Check the compression of the disc springs shortly after the re-start of the jaw crusher. Retighten the disc springs if necessary.
2. Movable Jaw Installation (Figure 6.6)
IMPORTANT! Check the compression of the disc springs shortly after the re-start of the jaw crusher. Retighten the disc springs if necessary.
IMPORTANT! Prior to starting the crusher, the crusher discharge setting must be adjusted.
IMPORTANT! This installation and removal procedure of the jaws is also used on a C3054 jaw crusher with one exception. The C3054 does not use the filling wedges. –
Clean all jaw seating surfaces (Figure 6.9).
–
Insert and lock the jaw lifting tool to the jaw according to appendix A.
–
Install the jaw into the crushing cavity. Make sure that the jaw seating surface has full contact with the lower wedge. DANGER! A working platform should be installed into the crushing cavity before entering.
EN
140588-6_K
NORDBERG C SERIES INSTRUCTION MANUAL 6-13
CHAPTER 6 - REPLACEMENT OF WEAR PARTS
6.5.2 TWO-PIECE JAW REMOVAL
–
Exit the crushing cavity and remove the working platform.
To remove a two piece jaw, refer to Figure 6.10 and proceed as follows:
–
Remove the upper jaw.
–
Place the jaw on wooden blocks. (Figure 6.5)
1. Stationary Jaws DANGER! A working platform should be installed into the crushing cavity before entering.
DANGER! A working platform should be installed into the crushing cavity before entering. –
Insert a working platform into the crushing cavity.
–
Remove material build up from the upper jaw lifting holes.
–
Remove material build up between the stationary upper jaw and cheek plates.
–
–
–
NOTE: A smaller working platform might be required, as it is fitted further into the crushing cavity when the lower two piece jaw is removed. DANGER!
Insert the jaw lifting tool into the lifting holes of the upper jaw and lock it in place. Refer to Appendix A for more information..
Properly retain the jaw from unintended movement before releasing the locking mechanism of the lifting tool. –
Remove material build up from the lower stationary jaw lifting holes.
DANGER!
–
Properly retain the jaw from unintended movement before releasing the locking mechanism of the lifting tool.
Remove material build up between the stationary lower jaw and cheek plates.
–
Insert the jaw lifting tool into the lifting holes of the lower jaw and lock it in place. Refer to Appendix A for more information
Make sure the lifting hoist is capable of lifting the weight of the two piece jaw.
DANGER! Never place yourself or other personnel in a position beneath or adjacent to a jaw that is not properly secured against unintended movement.
WARNING! The lifting tool’s locking mechanism must be engaged (cammed over into the locking position and secured with the butterfly screw) prior to attempting to remove any jaw locking components. Never attempt to lift a jaw without the lifting tool’s locking mechanism fully engaged and in the locked position.
6-14
Insert the working platform into the crushing cavity.
–
Remove the hex nuts (13) and jaw disc spring assembly (11).
–
Remove the jaw bolts (8), tightening wedge (6), and filling wedge (4).
NORDBERG C SERIES INSTRUCTION MANUAL
WARNING! The lifting tool’s locking mechanism must be engaged (cammed over into the locking position and secured with the butterfly screw) prior to attempting to remove any jaw locking components. Never attempt to lift a jaw without the lifting tool’s locking mechanism fully engaged and in the locked position.
140588-6_K
EN
CHAPTER 6 - REPLACEMENT OF WEAR PARTS
–
Remove the disc spring assembly (11) from center jaw bolts (7)
–
Remove the jaw bolts and center wedge.
–
Exit the crushing cavity and remove the working platform.
Callout 1 3 4 6
Description Fixed jaw Center wedge Filling wedge Filling wedge
–
Remove the lower jaw.
–
Place the jaw on wooden blockins. (Figure 6.5)
Callout 7 8 11 13
Description Jaw bolt Jaw bolt Spring package Hex nut
Figure 6.10 Removal of a fixed jaw
EN
140588-6_K
NORDBERG C SERIES INSTRUCTION MANUAL 6-15
CHAPTER 6 - REPLACEMENT OF WEAR PARTS
–
2. Movable Jaw removal (ref. Figure 6.11) DANGER! A working platform should be installed into the crushing cavity before entering.
Insert the working platform into the crushing cavity.
NOTE: Smaller working platform might be required, as it is fitted further into the crushing cavity when the lower two piece jaw is removed. –
Remove material build up from the lower movable jaw lifting holes.
–
Insert a working platform into the crushing cavity.
–
Remove any loose material from between the lower movable jaw and cheek plates.
–
Remove material build up from the upper movable jaw lifting holes.
–
–
Remove any loose material from between the upper movable jaw and cheek plates.
Insert the jaw lifting tool into the lifting holes of the jaw, and lock it in place. Refer to Appendix A for additional information.
–
–
Insert the jaw lifting tool into the lifting holes of the jaw, and lock it in place. Refer to Appendix A for additional information.
Remove the disc spring assembly from the center movable jaw bolts (9).
–
Remove the jaw bolts and center wedge.
–
Exit the crushing cavity and remove the work platform..
DANGER! Properly retain the jaw from unintended movement before releasing the locking mechanism of the lifting tool.
DANGER! Never place yourself or other personnel in a position beneath or adjacent to a jaw that is not properly secured against unintended movement.
WARNING! The lifting tool’s locking mechanism must be engaged (cammed over into the locking position and secured with the butterfly screw) prior to attempting to remove any jaw locking components. Never attempt to lift a jaw without the lifting tool’s locking mechanism fully engaged and in the locked position. –
Remove the hex nuts (13) and jaw disc spring assembly (11).
–
Remove the jaw bolts (10), tightening wedge (5), and filling wedge (4).
–
Exit the crushing cavity and remove the working platform.
–
Remove the jaw (2).
–
Place the jaw on wooden blocks. (Figure 6.5)
–
Remove the lower jaw.
–
Place the jaw on wooden blocks. (Figure 6.5)
NOTE: If the jaw is being rotated, before reinstallation make sure that all the jaw seating surfaces are clean.
NOTE: If the jaw is being rotated, before reinstallation make sure that all the jaw seating surfaces are clean.
6-16
NORDBERG C SERIES INSTRUCTION MANUAL
140588-6_K
EN
CHAPTER 6 - REPLACEMENT OF WEAR PARTS
Callout 2 3 4 5
Description Moving jaw Center wedge Filling wedge Tightening wedge
Callout 9 10 11 13
Description Jaw bolt Jaw bolt Spring package Hex nut
Figure 6.11
EN
140588-6_K
NORDBERG C SERIES INSTRUCTION MANUAL 6-17
CHAPTER 6 - REPLACEMENT OF WEAR PARTS
6.5.2.1 Two Piece Jaw Assembly Before installing new or partially worn jaws, make sure that the jaw and crusher cavity (front frame and pitman) seating surfaces are clean. The jaws must have metal to metal contact on all seating surfaces. Check the condition of the protection plate (if equipped). Replace if necessary. IMPORTANT! When rotating the jaws, it is a good practice to check the seating surfaces of the jaw for straightness (Ref. Figure 6.4). This is easily accomplished with the use of a straight edge. The jaw can warp or deform if the jaw is not properly tightened, or allowed to wear thin while crushing.
CAUTION! DO NOT install jaws into the Crusher if the jaw seating surfaces are not straight. Warped or distorted jaws can cause severe damage to the crusher seating surfaces. Contact your Metso Minerals representative for assistance.
NOTE: If the ends of the jaws are bent in, or distorted, before the jaws can be installed, excess material must be removed to original shape by torching. To install a two piece jaw refer to Figure 6.12, Figure 6.13, Figure 6.14, and Figure 6.15 and proceed as follows:
6-18
NORDBERG C SERIES INSTRUCTION MANUAL
140588-6_K
EN
CHAPTER 6 - REPLACEMENT OF WEAR PARTS
Figure 6.12 Jaw seating surfaces
1. Two Piece Stationary Jaw Installation (Figure 6.10) –
Clean all jaw seating surfaces (Figure 6.12).
–
Insert and lock the the jaw lifting tool to the jaw according to appendix A.
–
Install the jaw into the crushing cavity, making sure that the jaw seating surface makes full contact with the lower wedge.
–
WARNING! Properly retain the jaw from unintended movement before releasing the locking mechanism of the lifting tool.
DANGER! A working platform should be installed into the crushing cavity before entering.
EN
Insert the working platform into the crushing cavity.
140588-6_K
–
Install the center wedge (3) and jaw bolts (7).
–
Install the spring assembly (11) making sure that the disc spring stack up is according to Figure 6.15.
NORDBERG C SERIES INSTRUCTION MANUAL 6-19
CHAPTER 6 - REPLACEMENT OF WEAR PARTS
–
–
Tighten the center jaw bolt nuts until most of the clearance between all the wedge retention components is removed. The center wedge should be positioned farthest away from the front casting on top of the lower jaw.
2. Movable Two Piece Jaw Installation (Figure 6.11)
Clean all jaw seating surfaces of the stationary upper jaw (Figure 6.12).
–
Insert and lock the the jaw lifting tool to the jaw according to appendix A.
–
Install the jaw into the crushing cavity, making sure that the jaw seating surface makes full contact with the center wedge.
–
Clean all jaw seating surfaces (Figure 6.12).
–
Insert and lock the the jaw lifting tool to the jaw according to appendix A.
–
Install the lower movable jaw into the crushing cavity, making sure that the jaw seating surface makes full contact with the lower wedge.
DANGER! A working platform should be installed into the crushing cavity before entering.
DANGER! A working platform should be installed into the crushing cavity before entering.
–
Insert the working platform into the crushing cavity.
–
Install the center wedge (3) and jaw bolts (9).
–
Install the spring assembly (11) making sure that the disc spring stack up is according to Figure 6.15.
–
Tighten the center jaw bolt nuts until most of the clearance between all the wedge retention components is removed. The center wedge should be positioned farthest away from the pitman on top of the lower jaw.
–
Insert the working platform into the crushing cavity.
–
Install the filling wedge (6), tightening wedge (4) and jaw bolts (8).
–
With center jaw bolt hex nuts, adjust the gap between the lower and upper jaw. A gap of 5 - 8 mm (.20” - .30”) must exist between the two jaws. Refer to Figure 6.13.
–
Tighten the disc spring assembly per Chapter 5.6 , and lock with a double hex nut (13).
–
Clean all jaw seating surfaces of the movable upper jaw (Figure 6.12).
–
Remove the jaw lifting tool.
–
–
Remove the working platform.
Insert and lock the the jaw lifting tool to the jaw according to appendix A.
–
Install the jaw into the crushing cavity, making sure that the jaw seating surface makes full contact with the center wedge.
IMPORTANT! Check the compression of the disc springs shortly after the re-start of the jaw crusher. Retighten the disc springs if necessary.
DANGER! A working platform should be installed into the crushing cavity before entering.
6-20
NORDBERG C SERIES INSTRUCTION MANUAL
140588-6_K
EN
CHAPTER 6 - REPLACEMENT OF WEAR PARTS
–
Insert the working platform into the crushing cavity.
–
Install the filling wedge (4), tightening wedge (5) and jaw bolts (10).
–
With center jaw bolt hex nuts, adjust the gap between the lower and upper jaw. A gap of 5 - 8 mm (.20” - .31”) must exist between the two jaws. Refer to Figure 6.13.
WARNING! Properly retain the jaw from unintended movement before releasing the locking mechanism of the lifting tool.
IMPORTANT! Check the compression of the disc springs shortly after the re-start of the jaw crusher. Retighten the disc springs if necessary.
–
Clean all jaw seating surfaces of the stationary upper jaw (ref. Figure 6.12).
–
Insert and lock the the jaw lifting tool to the jaw according to appendix A.
–
Install the lower movable jaw into the crushing cavity, making sure that the jaw seating surface makes full contact with the lower wedge.
IMPORTANT! Prior to starting the crusher, the crusher discharge setting must be adjusted.
DANGER! A working platform should be installed into the crushing cavity before entering.
EN
–
Insert the working platform into the crushing cavity.
–
Install the filling wedge, tightening wedge and jaw bolts.
–
With center jaw bolt hex nuts, adjust the gap between the lower and upper jaw. A gap of 5 - 8 mm (.20” - .31”) must exist between the two jaws. Refer to Figure 6.13.
–
Install the disc spring assembly making sure that the disc spring stack up is according to Figure 6.15
–
Tighten the filling wedge spring assembly Chapter 5.6 , and lock with double hex nut.
–
Remove the jaw lifting tool.
–
Remove the working platform.
140588-6_K
NORDBERG C SERIES INSTRUCTION MANUAL 6-21
CHAPTER 6 - REPLACEMENT OF WEAR PARTS
Figure 6.13
Figure 6.14
6-22
NORDBERG C SERIES INSTRUCTION MANUAL
140588-6_K
EN
CHAPTER 6 - REPLACEMENT OF WEAR PARTS
6.7 FEED HOPPER LINER REPLACEMENT The jaw crusher feed hopper is lined with an abrasion resistant plate. This liner should be replaced, and not allowed to be worn through. Abrasion of the material being crushed will dictate the frequency of replacement. 6.8 TOGGLE PLATE SEAT REPLACEMENT The toggle plate seats are hardened in the toggle plate contact area. The hardness depth is approximately 3 mm (.12”). If the seats are worn more than 3 mm (.12”), they should be replaced.
Callout 1 2 3 4
Description Washer Cup spring Spring casing Rubber plate Figure 6.15 Assembly order
6.6 PITMAN EYE PROTECTION PLATE REPLACEMENT Pitman eye protection plate is designed to protect the pitman from wear. The wear to the protection plate is contributed by feed material impact if the feed material enters the crushing cavity too fast. In addition, the protection plate will show premature wear, if it is allowed for the feed material to be crushed to high in the cavity. To prevent the protection plate from wearing through, periodic replacement is necessary.
EN
140588-6_K
NORDBERG C SERIES INSTRUCTION MANUAL 6-23
CHAPTER 6 - REPLACEMENT OF WEAR PARTS
This Page Left Intentionally Blank.
6-24
NORDBERG C SERIES INSTRUCTION MANUAL
140588-6_K
EN
A
APPENDIX
NORDBERG C-SERIES JAW CRUSHER'S JAW-LIFTING TOOL SAFETY, OPERATING AND MAINTENANCE INSTRUCTIONS
4. Commissioning and operating conditions
1. Purpose of the jaw-lifting tool The jaw-lifting tool that is provided with Nordberg C Series jaw crushers is intended for the lifting of genuine Metso Minerals Nordberg C Series wear parts (jaws) only. The jaw-lifting tool is not designed nor tested for the lifting of other types of jaws (including copies of the Nordberg C Series jaws).
The jaw-lifting tool is supplied fully assembled and it is ready for immediate use.
2. Storage of the jaw-lifting tool
The maximum lifting load is mentioned on the attached tag of the jaw-lifting tool. Table 1 shows available lifting tools.
The jaw-lifting tool can be used in the same operating conditions as the jaw crusher.
5. Technical data
When not in use the jaw-lifting tool should normally be kept on a properly designed rack. They should not be left lying on the ground where they may 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
Lifting tool 582133 582151 585042
Maximum lifting load (Working load limit, WLL) 1500 kg (3307 lbs) 2800 kg (6173 lbs) 5000 kg (11023 lbs)
Table 1 WARNING! Before lifting any wear parts, check the weight of the component and ensure that the lifting equipment being used is adequate to lift the weight. Read carefully all instructions concerning the jaw-lifting tool and make sure that the tool is inspected regularly. Prior to lifting, make sure that the jaw-lifting tool is locked and does not come out of the lifting hole. The jaw-lifting tool is only meant for the lifting of genuine Metso Minerals Nordberg C Series jaws. It is neither designed nor tested for unfastening used jaws that may not readily come loose prior to lifting. Do not overload the jaw-lifting tool. The maximum lifting load is found on the tag of the jaw-lifting tool (see Table 1). Stop the lifting procedure immediately if the jaw is stuck to its location. Load the lifting tool evenly and carry out lifting and displacement of the jaw carefully. Keep the lifting zone free of people during lifting. Do not use the jaw-lifting tool in a hurry.
EN
6. The jaw-lifting tool verification before first use and in service Before first use Before first use of the jaw-lifting tool it should be ensured that: a. the jaw-lifting tool is precisely as ordered; b. the manufacturer's certificate is to hand; c. the identification and working load limit marking on the jaw-lifting tool correspond to the information on the certificate; d. full details of the jaw-lifting tool are recorded.
N11450704_K
JAW LIFTING TOOL A-1
APPENDIX A
b. The hook to which the jaw-lifting tool is attached should be directly above the centre of gravity.
Before each use Before each use the jaw-lifting tool should be inspected for obvious damage or deterioration (see 8 Maintenance / Inspection). If faults are found during this inspection, the procedure given in 8 Maintenance should be followed.
Method of connection The jaw-lifting tool is attached to the load and the lifting machine by means of terminal fittings such as hooks and links. Chains should be without twists or knots. The lifting point should be seated well down in a hook and the hook should be free to incline in any direction so as to avoid bending. For the same reason, the master link should be free to incline in any direction on the hook to which it is fitted.
The jaw-lifting tool must be inspected visually before every lift and more precisely at least once a year. See detailed instructions below. Inspections must be documented for own as well as authority audits. A damaged jaw-lifting tool must be replaced or repaired immediately. Special attention should be paid to the condition of the threads, welds and fasteners.
Straight leg In this case lower terminals are connected directly to the attachment points. Selection of hooks and attachment points should be such that the load is carried in the seat of the hook and tip loading of the hook is avoided.
The jaw-lifting tool should be clean enough to observe possible damages. Adequate lighting should be provided and the jaw-lifting tool should be examined throughout its length to detect any evidence of wear, distortion or external damage.
In order to prevent dangerous swaying of the load and to position it for loading, a tag line is recommended.
7. Handling the load Preparation Attention should be given to any specific instructions provided for the handling of the load. Before starting the lift, it should be ensured that the load is free to move and is not bolted down or otherwise obstructed.
When loads are accelerated or decelerated suddenly, high dynamic forces occur which increase the stresses in the chain. Such situations, which should be avoided, arise from snatch or shock loading e.g. from not taking up the slack chain before starting to lift or by the impact of arresting falling loads. Safety of lift
It is essential that the mass of the load to be lifted is known. If the mass is not marked the information should be obtained from the consignment notes, manuals, plans etc. If such information is not available the mass should be assessed by calculation.
Hands and other parts of the body should be kept away from the chain to prevent injury as the slack is taken up. When ready to lift, the slack should be taken up until the chain is taut. The load should be raised slightly and a check made that it is secure and assumes the position intended. This is especially important with basket or other loose hitches where friction retains the load.
Centre of gravity
Landing the load
The position of the centre of gravity of the load should be established in relation to the possible points of attachment of the chain sling. To lift the load without it tilting or toppling the following conditions should be met:
The landing site should be prepared. It should be ensured that the ground or floor is of adequate strength to take the weight taking account of any voids, ducts, pipes etc. which may be damaged or collapse. It should also be ensured that there is adequate access to the site and that it is clear of any unnecessary obstacles and people. It may be necessary to provide timber bearers or similar
Mass of the load
a. For two leg chain slings the attachment points should be either side of and above the centre of gravity.
A-2
JAW LIFTING TOOL
N11450704_K
EN
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 to conditions which affect their safety. It is necessary therefore to ensure, as far as is reasonably practicable, that the chain sling should be safe for continued use.
Figure 1
If the tag or label identifying the chain sling and its working load limit becomes detached and the necessary information is not marked on the master link itself, or by some other means, the jaw-lifting tool should be withdrawn from service.
e. Cuts, nicks, gouges, cracks, excessive corrosion, heat discoloration, bent or distorted links or any other defects. f. Check the condition of the pin in position 1 (see Figure 2) below. If the pin is worn by 10% (or more) of its original dimension, it must be replaced immediately.
The chain sling should be withdrawn from service and referred to a competent person for thorough examination if any of the following are observed: a. The chain sling markings are illegible, i.e. information on the chain sling identification and/or the working load limit. 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 the links or noticeable difference in the leg length of multi-leg chain slings, the chain may have been stretched. d. Wear by contact with other objects usually occurs on the outside of the straight portions of the links where it is easily seen and measured. Wear between adjoining links is hidden. The chain should be slack and adjoining links rotated to expose the inner end of each link. Inter-link wear, as measured by taking the diameter indicated ( d1) and one at right angles, (d2) may be tolerated until the mean of these diameters has been reduced to 90 % of the nominal diameter (dn) (see Figure 1) provided
d +d 2 1
EN
2
Figure 2
> 0.9d n
N11450704_K
JAW LIFTING TOOL
A-3
APPENDIX A
If any chain link within the leg of a chain sling is required to be replaced then the whole of the chain within that leg should be renewed.
Dimension L (4), measured between positions 2 and 3, must not exceed 10% of the value given in Table 2 below. If dimension L (4) exceeds 10% of the original value, the jaw-lifting tool must be replaced immediately. Lifting tool 582133 582151 585042
The repair of chain in a welded the jaw-lifting tool should only be carried out by the manufacturer using a resistance butt or flash butt welding process.
Check dimension L 382 +38 mm (15.04" +1.50") 367
+37 mm
395
+40 mm
(14.45"
Components that are cracked, visibly distorted or twisted, severely corroded or have deposits which cannot be removed should be discarded and replaced. Minor damage such as nicks and gouges may be removed by careful grinding or filing. The surface should blend smoothly into the adjacent material without abrupt change of section. The complete removal of the damage should not reduce the thickness of the section at that point to less than the manufacturers specified minimum dimensions or by more than 10 % of nominal thickness of the section.
+1.47")
(15.55” +1.57”)
Table 2 g. Check the condition of the locking mechanism (5). h. Lubricate the mechanism (6) with spray vaseline oil and turning the lever. i. Check the surfaces of the centre pin (7) and shoulder (8) visually.
A thorough examination should be carried out by a competent person at intervals not exceeding twelve months. This interval should be less where deemed necessary in the light of service conditions.
In the case of the jaw-lifting tool on which repair work has involved welding, each repaired chain sling should be proof tested following heat treatment using a force equivalent to twice the working load limit and thoroughly examined before it is returned to use. However, where repair is carried out by inserting a mechanically assembled component, proof-testing is not required providing that the component has already been tested by the manufacturer in accordance with the relevant European standard.
Records of such examinations should be maintained.
The accuracy of the tensile test equipment should be of class 2 as given in EN 10002-2.
j. The locking bolt (9) must be able to lock the lever during lifting. If worn or damaged replace the jaw-lifting tool immediately. Thorough examination
Chains slings should be thoroughly cleaned so as to be free from oil, dirt and rust prior to examination. Any cleaning method which does not damage the parent metal is acceptable. Methods to avoid are those using acids, overheating, removal of metal or movement of metal which may cover cracks or surface defects. Adequate lighting should be provided and the chain sling should be examined throughout its length to detect any evidence of wear, distortion or external damage. Repair Any replacement component or part of the chain sling should be in accordance with the appropriate European Standard for that component or part.
A-4
JAW LIFTING TOOL
9. Operating instructions WARNING! Before lifting any wear parts, check the weight of the component and ensure that the lifting equipment being used is adequate to lift the weight. a. Clean the lifting hole of jaw in order to insert the jaw-lifting tool in. Make sure that there is not any material in the jaw-lifting hole, as it may prevent jaw-lifting tool's locking mechanism to function properly.
N11450704_K
EN
APPENDIX A
b. Jaw-lifting holes can be kept clean by covering them with polyurethane. The polyurethane must withstand ambient temperatures and must be melted away with a torch prior to inserting the jaw-lifting tool. c. Turn the lever to the installation position so that the hinged tip of centre pin and the stationary part of the pin form a flush shape (Ref. Figure 2). The lever must remain locked in this position. d. Insert both hooks into the lifting holes and turn the levers 180 degrees in order to lock the pins to the jaw. The levers lock themselves to this position but as an additional safety precaution the locking mechanisms are secured by means of screwing in butterfly screws. e. Before beginning the hoist make sure that jaw is loose. f. Start the hoist slowly. If the jaw jams, stop lifting and unfasten jaw. g. Keep the hoisting zone free of people at all times. h. Never stand underneath a suspended load.
Figure 3 Lifting tool usage: A) Locked B) Unlocked
EN
N11450704_K
JAW LIFTING TOOL
A-5
APPENDIX A
This Page Left Intentionally Blank.
A-6
JAW LIFTING TOOL
N11450704_K
EN
B
APPENDIX
NORDBERG C-SERIES JAW CRUSHER'S CHEEK PLATE LIFTING TOOL SAFETY, OPERATING AND MAINTENANCE INSTRUCTIONS
Load the lifting tool evenly and carry out the lifting and displacement of the cheek plate carefully. Keep the lifting zone free of people during lifting. Do not use the cheek plate lifting tool in a hurry.
1. Purpose of the cheek plate lifting tool The cheek plate lifting tool that is provided with Nordberg C Series jaw crushers is intended for the lifting of genuine Metso Minerals Nordberg C Series wear parts (cheek plates) only. The cheek plate lifting tool is not designed nor tested for the lifting of other types of objects.
4. Commissioning and operating conditions The cheek plate lifting tool is supplied fully assembled and it is ready for immediate use. The cheek plate lifting tool can be used in the same operating conditions as the jaw crusher.
2. Storage of the cheek plate lifting tool When not in use the cheek plate lifting tool should normally be stored carefully away from damaging materials, such as dirt or sand. They should not be left lying on the ground where they may be damaged. If it is likely that the cheek plate lifting tool will be out of use for some time they should be cleaned, dried and protected from corrosion, e.g. lightly oiled. 3. Safe use WARNING! Before lifting any wear parts, check the weight of the component and ensure that the lifting equipment being used is adequate to lift the weight. Read all instructions concerning the cheek plate lifting tool carefully and make sure that the tool is inspected regularly. Prior to lifting, make sure that the cheek plate lifting tool is locked and does not come out of the lifting hole. The cheek plate lifting tool is only meant for the lifting of genuine Metso Minerals Nordberg C Series cheek plates. It is neither designed nor tested for unfastening used cheek plates that may not readily come loose prior to lifting. Do not overload the cheek plate lifting tool. The maximum lifting load is found on the tag of the cheek plate lifting tool (see Table 1). Stop the lifting procedure immediately if the cheek plate is stuck to its location.
EN
N11456138_K
CHEEK PLATE LIFTING TOOL B-1
APPENDIX B
5. Technical data The maximum lifting load is mentioned on the attached tag of the cheek plate lifting tool. Table 1 shows available lifting tools and the corresponding lifting hole sizes. Lifting tool MM0209800 MM0209814
Maximum lifting load (Working load limit, WLL) 1000 kg (2204 lbs) 500 kg (1102 lbs)
Diameter of lifting hole 80 mm (3.1”) 40 mm (1.6”)
Table 1 The cheek plate lifting tool should be clean enough to observe possible damages.
6. The cheek plate lifting tool verification before first use and in service
Adequate lighting should be provided and the cheek plate lifting tool should be examined throughout its length to detect any evidence of wear, distortion, or external damage.
Before first use Before first use of the cheek plate lifting tool it should be ensured that: a. the cheek plate lifting tool is precisely as ordered;
7. Handling the load Preparation
b. the manufacturer's certificate is at hand; c. the identification and working load limit marking on the cheek plate lifting tool correspond to the information on the certificate;
Attention should be given to any specific instructions provided for the handling of the load. Before starting the lift, it should be ensured that the load is free to move and is not bolted down or otherwise obstructed.
d. full details of the cheek plate lifting tool are recorded.
Mass of the load It is essential that the mass of the load to be lifted is known. If the mass is not marked, the information should be obtained from the consignment notes, manuals, plans, etc. If such information is not available, the mass should be assessed by calculation.
Before each use Before each use the cheek plate lifting tool should be inspected for obvious damage or deterioration (see paragraph 8 Maintenance / Inspection). If faults are found during this inspection, the procedure given in paragraph 8 Maintenance should be followed.
Centre of gravity
The cheek plate lifting tool must be inspected visually before every lift and more precisely at least once a year. See detailed instructions below. Inspections must be documented for own as well as authority audits. A damaged cheek plate lifting tool must be replaced or repaired immediately. Special attention should be paid to the condition of the threads, welds, and fasteners.
B-2
CHEEK PLATE LIFTING TOOL
The position of the centre of gravity of the load should be established in relation to the possible points of attachment of the chain sling. To lift the load without tilting or toppling it, the following conditions should be met: a. For two leg chain slings the attachment points should be on either side of and above the centre of gravity. b. The hook to which the cheek plate lifting tool is attached should be directly above the centre of gravity.
N11456138_K
EN
APPENDIX B
Method of connection The cheek plate lifting tool is attached to the load and the lifting machine by means of terminal fittings such as hooks and links. Chains should not have any twists or knots. The lifting point should be seated well in the hook and the hook should be free to incline in any direction to avoid bending. For the same reason, the master link should be free to incline in any direction on the hook to which it is fitted. Straight leg
8. Maintenance Inspection During service, the cheek plate lifting tool is subjected to conditions which affect their safety. It is necessary therefore to ensure, as far as is reasonably practicable, that the chain sling should be safe for continued use. If the tag or label identifying the chain sling and its working load limit becomes detached and the necessary information is not marked on the master link itself, or by some other means, the cheek plate lifting tool should be withdrawn from service.
In this case the lower terminals are connected directly to the attachment points. The hooks and attachment points should be selected so that the load is carried in the seat of the hook and tip loading of the hook is avoided.
The chain sling should be withdrawn from service and referred to a competent person for thorough examination if any of the following are observed:
In order to prevent dangerous swaying of the load and to position it for loading, a tag line is recommended.
a. The chain sling markings (information on the chain sling identification and/or the working load limit) are illegible.
When loads are accelerated or decelerated suddenly, high dynamic forces occur that increase the stresses in the chain. Such situations, which should be avoided, arise from snatch or shock loading, e.g. from not taking up the slack chain before starting to lift or by the impact of stopping falling loads.
b. Distortion of the upper or lower terminals. c. Chain stretch.
Safety of lift Hands and other parts of the body should be kept away from the chain to prevent injury as the slack is taken up. When ready to lift, the slack should be taken up until the chain is taut. The load should be raised slightly and a check made that it is secure and assumes the position intended. This is especially important with basket or other loose hitches where friction retains the load. Landing the load The landing site should be prepared. It should be ensured that the ground or floor is of adequate strength to take the weight taking into account any voids, ducts, pipes, etc. which may be damaged or collapse. It should also be ensured that there is adequate access to the site and that it is clear of any unnecessary obstacles and people. It may be necessary to provide timber bearers or similar material to avoid trapping the chain sling or to
EN
protect the floor or load or to ensure the stability of the load when landed.
If the chain links are elongated or if there is any lack of free articulation between the links or noticeable difference in the leg length of multi-leg chain slings, the chain may have been stretched. d. Wear by contact with other objects usually occurs on the outside of the straight portions of the links where it is easily seen and measured. Wear between adjoining links is hidden. The chain should be slack and adjoining links rotated to expose the inner end of each link. Inter-link wear, as measured by taking the diameter indicated (d1) and one at right angles, (d2) may be tolerated until the mean of these diameters has been reduced to 90 % of the nominal diameter (dn) provided. (see Figure 1)
N11456138_K
d +d 2 1
2
> 0.9d n
CHEEK PLATE LIFTING TOOL
B-3
APPENDIX B
e. Cuts, nicks, gouges, cracks, excessive corrosion, heat discoloration, bent or distorted links or any other defects. f. Check the condition of the pin in position 1 (see Figure 2). If the pin is worn by 10% (or more) of its original dimension (MM0209800 = 10 mm, 0.39"; MM0209814 = 8 mm, 0.31”), it must be replaced immediately. Figure 1
Figure 2
Dimension L (4), measured between positions 2 and 3, must be within the values given in Table 2. If dimension L (4) is outside of the values given in the table, the cheek plate lifting tool must be replaced immediately.
B-4
CHEEK PLATE LIFTING TOOL
Lifting tool MM0209800 MM0209814
Min. length L 210 mm (8.3”) 182 mm (7.2”)
Max. length L 250 mm (9.8”) 222 mm (8.7”)
Table 2
N11456138_K
EN
APPENDIX B
the thickness of the section at that point to less than the manufacturer’s specified minimum dimensions or by more than 10 % of nominal thickness of the section.
g. Check the condition of the locking mechanism (8). h. Lubricate the mechanism (7) with spray vaseline oil and turning the lever. i. Check the surfaces of the centre pin (5) and shoulder (6) visually. j. The locking bolt must be able to lock the lever during lifting. If worn or damaged replace the cheek plate lifting tool immediately. Thorough examination A thorough examination should be carried out by a competent person at intervals not exceeding twelve months. This interval should be less where deemed necessary in the light of service conditions.
If the repair work of the cheek plate lifting tool has involved welding, each repaired chain sling should be proof-tested following heat treatment using a force equivalent to twice the working load limit, and thoroughly examined before it is returned to use. However, where repair is carried out by inserting a mechanically assembled component, proof-testing is not required providing that the component has already been tested by the manufacturer in accordance with the relevant European standard. The accuracy of the tensile test equipment should be of class 2 as given in EN 10002-2.
Records of such examinations should be maintained. Chains slings should be thoroughly cleaned so as to be free from oil, dirt and rust prior to examination. Any cleaning method which does not damage the parent metal is acceptable. Methods to avoid are those using acids, overheating, removal of metal, or movement of metal which may cover cracks or surface defects. Adequate lighting should be provided and the chain sling should be examined throughout its length to detect any evidence of wear, distortion or external damage. Repair Any replacement component or part of the chain sling should be in accordance with the appropriate European Standard for that component or part. If any chain link within the leg of a chain sling has to be replaced then the whole of the chain within that leg should be renewed. Any chain repairs that require welding should only be carried out by the manufacturer using a resistance butt or flash butt welding process. Components that are cracked, visibly distorted or twisted, severely corroded, or have deposits which cannot be removed should be discarded and replaced. Minor damage such as nicks and gouges may be removed by careful grinding or filing. The surface should blend smoothly into the adjacent material without abrupt change of section. The complete removal of the damage should not reduce
EN
9. Operating instructions WARNING! Before lifting any wear parts, check the weight of the component and ensure that the lifting equipment being used is adequate to lift the weight. a. Clean the lifting hole of the cheek plate in order to insert the cheek plate lifting tool. Make sure that there is no material in the cheek plate lifting hole, as it may prevent the cheek plate lifting tool's locking mechanism from functioning properly. b. Cheek plate lifting holes can be kept clean by covering them with polyurethane. The polyurethane must withstand ambient temperatures and must be melted away with a torch prior to inserting the cheek plate lifting tool. c. Turn the lever to the installation position so that the hinged tip of the centre pin and the stationary part of the pin form a flush shape (Ref. Figure 2). The lever must remain locked in this position. d. Insert the hook into the lifting hole and turn the lever 180 degrees in order to lock the pins to the jaw. The lever locks
N11456138_K
CHEEK PLATE LIFTING TOOL
B-5
APPENDIX B
to this position but as an additional safety precaution the locking mechanism is secured with a butterfly screw. e. Before beginning the hoist make sure that the cheek plate is loose. f. Start the hoist slowly. If the cheek plate jams, stop the lifting and unfasten the cheek plate. g. Keep the hoisting zone free of people at all times. h. Never stand underneath a suspended load.
B-6
CHEEK PLATE LIFTING TOOL
N11456138_K
EN
APPENDIX B
This Page Left Intentionally Blank.
EN
N11456138_K
CHEEK PLATE LIFTING TOOL
B-7
7.9LEUDWLQJFKXWHV DQGVFUHHQV Instruction manual 140401
0HWVR0LQHUDOV
Instruction manual
Vibrating chutes
9LEUDWLQJFKXWHV This instruction manual is valid for vibrating chutes manufactured by Nordberg-Lokomo Oy.
Because of the continuous development of the product, the manufacturer reserves a right to alter the technical specifications written in this manual, without any advance information. This is the second edition published in may 1999 in Tampere, Finland.
Manufacturer: Metso Minerals (Tampere) OY PL 306 33101 Tampere Finland Tel. +358-204 84 142 Fax. +358-204 84 143
6/99
Instruction manual
Vibrating Chutes
9LEUDWLQJ&KXWHV TABLE OF CONTENTS 1.
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WARNING SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTENDED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTRUCTION MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE AND REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OTHER SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1 2-1 2-1 2-1 2-2 2-3 2-3 2-4 2-6
3. 3.1 3.2 3.3 3.4 3.5 3.6
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Used terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nordberg vibrating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Uses of Nordberg vibrating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Principle of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare and ware parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1 3-1 3-1 3-2 3-2 3-3 3-4
4. 4.1 4.2 4.3 4.4 4.5 4.6
INSTALLATION, OPERATION AND TRANSPORT. . . . . . . . . . . . . . . . . . . . Foundation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting a hydraulic drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1 4-1 4-2 4-2 4-2 4-3 4-3
5. 5.1 5.2 5.3 5.4 5.5
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring the stroke and the stroke angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1 5-1 5-1 5-1 5-1 5-2
6. 6.1
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Vibrating motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
7. 7.1 7.2 7.3
PERIODICAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Every three months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6/99
140401
7-1 7-1 7-1 7-1
Vibrating Chutes
Instruction manual
8. 8.1 8.2
OTHER MAINTENANCE ACTIVITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Pre-tightening of screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Changing of grizzly cassettes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
9.
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
140401
6/99
Preface
35()$&( This instruction manual is intended to assist owners and users of Nordberg products in the proper use of the equipment.
This instruction manual must be read and used by each person who works with the equipment, typically:
It includes important references to safe, proper and economical operation of the equipment. Following these instructions will help to avoid possible danger, reduce repair costs and breakdowns and to increase the reliability and life of the equipment.
— operations, including installation, startup, operation, application engineering, materials handling, site labour, environmental engineering and safety departments. — maintenance, including inspection and repair. — transport, materials handling and rigging.
This manual must be complemented by those instructions necessary because of existing national mandatory rules relating to accident prevention and environmental protection. A copy of this manual must be kept at the equipment’s location and made available to the operators as required. In addition to this manual and accident prevention regulations mandatory in the country of use and at the equipment’s place of operation, generally recognized rules for safe and professional operation must be observed.
Note that this instruction manual contains information and instructions on alternative and optional equipment. Normally the machines have only some of them. Before maintaining and servicing, find out which alternative and optional equipment your machine has. See separate instruction manuals for more detailed instructions when servicing the main components. There may be optional equipment which have separate instruction manuals. Those manuals must be read and used by each person who works with the equipment.
1/95
1-00-B
1-1
SAFETY
SECTION
2
Please refer to the general Safety Instructions in Part A of this Instruction Manual folder.
02/05
2-00-EN
SAFETY
2-1
SECTION 2 - SAFETY
This Page Left Intentionally Blank.
2-2
SAFETY
2-00-EN
02/05
General
Vibrating Chutes
*(1(5$/ The operation manual deals with vibrating TK feeders and screens. Henceforth these will be generally called vibrating devices.
3.1 Used terms — Capacity = Transport ability of vibrator in tons per hour. — Sorting capacity = Sorting ability of vibrator in tons per hour. — Feeding end (F) = The end of the vibrator, where material is fed into. — Discharge end (D) = The end of the vibrator, where material is discharged from. — Vibrator = The mechanism in the vibrating device that makes the device vibrate. — Grizzly (G) = Grating structure in the vibrating device that separates the fine matter from the fed material. — Screen deck = Cloth structure in vibrating device that sorts the fed material into fractions. — Stroke length = Distance between vibration motion extreme positions of vibrating device. — Stroke angle = Direction of stroke movement in relation to horizontal.
3.2 Nordberg vibrating devices The Nordberg vibrating devices have either a closed bottom, or a screen deck and one or more grizzlies. There are different sizes of vibrating devices for various uses. The vibrating devices have either a direct squirrel-cage motor drive or a regulating drive with a frequency converter, some vibrating device types have a hydraulic drive. Grizzlies and screen cloths are available for different uses and they can be changed.
FIGURE 3.1.1 Terms used in the operation manual
7/00
140401
3-1
Vibrating Chutes
General
3.3 Uses of Nordberg vibrating devices The vibrating devices manufactured by Metso Minerals are used for feeding, transport and sorting of stone material, concrete and asphalt. 3.4 Principle of operation The body is supported on its base by springs, which the body vibrates on. Material is fed into the feeding end of the vibrating device and it is discharged from its discharge end.
The stroke angle of interconnected shafts is defined by the reciprocal position of the shafts and the position of the vibrator. The vibrating device can have a grizzly or a screen deck that lets the fine grain sizes through. The capacity (feeding efficiency) is regulated by altering the eccentric masses of the vibrator. The capacity can also be regulated by changing the speed of rotation of the vibrator by means of an optional frequency converter or a hydraulic drive, if needed.
Two identical rotating mechanisms revolving in opposite directions provide a rectilinear stroke movement. The material on the vibrating device moves due to the fact that the vertical movement of the base is quicker than that produced by the gravitational pull. Therefor the material comes off the bottom, continuing its movement in the direction of the movement of the moment of the base. The stroke angle of free synchronizing shafts is defined by the center of gravity and the position of the vibrator.
TYPE MARKING
TK 13 - 20 - 3V Vibrator Body width (dm) Body length (dm)
No marks = closed bottom S = with screen deck 2V = two stage grizzly 3V = three stage grizzly
FIGURE 3.2.1 Type marking of vibrating chutes
3-2
140401
7/00
General
Vibrating Chutes
3.5 Spare and ware parts Nordberg produces, with the same type marking, vibrating devices that differ from each other. In order to secure the right information concerning each vibrating device, the part number related to the device in question should always be quoted. The original Nordberg parts have precise measures and they are made out of the most appropriate material. Original parts make certain that your device works impeccably and they maintain the guarantee. The original Nordberg parts signify savings in your overall costs: — The parts are tested in practice — You can avail of the newest development changes at once — No sudden breakages — Reliable quick deliveries — All parts with one order — Parts also for older types
In order for the ordering of spare parts to be as quick and easy as possible, the order must include the following information: — Device type, part number and production number — Order number, title and amount of parts to be ordered — Official name and complete address of firm that pays the invoice — Precise delivery instructions, way of delivery and address If the original spare parts book has been lost, you can order a new one from Nordberg.
8VHRQO\ RULJLQDO 1RUGEHUJ VSDUHDQG ZHDULQJ SDUWV
7/00
140401
3-3
Vibrating Chutes
General
3.6 Optional equipment Grizzlies
Screen cloths
The grizzlies can be changed and there is a choice of different types of grizzlies with different grizzly openings.
The cloth can be changed and there are cloths with different hole size.
There are three different types of grizzlies in figure 3.6.1. On the left is a plate grizzly, in the middle a rod grizzly and on the right a bar grizzly. Measure G is the grizzly opening at the end, which is mainly used to identify the grizzlies. The choice of the grizzly depends on the feed to be used and the required sorting limit, among others. Contact a Nordberg specialist when you want to choose a grizzly.
The choice of the cloth depends on the feed to be used, the required sorting limit and the purity requirements of the fractions, among others. Contact a Nordberg specialist when you want to choose a screen cloth. The tightening of the screen cloth is done with tightening bars, hook screws and wedges. The tension of the screen cloth always depends on the cloth properties. The biggest recommended cloth screen hole size is 50-60 mm.
Figure 3.6.1 Different kinds of grizzlies.
3-4
140401
7/00
Installation
Vibrating Chutes
,167$//$7,2123(5$7,21 $1'75$163257 4.1 Foundation The vibrating device is mounted on springs, and the spring fixing plates are installed onto a firm foundation. The mounting surfaces for the fixing plates have to be horizontal. Vertical springs have to be in vertical position. If the upper spring support is adjustable, verify that it is parallel to the lower fixing plate. See if the springs on both sides are compressed an equal amount, you will notice the distortion of the base from the compression. Spacer plates can be used underneath the fixing plates, if needed.
stroke movement of the vibrating device becomes vague decreasing the output. Observe that you also have to pay attention to the horizontal rigidity of the base. The support forces of the vibrating device can be found in the information related to each type. No undue parts may be fixed onto the body of the vibrating device, e.g. feeding funnels, chutes, etc. These have to be fixed onto their own support structures, apart from the vibrating device.
Figure 4.1.1 Straightness requirements of the vibrating device foundation Figure 4.1.1 shows the straightness requirements for the foundation. The spring bases of the vibrating device have to be on the same level with each other up to a precision of 10 mm. The supporting structures have to be placed directly below the springs. Verify that the lower structures of the vibrating device are not elastic. If the lower structure is elastic, the
2/99
If extra masses are fixed onto the body, the center of gravity moves downward and the body movement becomes uneven. Besides, feeding output decreases due to the increase in weight. — sideways15 mm — lengthwise30 mm — vertical direction50 mm
140401
4-1
Vibrating Chutes
Installation
The vibrating device should be installed in such a way that the distances between the vibrating device and other structures (e.g. supporting structures, funnels, chutes, silos), when loaded, are at least as follows. This relatively large free space between the body and other structures is needed for the momentary irregular swinging motion when starting and stopping the device. Eventual beams under the body have to be installed in such a way that the material that gathers on top of them does not touch the body. Correspondingly, the fixing points of the springs have to be such that there is no possibility for sufficient material to gather near to them as to cover the springs and damage them. If the body hits the funnel, or another fixed structure, when the vibrating device is running, loading increases to a multiple of the designed loading, leading to a device failure. The discharge opening of the funnel that feeds material onto the vibrating feeder may not be essentially smaller than the body width. This way the whole transversal area of the body can be utilized. Nevertheless, movement gaps of the previously mentioned size have to be left between the body side plate and the side of the funnel. The sides may not extend too far down into the body in order for fed material not to get squeezed between the lower edge of the funnel and the bottom of the vibrating device. The sides have to reach, however, to at least 70 mm below the top edge of the vibrating device body. Chains or a hatch may be used to conduct the material flow discharging from the feeding funnel onto the vibrating device. The hatch may not extend too near to the bottom of the vibrating device. Especially in connection with vibrating devices with a closed bottom, the feeding funnel discharge opening has to be designed and placed in such a way that material cannot have a free flow over the discharge end when the vibrating device is not running. When designing feeding funnels, it has to be observed that the pressure caused by material
4-2
does not exceed the maximum allowable value of the vibrating device (see specifications, chapter ASupport loads and AMinimum measure of springs, loaded). The design of the feeding funnel has to be such that it carries part of the feed mass. When installing funnels, channels or other structures near to the feeder body, the gaps between the structures have to be guarded according to safety regulations of the country of operation (e.g. EN 294).
4.2 Service level There has to be a service level around the vibrating device in order to make maintenance and operation easy. If the service level has not been ordered and delivered together with the device, it has to be built by the user. The service platform of crushing equipment has to comply with the safety regulations valid in the country of operation. All instructions on crushing equipment service levels in force in the country of operation of the vibrating device must observed.
4.3 Transport During transport, the vibrating device must be firmly fixed onto the trailer. Most vibrating chute types have transport supports designed for this purpose. Turn the device into the most appropriate position according to the way of transport (e.g. vibrators upwards and the body downwards).
4.4 Welding The body and other parts of the vibrating device may not be welded without the consent of the manufacturer.
140401
2/99
Installation
Vibrating Chutes
4.5 Electrification It has to be noted that the separate vibrators of electrically driven vibrating devices have to be connected to turn in opposite directions. Safety regulations of the country of operation of the vibrating device have to be observed in electrification. When the operation frequency of the device changes, the vibrators’ regulating values have to be set to correspond to the new frequency. Especially when connecting a spare part vibrator, the regulating values have to be checked. The regulating values can be found in the specification annex.
4.6 Connecting a hydraulic drive It has to be observed that the separate vibrators in hydraulically operated vibrating feeders must be connected to turn in opposite directions.
2/99
140401
4-3
Operation
Vibrating Chutes
23(5$7,21 5.1 Before starting
5.4 Operation
NOTE! Remove eventual transport supports and inspect the device as indicated in point 7.1.
Do not drop big stones into an empty vibrating device, the bottom might get damaged. Try to keep material on the bottom of the device in order to soften the blows of falling big stones. Stones may not be dropped onto the grizzly of the vibrating device. Stones stuck into grizzly openings must be removed in order not to damage the grizzly.
Make sure that the electric connections are properly done and that the cables etc. are in condition of operation. Operate the device only when all necessary safety devices are installed (e.g. covers, emergency stop devices, etc.) and they are in condition of operation.
Material should be fed correctly onto the vibrating device, this conserves the device and gives it a longer service life.
Make sure before starting the device that startup puts nobody in danger. Walk around the device and make sure that nobody is on top of, beside or under it. Warn those in the vicinity before starting.
Check at least once during a shift, as indicated in point 7.1, that the device works properly and for possible failures. Report changes (also in the operation of the device) immediately to the person responsible at the job-site. The device has to be stopped and safety measures have to be taken, if needed.
5.2 Starting When starting the process, the devices removing material from the vibrating feeder have to be started before starting the vibrating device, and the feeding devices after the vibrating device.
Do not climb onto the device when it is running. Also, do not touch moving parts on the device when it is running. When the device is running, do not approach it so much that feed material may pose a risk.
Make sure that in a vibrating device with two vibrators, both vibrators start. Using the vibrating device only with one vibrator (e.g. in a failure situation) leads quickly body damage.
5.3 Stopping The vibrating device and the peripheral devices are stopped in the opposite sequence in respect to starting.
2/99
140401
5-1
Vibrating Chutes
Operation
5.5 Measuring the stroke and the stroke angle There are stickers on the device, where the stroke and stroke angle can be read on during operation. There are black circles of a diameter of 1...20 mm on the sticker. The difference between the diameters is one millimeter. When the body vibrates, the eye perceives two circle rows underneath each other. The stroke is indicated by the circles below each other that are tangent to each other. The diameter of the circle concerned is the stroke. In order to help the determination of the diameter, there is a circular ring in the circles of 5, 10, 15 and 20 mm.
In order to determine the stroke angle, there is a dot in the sticker and lines at 15° intervals. The line, the direction of which the dot seems to move, determines the stroke angle. If the dot moves between the lines, the stroke angle can be estimated according to the nearest lines. In the example of figure 5.5.2 the stroke is 13 mm and the stroke angle is 55°.
FIGURE 5.5.1 Sticker that is to be used when defining the stroke and stroke angle
FIGURE 5.5.2 The stroke of the feeder in the figure example is 13 mm and the stroke angle 55°
5-2
140401
2/99
Lubrication
Vibrating Chutes
/8%5,&$7,21 6.1 Vibrating motor The instructions for vibrator lubrication are in a separate vibrator operation instruction. NOTE! Excessive lubrication may damage the bearings and other parts of the device.
7/00
140401
6-1
Periodical maintenance
Vibrating Chutes
3(5,2',&$/0$,17(1$1&( 7.1 Daily
7.2 Monthly
Check all safety devices and that they work properly. Repair revealed faults at once.
Check that nothing touches the moving body (sufficient free space around)
Check the state and fixing of wearing parts, change or tighten them if needed. If there is a screen cloth in the device, its tension has to be regularly checked. Check the electric devices, especially the connection and condition of the cables leading into the vibrators. Listen to the sound of the vibrating device. The cause of all extraordinary sounds has to be determined.
7.3 Every three months Check the condition of the vibrating device. All screws, nuts and connections have to be checked and tightened, if needed, in order to avoid damages. See pretightening torque of screws in chapter 8.1 "Pretightening of screws". Check the springs (wear, corrosion, breaks, protections).
2/99
140401
7-1
Other maintenance
Vibrating Chutes
27+(50$,17(1$1&( $&7,9,7,(6 8.1 Pre-tightening of screws
8.2 Changing of grizzly cassettes
The torques in the table have to be used to tighten all screws. In order to achieve the right pre-tightening tension in the screws, the threads have to be clean, dry and zink-plated.
When ordering a grizzly, make sure that it suits the vibrating feeder and the application in question.
The tightening instructions of the vibrator fixing screws are in the vibrator operator’s manual.
Special attention has to be paid to safety at work when changing the grizzly (see chapter 2). The working levels have to be sturdy and the lifting devices appropriate for the purpose. The lifting ropes have to be fixed properly. When lifting, nobody may be underneath the load to be lifted or too near to it.
Torque
Screw M 10
47 Nm
4,8 kpm
35 ft lbs
M 12
81 Nm
8,3 kpm
60 ft lbs
M 14
129 Nm
13 kpm
95 ft lbs
M 16
196 Nm
20 kpm
145 ft lbs
M 18
270 Nm
27 kpm
199 ft lbs
M 20
382 Nm
39 kpm
281 ft lbs
M 22
519 Nm
53 kpm
383 ft lbs
M 24
662 Nm
67 kpm
488 ft lbs
M 27
975 Nm
99 kpm
719 ft lbs
M 30
1320 Nm
135 kpm
973 ft lbs
2/99
The tightening torques of the screws are explained in the previous point.
The grizzlies are described more in detail in the Specifiactions annex.
140401
8-1
Troubleshooting
Vibrating Chutes
7528%/(6+227,1* In spite of careful operation of the vibrating device according to instructions, as well as of careful quality control in the production of the vibrating device, different failures may turn up in the vibrating device and the process associated with it.
The following presents some possible failures and their corrective procedures. FAILURE
CAUSE
Small feeding capacity.
Feeding funnel or discharge opening too small and they vault.
Uneven vibration.
2/99
PROCEDURE
Body touches fixed structure or material.
Change structures so that body has sufficient swinging room. (point 4.1)Design structures so that no material can gather on top of them.
Feed material is wet or unclean.
Choose feed again or prepare it to be suitable, e.g. by mixing.
Grain size of feed is too big and it vaults.
Reduce grain size of feed.
Wrong vibrator speed of rotation.
Check vibrator control circuit and speed of rotation.
Uneven vibration
See following point.
Material in feeding funnel weighs too much on the vibrating device.
Change structure of funnel.
The strokes at the different ends of the body are remarkably unequal in size.
Contact Nordberg specialist.
Wrong stroke angle.
Contact Nordberg specialist.
Lower structure of vibrating device or ground gives in.
Reinforce structure and place better foundation under support structures.
Extra structures have been fixed onto the body.
Remove extra structures from body and fix them on other structures.
Material has stuck onto the body.
Remove stuck material.
Broken springs.
Replace them with new springs.
140401
9-1
Vibrating Chutes
Troubleshooting
FAILURE
CAUSE
PROCEDURE
Vibrating device vibrates sideways
Only one vibrator works.
Device may not be operated with only one of the vibrators working. Contact Nordberg specialist.
Both vibrators turn in same direction.
Check vibrator control circuit.
Operation base gives in.
Make better foundations according to manufacturer’s instructions.
Loose screws in body.
Tighten screws.
Body touches other structures.
Verify that spacings are according to chapter 4. point 1.
Air does not circulate enough around vibrator.
Improve air circulation.
Insufficient lubrication in bearings.
Lubricate bearings.
Too much grease in bearings.
Stop device, let it cool down and start again.
Grease has become stiff due to cold weather.
Warm the vibrator.
Fault in vibrator control circuit.
Check vibrator control circuit.
Too high speed of rotation of hydraulic driven vibrator.
Only one vibrator is working.
Device may not be operated with only one of the vibrators working. Contact Nordberg specialist.
Hydraulic oil leaks from hydraulic vibrator.
Shaft packing of hydraulic motor leaks.
Contact Nordberg specialist.
The body clatters.
Vibrator becomes too hot.
Vibrators will not start.
9-2
140401
2/99
Instruction manual, V150 hydraulic drive
APPENDIX
2
Terms used
General instructions
Fixed side = the side of the fixed bearing, A side
The cooling openings on the sides of the vibrator must not be covered. Covering the openings prevents air from circulating and can cause the bearings to overheat. The cooling openings are shown in the figure 946893 (marked with number 1). Also, avoid covering the slots on the circle of the vibrator.
Free side = the side of the moving bearing, B side Drive axle = the axle containing the drive motor Driven axle = the axle being rotated via the gear assembly Half = the frame is made of two, identical halves
The tightness of the fixation screws of the vibrator (shown in the figure 946893, marked with number 2) must be checked in connection with other maintenance operations of the device. One indication of loose screws is a rusty streak coming from the screw joints. The loose screws must be re-tightened at the torque of 662 Nm. The frame of the vibrator is made of ball graphite cast iron which must not be subjected to physical force. This is especially important in cold weather.
946895
10/00
V150 HYDRAULIC DRIVE
INSTRUCTION MANUAL
2-1
APPENDIX 2 - INSTRUCTION MANUAL, V150 HYDRAULIC DRIVE
Checking the oil level and changing the oil The oil level is checked by opening the cap shown in figure 946894 (7) while the machinery is in the angle of 45 degrees. Some oil should drip from the cap. The oil level indication is reliable when the machinery has been stopped for at least 30 minutes. The oil is changed for the first time at 200 running hours. In the future, oil must be changed every 1,000 running hours and at least twice a year. For oil change, drain the machinery of oil by opening the cap (2) in figure 946894 while the machinery is in operational position. Oil is filled through either of the two caps (3). The recommended oil volume is 4 litres (allowable range is 3.5 to 4.5 litres, this corresponds to oil level of the cap (1) with the angle of 42.5º to 47.5º). Absolute cleanliness is imperative when changing the oil. Recommended oil qualities: For summer use (temperature above -10 ºC): Manufacturer BP ESSO FINA MOBIL NESTE SHELL TEBOIL TEXACO
2-2
INSTRUCTION MANUAL
Oil Energol GR-XP 150 Spartan EP 150 Giran 150 Mobilgear 629 Vaihteisto 150 EP Omala Oil 150 Pressure Oil 150 Meropa Lubricant 150
For winter use and for cold conditions (temperature below -10°C): Manufacturer BP ESSO FINA MOBIL NESTE SHELL TEBOIL TEXACO
Oil Energol GR-XP 100 Spartan EP 100 Giran 100 Mobilgear 627 Vaihteisto 100 EP Omala Oil 100 Pressure Oil 100 Meropa Lubricant 100
The recommended temperature of use with oil is -30 to 95 ºC. NOTE: The above recommendations are for reference only. To ensure the optimal lubrication efficiency for the bearings, the viscosity of the oil has to be 30 to 40 cST in the temperature of use. An adhesive label with more details is attached on the side of the machinery. The label has space for the first few oil change dates.
V150 HYDRAULIC DRIVE
10/00
APPENDIX 2 - INSTRUCTION MANUAL, V150 HYDRAULIC DRIVE
Breather A blocked breather causes the internal pressure of the machinery to rise which causes increased wear of the seals and leads to oil leaks. If the feeder is turned (during transportation) so that oil can travel to the breather, the breather should be removed and the connection should be closed using the cap in the aluminium cover. The breather is screwed in to replace the cap. Make sure no dust or dirt enters the connection threads and the oil cavity. When the machinery is taken into use, the breather is reinstalled in the operational position and the cap is reinstalled in the cover. The breather MUST be in operational position whenever the device is in use. Pay special attention to making sure that the cup spacer (shown with number 1 in figure 946894) is always installed correctly. The breather must always be replaced in connection with changing the oil (see above).
946894
10/00
V150 HYDRAULIC DRIVE
INSTRUCTION MANUAL
2-3
APPENDIX 2 - INSTRUCTION MANUAL, V150 HYDRAULIC DRIVE
Adjusting the angle of stroke Adjusting the angle of stroke influences the flow speed of material and the accuracy of the grizzling operation. See the table below Change in the Flow speed of angle of stroke material Raising Lowering
Slower Faster
Accuracy of the grizzling operation Better Worse
The angle of stroke is adjusted as indicated in figure 946895. Both the aluminium covers must be removed to adjust the angle of stroke. 1. Open the retaining screw (1) of the weight. Loosen the tightening screw (3, 4) of the driven axle. Consequently, loosen the screw (2) at the end of the axle. Beware of rotating axles when loosening the weights.
2. Position the weight as desired using the retaining screw (1). Both sides must be positioned the same way, and symmetrically in relation to the centre line of the feeder. 3. Tighten the weight axially using the screw (2) at the end of the axle at the torque of 196 Nm (20.0 kpm). Use Loctite 270 to lock the screw. 4. Tighten the tightening screw (3, 4) of the weight, and use Loctite 270 to lock. 5. Finally, check that the tightness of the retaining screw is 24 Nm (2.4 kpm). Use Loctite 270 to lock. 6. Install the aluminium covers and the hydraulic motor. NOTE: The vibrator must not be used without the aluminium covers due to risk of accidents! Instead of Loctite 270, the screws can be locked using similar products from other manufacturers.
946895
2-4
INSTRUCTION MANUAL
V150 HYDRAULIC DRIVE
10/00
APPENDIX 2 - INSTRUCTION MANUAL, V150 HYDRAULIC DRIVE
Replacing the seal Instructions for changing the seal in the fixed side (the side indicated in the figure) of the drive axle (the axle with the drive motor):
1. Open the vibrator cover (1).
1. Open the vibrator cover (1). 2. Loosen the screws (2) of the weight. Refer to section "Adjusting the angle of stroke". Beware of rotating axles when loosening the weight. 3. Open screw (3) and remove the flange (4) and the coupling half (5). The coupling half can be heated to max. 100ºC to facilitate removal. 4. Remove the weight (6) and pull the sleeve off together with the O rings (7). 5. Replace the seal (8). The detailed pictures T and U indicate the correct position of the seal and the sleeve. Make sure that the spacer ring (17) is placed in between the bearing and the sleeve (7) on the fixed side. 6. Reinstall the sleeve (7). 7. Reposition the weight (6) using the retaining screw. 8. Reinstall the coupling half (5) and the flange (4). 9. Tighten the weight axially using the screw (3) at the end of the axle at the torque of 196 Nm (20.0 kpm). Use Loctite 270 to lock the screw. 10. Tighten the tightening screw of the weight (2). Use Loctite 270 to lock. 11. Finally, check that the tightness of the retaining screw is 24 Nm (2.4 kpm). Use Loctite 270 to lock. 12. Reinstall the vibrator cover (1).
10/00
The seal on the free side of the drive axle is changed similarly. The procedure with the driven axle (the axle being rotated by the drive axle via the gear assembly): 2. Loosen the screws (11). 3. Open screw (9) and remove the flange (10). 4. Remove the weight (12) and the sleeve (13). 5. Pull the sleeve out together with the O rings (14). 6. Replace the seal (15). The detailed pictures T and U indicate the correct position of the seal. 7. Reinstall the sleeves (14 and 13). 8. Reposition the weight (12) using the retaining screw. 9. Reinstall the flange (10). 10. Tighten axially using the screw (9) at the end of the axle at the torque of 196 Nm (20.0 kpm). Use Loctite 270 to lock the screw. 11. Tighten the tightening screw of the weight (11). Use Loctite 270 to lock. 12. Finally, check that the tightness of the retaining screw is 24 Nm (2.4 kpm). Use Loctite 270 to lock. 13. Reinstall the vibrator cover (1). Fluorocarbon seals (e.g. VITON etc.) may leak when cold. This is a normal phenomenon and does not necessitate any corrective actions. If the axle is corroded at the location of the O ring (7) of the sleeve or in the countersurface of the lip seal, the sleeve can be turned so that the O ring meets a non-corroded spot of the axle and the lip surface gets a new countersurface.
V150 HYDRAULIC DRIVE
INSTRUCTION MANUAL
2-5
APPENDIX 2 - INSTRUCTION MANUAL, V150 HYDRAULIC DRIVE
2-6
INSTRUCTION MANUAL
V150 HYDRAULIC DRIVE
10/00
APPENDIX 2 - INSTRUCTION MANUAL, V150 HYDRAULIC DRIVE
2.1 Hydraulic motor
Reassembling:
Remove the hydraulic motor (marked with number 1 in figure 931145) from the cover (2) so that you can inspect the coupling for wear and tear. If the coupling halves are not worn, only the spacer (8) needs to be changed. If the coupling halves, too, are worn, follow the procedure detailed below. Coupling half of the axle 1. Remove the cover (2) of the machinery. 2. Open the screw (3) at the end of the drive axle and remove the flange (4). 3. Remove the coupling half (5) from the drive axle. The half can be heated up to max. 100ºC to facilitate removal. Coupling half of the motor Open the retaining screw (6) and remove the coupling (7) from the motor axle. The half can be heated to max. 100ºC to facilitate removal. Beware of overheating and damaging the motor seals.
1. Install the coupling half (5) and the flange (4). The coupling half can be heated to max. 100ºC. 2. Tighten the screw (3) at the end of the axle and lock with Loctite 270. 3. Reinstall the cover (2) of the machinery. Make sure that the guiding surface of the hydraulic motor is aligned with the coupling half of the vibrator. Make sure the guide pins of the cover are properly in place. 4. Install the spacer (8) of the coupler at the end of the coupler in the axle side. 5. Install the coupling half (7) in the axle of the hydraulic motor. The coupling half can be heated to max. 100ºC. 6. Fix the coupling half with the retaining screw (6) and lock with Loctite 270. Make sure the axial position of the coupling is within the allowable range given by the manufacturer. 7. Install the hydraulic motor. Note the position according to the operational position
10/00
V150 HYDRAULIC DRIVE
INSTRUCTION MANUAL
2-7
APPENDIX 2 - INSTRUCTION MANUAL, V150 HYDRAULIC DRIVE
2-8
INSTRUCTION MANUAL
V150 HYDRAULIC DRIVE
10/00
APPENDIX 2 - INSTRUCTION MANUAL, V150 HYDRAULIC DRIVE
Additional weights Many additional weight options are available for the vibrator: Identification
Mass torque
N11897099
5.34 kgm
N11897100
6.10 kgm
N11897101
6.87 kgm
N11897103
7.58 kgm
N11897106
8.35 kgm
N11897111
9.12 kgm
N11897557
9.12 kgm
10/00
The procedure for installing additional weights is device specific. Installing additional weights is agreed on separately. Install the additional weights according to the instructions in the document 926418.
V150 HYDRAULIC DRIVE
INSTRUCTION MANUAL
2-9
TK11-42-2V Hydraulic drive V150
Technical specification
Specifications TK11-42-2V Hydraulic operation Part No.,
Vibrator
Revolutions of vibrator max [ rpm ]
Max. capacity (volume weight1,6 t/m3) [ t/h ]
Weight[ kg ]
First installation grizzly *)
Transport deck / Screen deck
N11902871
V150/ A2FM23/61W
1150
500
2900
5
Screen deck
N11902870
V150/ A2FM23/61W
1150
500
2950
4
Screen deck
N11902869
V150/ A2FM23/61W
1150
500
3300
1
ZICZACScreen deck
N11902868
V150/ A2FM23/61W
1150
500
2900
3
Screen deck
N11902867
V150/ A2FM23/61W
1150
500
2850
3
Transport deck
N11902866
V150/ A2FM23/61W
1150
500
2950
2
Screen deck
N11902865
V150/ A2FM23/61W
1150
500
2850
2
Transport deck
N11902864
V150/ A2FM23/61W
1150
500
3300
1
Screen deck
N11902863
V150/ A2FM23/61W
1150
500
3200
1
Transport deck
N11902873
V150/ A2FM23/61W
1150
500
2800
6
Screen deck
N11902872
V150/ A2FM23/61W
1150
500
2883
7
Screen deck
*) Numbering in connection with grizzlies.
10/02
A-1
Technical specification
TK11-42-2V Hydraulic drive V150
Main dimensions
Support loads / corner Static [ kN ]
Dynamic [ kN ]
A-2
Measures of springs F1
5,5
Free length [ mm]
270
F2
10,2
Allowed min. length [ mm ]
180
F1, hor.
±0,3
Wire diameter [ mm ]
18
F1, vert.
±1,0
Spring outside diameter [ mm]
116
F2, hor.
±0,4
F2, vert.
±1,6
10/02
TK11-42-2V Hydraulic drive V150
Technical specification
Transport supports The device has transport supports that are fastened during transport. The transport supports have to be removed for operation.
Lifting
The lifting lugs in the device have to be used when lifting the machine. These are marked in the figure below with letter Z. Verify that the lifting devices and instruments are appropriate for the lifting.
10/02
A-3
Technical specification
TK11-42-2V Hydraulic drive V150
Grizzlies Grizzly 1 Two adjustable bar grizzly cassettes. Part no. 912977-A Grizzly opening [ mm ] 47 - 96 Weight [ kg ] 894
Follow these instructions when adjusting the grizzly. 1.Clean the grizzly so that the bars can move sideways, and no sand goes between the wedge surfaces. 2.Loosen the screw at the end of the bar. Do not loosen too much, because the counterpart may fall into the funnel or it can come off its loop. If the screw is damaged, it can be changed into a new one. There is a normal nut in the counterpart.
grizzly openings at regular intervals are 47, 54, 62, 71, 82 and 96 mm. The bar should always be added to or removed from the border; this way the packing rubbers overlap the right way. 4.Adjust the outermost openings to the desired size and the bars in the right direction. 5.The bars in the middle are adjusted into regular intervals, or if a larger opening is required, every second opening is left bigger. 6.Tighten the screws (M20), beginning from the outermost, with a torque of 382 Nm (281 ft lbs). Tightening is repeated several times, because when a bar is tightened, it always loosens the adjacent bars. 7.The screws are retightened after 50 service hours and after that when need be, if you notice that the grizzlies have moved.
3.Choose the new grizzly opening area and add or remove a bar or bars (observe the overlapping packing rubbers at the end). The
A-4
10/02
TK11-42-2V Hydraulic drive V150
Technical specification
Grizzly 2
Grizzly 5
Two plate grizzly cassettes with a grizzly opening of 52 mm.
Sloped ZICZAC grizzly cassette with two changeable grizzly plates with opening of 38 mm.
Grizzly cassette Part no. 913480 Grizzly opening [ mm ] 52 Weight [ kg ] 238 Grizzly cassette Part no. 913481 Grizzly opening [ mm ] 52 Weight [ kg ] 240
Grizzly Part no. 926619 Weight [ kg ] 528 Grizzly plate Part no. 926567 Weight [kg] 94
Grizzly 3
Grizzly 6
Two plate grizzly cassettes with a grizzly opening of 70 mm.
Two plate grizzly cassettes with a grizzly opening of 50 mm.
Grizzly cassette
Grizzly cassette
Part no. 918039 Grizzly opening [ mm ] 70 Weight [ kg ] 220
Part no. 941161 Grizzly opening [ mm ] 50 Weight [ kg ] 175
Grizzly cassette
Grizzly cassette
Part no. 918040 Grizzly opening [ mm ] 70 Weight [ kg ] 221
Part no. 941162 Grizzly opening [ mm ] 50 Weight [ kg ] 175
Check before starting that the clearance of the grizzly end support is 3±2mm.
Grizzly 7
Grizzly 4 Two ZICZAC grizzly cassettes with a grizzly opening of 38 mm. Part no. N11893496
Sloped ZICZAC grizzly cassette with two changeable grizzly plates with opening of 60 mm. Grizzly Part no. 939096 Weight [ kg ] 54
Weight [ kg ] 585 Grizzly plate
Grizzly
Part no. 922894
Part no. 939093
Weight [kg] 95
Weight [kg] 90
10/02
A-5
Technical specification
TK11-42-2V Hydraulic drive V150
Grizzly 5 & 7 Changing the grizzly When changing grizzlies, the parts indicated in the picture have to be detached in numerical order in order to remove the grizzly cassette. Grizzlies 2-4 & 6
A-6
10/02
TK11-42-2V Hydraulic drive V150
Technical specification
Screen deck
4.Loosen the cotter bolts in point 3.
The screen deck of the device has to be opened in order to help remove stuck material.
5.Open the bolts in point 4.
Part no. 913839 Weight [ kg ] 178 Steel screen cloth (bent ends) Part no. 386928-21 (See spare parts book for more detailed information). The wire thickness and the aperture size is defined on a case by case basis. Opening the screen deck 1.Fasten a lifting tackle between points 1 and 3 and use it to lower the screen deck safely onto the ground. Never open the screen deck without the help of a lifting tackle, because you might get squeezed due to the weight of the deck (88 - 214 kg). 2.Remove the obstructing structures from the opening area of the screen deck. NOTE! It is prohibited to go under the deck.
6.Lower the screen deck calmly down with the lifting tackle. Changing the screen cloth 1.Loosen the screen cloth tightening screws. The screen cloth fixing plate is moved into its end position. 2.Remove the old screen cloth. 3.Check the condition of the protection rubbers of the screen cloth support deck, because the curvature of the cloth has to remain right. The protection rubbers are changed into new ones, if needed. 4.Install new screen cloth with the hook ends into their places. Tighten the screen cloth by means of the screws in point 5. Do not tighten the screen cloth too much in order not to damage it.
3.Open the bolts in point 2.
10/02
A-7
Technical specification
TK11-42-2V Hydraulic drive V150
Plate reinforced ends are always recommended to be used in the screen cloth in order for the screen cloth wires not to dig into the tightening plates. Closing the screen deck — Lift the screen deck up with the lifting tackle. — Tighten the bolts in point 4. — Tighten the screws in points 2 and 3 (M20).Tightening torque 382 Nm(281 ft lbs). NOTE! Never operate the device when the screen deck is open.
A-8
ZICZAC Screen deck The ZICZAC screen deck of the device has to be opened in order to help remove stuck material. Part no. N11892331 Weight [ kg ] 214 ZICZAC-Finger grizzly group Part no. N11892330 (See spare parts book for more detailed information
10/02
TK11-42-2V Hydraulic drive V150
Setup and opening of the ZICZAC screen deck grizzlies Opening the ZICZAC screen deck
Technical specification
Transport deck The transport deck of the device has to be opened in order to help remove stuck material.
See opening of the screen deck.
Title 913338 Weight [ kg ] 88
Setup of the ZICZAC screen deck grizzlies
Opening the transport deck
Before beginning to change or to setup the grizzlies, open first the rubber plate from the feeding end in order to get hold of the grizzlies at the feeding end.
See opening the screen deck. Closing the transport deck See closing the screen deck.
Screw C tightens the grizzly group into its place. The grizzly group position is adjusted with screws A and B so that height H is at least as big as the grizzly opening. Closing the the ZICZAC screen deck See closing the screen deck.
10/02
A-9
HYDRAULIC DRIVEN CONVEYORS INSTRUCTION MANUAL 140638-EN
PREFACE
CHAPTER
0
Hydraulic conveyors are operated hydraulically and used widely in Metso Minerals’ applications. They are available in several configurations for specific applications, both fixed position and with hydraulic raise and lower. This Instruction Manual is valid for hydraulic driven belt conveyors manufactured by Metso Minerals for the year 2006.
Due to the continuous development of the product, the manufacturer reserves the right to make changes to the product and/or manual without prior notice. This is the first edition of the Instruction Manual, published in November 2006 in Tampere, Finland. Metso Minerals (Tampere) Oy P.O. Box 306 FIN-33101 Tampere Finland Tel. +358 (0)20 484 142 Fax +358 (0)20 484 143
11/06
EN
CONVEYOR INSTRUCTION MANUAL 0-1
CHAPTER 0 - PREFACE
This Page Left Intentionally Blank.
0-2
CONVEYOR INSTRUCTION MANUAL
EN
11/06
TABLE OF CONTENTS 1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1 TYPE IDENTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 CONVEYOR PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 POINTS OF DANGER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1 2-1 2-2 2-2
3 CONVEYOR BASICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 CONVEYOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 CONVEYOR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 DRIVE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 TAIL DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 CARRYING ROLLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 RETURN ROLLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 BELT PLOUGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 BELT SCRAPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 IMPACT BEAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11 SIDE BEAMS / PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12 SIDE SKIRT RUBBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1 3-2 3-2 3-2 3-2 3-2 3-2 3-2 3-2 3-2 3-2 3-2 3-2
4 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 OPERATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.2 Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.4 If the conveyor suddenly stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.5 Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 REMOVING A BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Clearing of a jammed main conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1 4-1 4-1 4-1 4-1 4-2 4-2 4-3 4-3
5 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 BELT TRACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.1 Squaring the pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.2 Adjusting the idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 BELT SCRAPER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 BEARING LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1 5-1 5-1 5-2 5-3 5-4 5-5
CONVEYOR INSTRUCTION MANUAL
6 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.1 CONVEYOR REMOVAL AND MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.2 CONVEYOR BELT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.2.1 Punched belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.2.2 Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.3 CONVEYOR ROLLER RENEWAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 6.3.1 Carrying rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 6.3.2 Return rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 6.4 CONVEYOR DRIVE MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 6.5 DRIVE DRUM BEARING RENEWAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 6.6 TAIL DRUM BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 6.7 CONVEYOR BELT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 6.8 TRIP WIRE SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 6.9 DRIVE DRUM LAGGING RENEWAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 6.10 PRE CLEANER (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 6.11 PLOUGH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 6.12 TEST RUN AFTER REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
7 REFERENCE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.1 TIGHTENING TORQUES, UNITS OF MEASUREMENT AND CONVERSION TABLES . . . . . 7-1 7.2 CONVEYING TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
CONVEYOR INSTRUCTION MANUAL
GENERAL
CHAPTER
1
1.1 TYPE IDENTIFIER Example of type identifier: H6,5-15 H = Belt conveyor 6,5 = Belt width (0,65 m / 25,59 in) 15 = Length of conveyor (15 m / 49,2 ft) The conveyor's type identifier is given on the machine plate mounted to the conveyor frame.
Figure 1-1 Machine plate
11/06
EN
CONVEYOR INSTRUCTION MANUAL
1-1
CHAPTER 1 - GENERAL
1.2 CONVEYOR PURPOSE The belt conveyor is intended to transfer the process material in recycling crushing or screening applications in crushing plants. Any other use is not considered as intended. The directions right and left are defined from the direction of travel of the material from the feed heading perspective.
1-2
CONVEYOR INSTRUCTION MANUAL
EN
11/06
SAFETY
CHAPTER
2
2.1 POINTS OF DANGER •
Drive end
•
Tensioning end
•
Nip points of pulleys
•
Nip points of idlers
•
Loading and discharging locations
•
Material flow
•
Electric equipment and cables
Figure 2-1 Conveyor's points of danger
11/06
EN
CONVEYOR INSTRUCTION MANUAL
2-1
CHAPTER 2 - SAFETY
2.3 INSPECTIONS
2.2 GENERAL
The list of inspection items below can easily be included as part of the daily walk-around. Operating personnel should be alert to most of these items any time the plant is operating. At a minimum, these checks should be performed once a week.
NOTE: PERSONNEL SHALL NOT BE ALLOWED TO OPERATE, MAINTAIN OR BE NEAR THE CONVEYOR WITHOUT RECEIVING THOROUGH CONVEYOR SAFETY TRAINING AND REVIEWING THIS MANUAL.
1. Check belt location on troughing and return idlers and train if necessary. 2. Check belt tension and tighten if belt is slipping on drive pulley or sagging enough between troughing idlers to allow spillage.
The operator must be acquainted with the following: •
Structure and operation of the conveyor
•
Points of danger
•
Safe working and moving near the conveyor
•
Emergency stop functions and the locations of the emergency stop switches
3. Inspect lagging on drive pulley and replace if necessary. 4. Inspect troughing and return idlers under load. They should be in contact with the belt and running free.
The safety, operating, and maintenance instructions of the conveyor should always be easily available near the conveyor.
5. Check material loading area to make sure material is loaded evenly onto the center of the belt.
The instructions on safety etc. must be observed.
6. Check for spillage and eliminate the cause by adjusting side skirt rubbers, etc.
Unauthorized persons are not allowed to be near the conveyor.
7. Check, in several locations, that conveyor frame is level side-to-side.
The conveyor should only be used for it’s purpose and in the conditions jointly agreed upon by the user and the manufacturer.
8. Check belt cleaners to make sure that scraper blades are in good condition and properly adjusted.
The conveyor belt should not be used as an access or maintenance walkway.
9. Inspect belt fasteners for wear and replace as necessary.
No changes are allowed to be made on the conveyor without the manufacturer's written consent.
10. Run belt empty, and check for tears or other damage. Repair and eliminate cause(s) of damage.
All those moving near the conveyor must use the marked walkways, service platforms, stairs, and ladders, and these must always be kept clear.
11. Check conveyor belt travel area to make sure that nothing is interfering with or rubbing on the belt.
The conveyor must not be used for carrying persons.
12. Clean frame and guards. 13. Remove any material from around troughing and return idlers.
Caution must be observed when the conveyor is running. The conveyor area must have sufficient lighting.
NOTE: ONLY AUTHORIZED PERSONNEL MAY PERFORM THESE DUTIES.
No safety device are allowed to be removed.
2-2
CONVEYOR INSTRUCTION MANUAL
EN
11/06
CONVEYOR BASICS
CHAPTER
3
Figure 3-1 The main components of the conveyor
Reference 1 2 3 4 5 6 7 8 9 10 11 12
11/06
Description Frame Tail pulley Joint Return roller Finger guard Hydraulic folding Belt Snub roller Scraper Drive drum bearing Drive motor Drive drum
Reference 13 14 15 16 17 18 19 20 21 22
EN
Description Plough Impact beam Dust cover Skirt rubber Roller assembly Roller assembly wedge Belt tension mechanism Pinch guard Lifting lugs Locking bolts
CONVEYOR INSTRUCTION MANUAL
3-1
CHAPTER 3 - CONVEYOR BASICS
3.1 CONVEYOR BELT
3.6 RETURN ROLLERS
•
Consist of different layers
•
Rubber disc rollers
–
Top layer
•
Finger guards
–
Fabric layer
•
Speed sensor
–
Reinforced layer
•
Belt tracking
3.2 CONVEYOR FRAME
3.7 BELT PLOUGH
•
Plate structural
•
Polyurethane cleaner
•
Modular, bolted, pinned
•
Internal cleaner
•
V-shape
3.3 DRIVE DRUM •
Single drive motor
3.8 BELT SCRAPER
•
Dual motor drive
•
Pre cleaner
•
Friction coating
•
Polyurethane or steel tip
•
Bolted coating
•
Rubber strap or spring tensioning
•
Bearings 3.9 EMERGENCY STOP
3.4 TAIL DRUM
•
Trip wire switch
•
Self cleaning drum
•
Push button
•
Solid shaft design (bearings inside of the drum )
•
Standard design
•
Bearings
3.10 IMPACT BEAM
3.5 CARRYING ROLLERS •
Fixed rollers
•
Hanging rollers
•
Shock rollers
•
Anti magnetizing rollers
•
Shock absorber
•
Polyethylene coated for low friction
3.11 SIDE BEAMS / PLATES •
Roller mounting
•
Skirt rubber mounting
•
Dust cover mounting
•
Standard profiles
3.12 SIDE SKIRT RUBBERS •
3-2
CONVEYOR INSTRUCTION MANUAL
EN
Spill prevention
11/06
OPERATING INSTRUCTIONS
CHAPTER
4
4.1 OPERATING
4.1.2 Before starting
4.1.1 General
•
Check that the conveyor is free from foreign objects.
•
Make sure that the conveyor belt, the drive and tensioning pulleys, and the idler assemblies are free to rotate. Wet belts can freeze to the pulley so firmly that the rubber will tear loose from the fabric when the conveyor is started. A thin coating of ice on an inclined belt surface can cause a load to slide.
•
Make sure that the mechanical parts and guards of the conveyor are in place, and the inspection and service doors closed.
IMPORTANT! Only persons with a proper training on the operation of the conveyor are allowed to operate the conveyor during a test run and normal work. The operator must be well acquainted with the following: – Structure of the conveyor –
Operating functions
–
Points of danger
•
–
Safe working and moving near the conveyor
Check that all personnel are clear of the conveyor and the discharge area.
•
Give a starting alarm.
–
Removing a block WARNING! Before starting the conveying process and during the operation, make sure that the restricted area is clear of people.
Normal starting and stopping are done with the operating switch, or with the IC panel. (IC = Intelligent control) Further information about using the IC control system is provided in the separate IC instruction manual. When the conveyor is in operation, working and moving in its immediate surroundings must be done with caution. If the conveyor stops by itself, the reason for this must be determined and corrected before attempting to restart the conveyor. A running conveyor must be constantly monitored. The safety switch (Located in the main panel) should not be used to stop the conveyor in normal operation. This can cause unnecessary wear on the switch or a blockage of overflowing material. When the conveyor is running, any cleaning, maintenance, and block removing operations are strictly forbidden. When the diesel engine is running, operations such as cleaning, maintenance, and removing blockages are strictly forbidden.
11/06
EN
4.1.3 Operation •
Start the conveyor (process) with the operating switch, or with the IC panel.
•
The conveyor is a part of the crushing process. If the conveyor is used by a forced control, please consult separate IC instruction manual.
•
Check that the conveyor belt runs centrally on the idlers.
•
Check that the drive and tensioning pulleys, as well as the idler assemblies and the idlers rotate normally.
•
Make sure that the material feeds onto belts properly and that the load does not exceed rated capacity.
•
Observe the operation of the conveyor during running.
CONVEYOR INSTRUCTION MANUAL
4-1
CHAPTER 4 - OPERATING INSTRUCTIONS
4.1.4 If the conveyor suddenly stops •
Detect the reason for stopping: overloading, device fault, emergency stop, slipping drum etc.
•
Shut down the diesel engine before attempting to clear any blockage. Lock and tag controls.
•
Remove the cause that prevents operation.
•
Restart the conveyor according to the starting procedures.
•
Allow the conveyor to empty before stopping it.
•
Stop the conveyor with the operating switch, or with the IC panel to insure proper operation.
•
Resume crushing process.
4.1.5 Emergency stop •
The emergency stop push button or trip wire will stop the conveyor in the event of an emergency.
•
Test function regularly, every 40 hours.
•
The emergency stop push button or trip wire should not be used to stop the conveyor in normal operation. This can cause unnecessary wear on the switch.
4-2
CONVEYOR INSTRUCTION MANUAL
EN
11/06
CHAPTER 4 - OPERATING INSTRUCTIONS
4.2 REMOVING A BLOCK
4.2.1 Clearing of a jammed main conveyor
CAUTION! Never try to clear the blockage with an excavator. This will cause severe damage to your Lokotrack. If the conveyor stops, follow these instructions: • Stop the process and the feeding equipment. Shut down the engine. Wait until the process has stopped completely. •
Lock the safety switch/valve into the off or disabled position to make sure that the conveyor cannot be accidentally started while the block is being removed.
•
Make sure that material feed to the conveyor cannot start while the block is being removed. Make sure also that the primary Lokotrack is not feeding your LT. Alert loader/excavator operator that maintenance is in process. When removing the block, use suitable equipment and wear appropriate personal protection.
•
If guards or other structures have to be removed, install them back into place when the block has been cleared. Unlock the safety switch/valve.
•
Start the conveyor according to the starting procedures.
Stop the process immediately.
•
Shut down the engine. Wait until the process has stopped completely.
•
Lock the safety switch/valve into the off or disabled position to make sure that the conveyor cannot be accidentally started while the block is being removed.
•
Clear the jammed main conveyor as well as possible. Do not use the excavator. When most of the material is removed, start the main conveyor by using a manual start on the IC panel. If necessary, the main conveyor can be driven in both directions (This is an optional feature in some models).
NOTE: The opposite direction drive is not used with the vibrating chute. •
•
•
•
Observe the belt running direction. Do not reverse the conveyor more than 0,5 m (1’6”). Do NOT use this method, if the rock is too big to pass under the magnetic separator.
For more information please consult separate IC and LT instruction manuals. WARNING! Do NOT use this method, if the rock is too big to pass under the magnetic separator! Use a hook to remove iron bars and wires. Be very careful not to hurt yourself. Never use the hook when the machine is running.
11/06
EN
CONVEYOR INSTRUCTION MANUAL
4-3
CHAPTER 4 - OPERATING INSTRUCTIONS
This Page Left Intentionally Blank.
4-4
CONVEYOR INSTRUCTION MANUAL
EN
11/06
MAINTENANCE
CHAPTER
5
5.1 BELT TRACKING A properly trained conveyor belt will travel over the center of the troughing rolls, pulleys and return rolls, resulting in lower maintenance costs and improved operation. Conveyor belts can be trained to track properly, unless they are warped or curved from improper manufacture, use or storage. Before any belt adjustment is done, make sure that the conveyor is in level. To inspect that the conveyor is levelled correctly, refer to the unit level indicator for the unit straightness. When adjusting the belt, the following items can be used to control the belt tracking: –
Drive drum position
–
Return roller position
–
Carrying rollers
–
Tail pulley position
Before adjustment, make sure that the conveyor belt is undamaged. A damaged belt will not track properly.
5.1.1 Squaring the pulleys In short conveyors the belt tracking is heavily affected by the position of the drive drum and tail pulley. Before making tracking adjustments, check that the head and tail pulleys are both square to the conveyor frame.
Figure 5-1 Squaring the tail pulley
Squaring the head pulley - Repeat the above process for the head pulley. When adjusting the drive drum location, remember always to loosen the slide beam locking bolts on both sides of the conveyor. This function allows the parts to move without causing any torsion on the drive motor. Adjust until the belt is properly tensioned and the drive pulley is square to the conveyor frame. Tighten the slide beam locking bolts slightly on both sides of the conveyor to the proper torque (30 Nm).
Squaring the tail pulley - Mark the frame member close to the tail pulley (Point A). Use a large square (1) to mark (Point B) on the opposite frame member so that a line between the two points is at a 90° angle to the imaginary centerline of the frame. Adjust tail pulley bearing blocks so that the distance C (the distance between marks A and B and the ends of the tail pulley shaft) is equal on both sides of the frame (fig. 5.1).
Figure 5-2 Loosen the slide beam locking bolts on both sides of the conveyor.
11/06
EN
CONVEYOR INSTRUCTION MANUAL
5-1
CHAPTER 5 - MAINTENANCE
5.1.2 Adjusting the idlers Adjust for run off by finding the point of maximum run off (D) and adjusting the idler or idlers (E) "ahead" of it. "Ahead" means those idlers which the belt contacts before the point of run off. Roller position exaggerated for illustration purposes in figure 5.3. 1.
Before adjustment
2.
After Adjustment
a. Return roller adjustment is used to center the belt on the tail pulley. Run the conveyor with the belt empty. Loosen the bolts (indicated with arrows in the figure 5.2) and displace the roller assembly. Tighten bolts and test for run off again.
Figure 5-4 Return idler adjustment
b. Carrying idler adjustment is used when the belt does not center with material. Each end of the carrying idler fits into an elongated hole that provides two mounting locations. See figure 5.5. Determine which direction the idler must turn and turn the idler by moving one end to the alternate location.
Figure 5-3 Eliminating run off
Loosen bolts and pivot roll (E) around its mid point the way you would turn a steering wheel to bring a car back into the center of its lane. Make small adjustments, retighten bolts and test for run off after each adjustment. If point of creep changes, adjust idler ahead of the new creep point. Figure 5-5 Carrying roller adjustment
Do not attempt to adjust idlers with the conveyor running. Lock out and tag controls while making adjustments.
5-2
CONVEYOR INSTRUCTION MANUAL
EN
11/06
CHAPTER 5 - MAINTENANCE
c. If the belt adjustment method a & b have not corrected the belt tracking completely, adjust the tail pulley slightly to make the final correction.
5.2 BELT TENSION The conveyor belt tension is adjusted by relocating the drive pulley position. When adjusting the drive drum location, remember always to release the slide beam locking bolts from both side of the conveyor. This function allows the parts to move without causing any torsion to the drive motor. A belt is properly tensioned when the sag of the loaded belt between two adjacent return rollers is 0,5 - 3% of the distance between the rollers when an empty belt is operating. Sag can be difficult to measure accurately, because of the small distances involved. The practical rule of thumb is, "The proper tension is the lowest possible tension that will prevent the drive pulley from slipping on the belt."
Figure 5-6 Tail pulley adjustment
If the conveyor has a vertical curve, the conveyor belt should remain touching all carrying rollers with material.
11/06
EN
CONVEYOR INSTRUCTION MANUAL
5-3
CHAPTER 5 - MAINTENANCE
5.3 BELT SCRAPER ADJUSTMENT The scraping force is done by spring force. Rubber, steel or gas springs are generally used methods. Belt scraper tension and condition must be checked daily. Observe the scraper wear daily and replace the scraping element when nesessary. The tension mechanism can be jammed or frosen in muddy / icy conditions and due to this the scraper operation must be checked in the beginning of every shift or daily.
Figure 5-8 Adjusting the rubber spring type pre-cleaner
Use tensioning screw Z to adjust the scraper with a rubber element tensioner.
Figure 5-7 Steel spring type pre-cleaner
Adjust the spring to set the scraper’s pressing force so that the belt becomes properly cleaned.
Figure 5-9 Scraper with rubber strap tensioning
The belt scraper in the picture above is adjusted by a rubber strap.
5-4
CONVEYOR INSTRUCTION MANUAL
EN
11/06
CHAPTER 5 - MAINTENANCE
5.4 BEARING LUBRICATION The bearing size will affect the needed grease amount. In the following table the amount of grease (in grams) is proportined to shaft diameter (in millimeters). Table 5-1 Shaft diameter / mm 40 55 60 80
Amount of grease / g 4 6 6 9
In practice an appropriate amount of grease to each bearing is about 5-10 grams (0.17....0.35 ounch) in every 40 - 50 hours. Use a multi-purpose grease with an NLGI-class 2 rating and a good resistance to water, cold (-30 C/ 22 F) and hot (continuous operating temperature + 100×C/212×F). The grease must have rust and oxidation (RO) inhibitors and it must contain EP-additives. Don't use grease containing molybdenium. The minimum viscosity of the base oil must be 160 mm2/s ( cSt ) in 40×C / 104×F and minimum viscocity index 80.
11/06
EN
CONVEYOR INSTRUCTION MANUAL
5-5
CHAPTER 5 - MAINTENANCE
This Page Left Intentionally Blank.
5-6
CONVEYOR INSTRUCTION MANUAL
EN
11/06
REPAIRS
CHAPTER
6
6.2 CONVEYOR BELT REPAIR
6.1 CONVEYOR REMOVAL AND MOUNTING
6.2.1 Punched belt When it is sensible to repair a punched belt?
DANGER! Always use conveyor’s lifting lugs and approved lifting equipment with adequate capacity when removing or mounting the conveyor.
As a rule of thumb, when a tear is larger than 15% of the belt’s width, it might be more reasonable to renew it. In case the belt is quite new and the tear is small, there are usually 3 possibilities to repair it –
Mechanical connector Repair like this is recommended only for a temporary solution. To avoid damage to the belt scraper, pick the correct fastener, set it properly and grind the bolt ends.
–
Surface patch Repair like this is recommended only for small areas. The patch material is available from belt distributors.
–
Fabric patch A glue-bonded layered patch of rubber and fabric is the recommended way of repairing the belt. The patch material is available from belt distributors.
DANGER! Never attempt to maintain or service the conveyor until the conveyor has stopped completely.
WARNING! Always use appropriate protective equipment (e.g. protective helmet, goggles) when operating, maintaining or servicing the conveyor.
If the conveyor is removed for a maintenance or a repair, ensure that the replacement structure is identical to the original one. If the conveyor’s supporting structure is damaged, the new repaired structure must always be equivalent to a new one. Use only genuine Metso spare parts. The warranty does not cover if either non-Metso or non-conforming parts are used. Never attempt to operate, maintain or service the conveyor unless you understand all procedures necessary to safely and properly perform the task. If you are unsure at any stage, please do not hesitate to contact the nearest authorized Metso Minerals’ service or dealer.
11/06
EN
CONVEYOR INSTRUCTION MANUAL
6-1
CHAPTER 6 - REPAIRS
6.2.2 Renewal
–
DANGER!
Find out the most appropriate bonding method; hot vulkanizing, cold vulcanizing or mechanical splicing. If electricity is needed, find out the power requirement.
Always use conveyor’s lifting lugs and approved lifting equipment with adequate capacity when removing or mounting the conveyor.
The power requirement depends on the equipment; e.g. Almex 1400 mm vulcanizing press with 32 A three-phase current operates in 400 V voltage.
Although they may look alike, all belts are not the same. Differences in carcass construction and covers will affect belt life and belt tracking. Use only genuine Metso spare parts.
The power requirement in this case: 400V x 32A x 1,73 = 22,5 kW –
The conveyor belt needs to be replaced when: –
The surface rubber is worn out
–
The edges are ripped, the belt is punctured, or the surface has bulged [indicating delamination].
–
When the belt can not be made to track properly.
WARNING! Hot vulcanizing press can cause burn injury. Follow manufacturer instructions. Use protective gloves and avoid contact with hot surfaces. Keep unauthorized personnel away from work area.
A worn belt might damage other parts of the conveyor. Replace the belt promptly when these conditions are observed. When ordering a new belt, notice the following –
Part number
–
Belt width, number of plies, cover thickness and length. If the belt will be field vulcanized, allow enough extra length to make the splice.
Whether you are using mechanical fasteners, hot vulcanizing or cold vulcanizing, always follow manufacturers instructions precisely.
WARNING! The vulcanizing process may release poisonous vapours with a narcotising effect. The vapours irritates eyes and skin, may cause cancer, have a possible risk of irreversible effects and may cause drowsiness and dizziness.
NOTE: If you are unsure at any stage, please do not hesitate to contact maker of the splice.
When preparing for a belt renewal, proceed as follows. –
6-2
WARNING!
Lower the conveyor into a working level or build an appropriate stand
Danger of fire. The vulcanizing material can become highly flammable in use.
–
Loosen the belt, remove the scrapers. Remove or alternatively loosen the skirts.
–
Inspect pulleys, bearings, idlers, impact beds, skirts and scrapers. Repair or replace as needed.
CONVEYOR INSTRUCTION MANUAL
EN
For further information concerning safety, see separate General Safety Instructions.
11/06
CHAPTER 6 - REPAIRS
The following table describes the main dimensions needed for using the hot-vulcanizing press. B = Belt width W = Width of the bars L = Length of the bars H = Height of the bars I = Current needed G = Weight of the tools Table 6-1 Need for space on conceyor and needed current B (mm) 600 1000 1200 1400 1600
W (mm) 1500 1500 2000 2000 2500
L (mm) 1500 1500 1500 1500 2000
H (mm) 600 600 700 700 1000
I (A) 32 32 32 32-63 63
G (kg) 200 300 400 400 600
The figures in table above is for reference only, based only on one supplier of hot-vulcanizing presses.
11/06
EN
CONVEYOR INSTRUCTION MANUAL
6-3
CHAPTER 6 - REPAIRS
Cold vulcanizing When bonding a belt by cold vulcanizing, always consult the supplier of the vulcanizing adhesives to select the most appropriate way for the task in hand.
WARNING! Cold vulcanizing adhesives are toxic and have a narcotising effect. The adhesive irritates eyes and skin, may cause cancer, has a possible risk of irreversible effects and its vapours may cause drowsiness and dizziness.
WARNING! Danger of fire. Cold vulcanizing adhesives can become highly flammable in use.
FIRST AID MEASURES INHALATION Supply fresh air. Consult a doctor in case of drowsiness, dizziness or difficulty breathing. SKIN CONTACT Wash immediately with water and soap and rinse throughly. Consult a doctor if skin is burned. EYE CONTACT Rinse the opened eye for several minutes using an emergency eye wash station or under running water. Then consult a doctor. SWALLOWING Contact a doctor. Have package or MSDS sheet (Material Safety Data Sheet) available. The chemical makeup of the specific compound will determine whether dilution or vomiting are appropriate.
6-4
CONVEYOR INSTRUCTION MANUAL
EN
11/06
CHAPTER 6 - REPAIRS
6.3 CONVEYOR ROLLER RENEWAL
d. Thread a wire through the roller’s link (fig. 6-3).
6.3.1 Carrying rollers Proceed as follows a. Remove the service hatch (1) (fig. 6-1). b. Remove the locking pin (2) (fig. 6-1).
3 6 2 1
Figure 6-3 Thread a wire
e. Pull the wire and remove the wedge (3) (fig. 6-1). Figure 6-1 Remove the service hatch
f. Remove the roller assembly.
c. Insert a wooden support (4) through the service hatch and support the roller assembly (5) (fig. 6-2).
g. Install a new roller assembly according to the direction of the travel of the belt into the front edge of the elongated hole (6). See figure 6-1. h. Install the wedge from the top. i. Install the locking pins. j. Check that the belt runs in the middle of the conveyor. Adjust if needed.
5 4
Figure 6-2 Support the roller assembly
11/06
EN
CONVEYOR INSTRUCTION MANUAL
6-5
CHAPTER 6 - REPAIRS
6.3.2 Return rollers
e. Install a new roller assembly into the groove of the support bracket. See figure 6-6 (Indicated with an arrow).
Proceed as follows a. Remove the finger guard (2) (fig. 6-4). b. Remove the lock plate (3) (fig. 6-4).
3
2 4 4 1
Figure 6-6 Install a new roller assembly
Figure 6-4 Remove the finger quard
f. Install the lock plate (3) (fig. 6-4). g. Install the finger guard.
c. Loosen the supports (4) (fig. 6-4).
h. Align the supports with the marks you made on the frame. Tighten the supports (4) (fig. 6-4). i. Position the finger guard and adjust it. The guard should be as close as possible to the belt and return roller without touching (<5 mm). Ensure that the return roller can turn freely.
4 1
j. Tighten the finger guard (2) (fig. 6-4).
5
k. Check that the belt runs in the middle of the conveyor. Adjust if needed.
Figure 6-5 Support the belt
d. Support the belt with a wooden support (5) or similar means, and remove the roller assembly (1) (fig. 6-5).
Figure 6-7 A finger guard with reliefs for rubber discs
6-6
CONVEYOR INSTRUCTION MANUAL
EN
11/06
CHAPTER 6 - REPAIRS
6.4 CONVEYOR DRIVE MOTOR REPLACEMENT
c. Mark the position of the slide (1), and block the drum with a wooden support (2) (fig. 6-10).
Proceed as follows a. Disconnect the hydraulic connections. See figure 6-8.
2 8
3
1
Figure 6-10 Block the drum
d. Loosen the motor flange bolts (8) (fig. 6-10). e. Loosen the slide’s locking screws (5), and move the slide (4) backwards by unscrewing the adjusting screw (6) (fig. 6-11).
Figure 6-8 Disconnect the hydraulic connections
b. Support the drum e.g. with a hoist as illustrated in the figure 6-9.
4 5
6
Figure 6-9 Support the drum
Figure 6-11 Move the slide backwards
11/06
EN
CONVEYOR INSTRUCTION MANUAL
6-7
CHAPTER 6 - REPAIRS
f. When the slide is back enough, remove the mounting bracket (3) of the drive motor (fig 6-10).
i. Remove the drive motor (fig 6-14).
g. Remove the screws (7)of the motor bracket as illustrated in the figure 6-12.
7 Figure 6-14 Remove the drive motor
7
Mount a new drive motor as follows a. Remove any paint from the mounting surface of the motor flange.
Figure 6-12 Motor bracket
b. Check the oil level from the flange’s side before mounting a new motor. Consult lubrication chart for proper oil specification. See figure 6-15.
h. Support the drive motor with a crane, and remove the motor flange bolts (8) as illustrated in figure 6-13.
8 Figure 6-15 Check the oil level Figure 6-13 Motor flange
6-8
CONVEYOR INSTRUCTION MANUAL
EN
11/06
CHAPTER 6 - REPAIRS
c. Mount the new drive motor. Use thread-locking compound in the screw connections. See figure 6-16.
Figure 6-16 Use thread-locking compound
d. Reinstall the motor bracket into the slide. e. Ensure the perpendicularity of the drive drum to the conveyor frame by measuring or using a square. f. Pre-fill the drive motor with oil. This will prevent scoring of the internal surfaces. Consult lubrication chart in Lokotrack Instruction Manual for proper oil specification.
Figure 6-17 Pre-fill drive motor with oil
g. Check that the belt runs in the middle of the conveyor. Adjust if needed.
11/06
EN
CONVEYOR INSTRUCTION MANUAL
6-9
CHAPTER 6 - REPAIRS
6.5 DRIVE DRUM BEARING RENEWAL
d. Loosen the slide’s locking screws (Indicated with arrows in the figure 6-21), and move the slide backwards by unscrewing the adjusting screw. See figure 6-11.
Proceed as follows a. Support the drive drum.
Figure 6-18 Support the drum
Figure 6-21 Move the slide backwards
b. Mark the position of the bearing housing. Remove the bolts of the bearing housing.
e. Disassemble the bearing housing.
CAUTION! Failure to lubricate as recommended and scheduled will cause a premature damage to the bearing.
Figure 6-19 Bearing removal
c. Mark the position of the slide (1), and block the drum with a wooden support (2) (fig. 6-20).
Figure 6-22 Disassemble the bearing housing
2 1 Figure 6-20 Block the drum
6-10
CONVEYOR INSTRUCTION MANUAL
EN
11/06
CHAPTER 6 - REPAIRS
f. Measure the bearing’s original distance, because the new bearing has to be mounted back to the original position. See figure 6-23.
h. Open the bearing’s taper connection by hitting the inner ring of the bearing as illustrated in the figure 6-25.
Figure 6-25 Open the taper connection
i. Remove the bearing. Figure 6-23 Measure the distance
g. Release the locking ring.
Figure 6-26 Remove the bearing
j. Mount a new bearing to its original position. See figure 6-23. Tighten the bushing. Figure 6-24 Release the locking ring
11/06
EN
CONVEYOR INSTRUCTION MANUAL
6-11
CHAPTER 6 - REPAIRS
k. Measure the bearing clearance according to manufacturer specification.
Figure 6-27 Measure the bearing clearance
l. Install the locking ring. m. Grease the bearing.
Figure 6-28 Grease the bearing
n. Assemble the bearing housing. o. Return the slide to its original position. See figure 6-21. p. Mount the bearing housing back to its original position. q. Tighten the slide's locking screws (Indicated with arrows in the figure 6-21).
6-12
CONVEYOR INSTRUCTION MANUAL
EN
11/06
CHAPTER 6 - REPAIRS
6.6 TAIL DRUM BEARING REPLACEMENT Proceed as follows a. Support the tail drum. b. Loosen the bearing’s centring screws.
Figure 6-31 Tighten the bearing
g. Because the bearing construction is a sliding type, the bearing on one end must be tightened to it’s center position in axial direction. Measure the bearing’s innermost and outermost position, and tighten to its center position with a torque wrench (as illustrated in the figure 6-31).
Figure 6-29 Remove the fastening bolts
c. Remove the fastening bolts of the bearing assembly. d. Remove the old bearing assembly. e. Install a new bearing assembly according to manufacturer’s instruction. f. When placing a new bearing assembly, enable the mounting with e.g. an iron bar as illustrated in the figure 6-30.
IMPORTANT! Only lock the bearing on one shaft end. The other bearing must be allowed to float to allow for shaft expansion and contraction. Failure to do so will cause a premature damage to the bearing.
Figure 6-30 Placing a new bearing assembly (with iron bar)
11/06
EN
CONVEYOR INSTRUCTION MANUAL
6-13
CHAPTER 6 - REPAIRS
6.7 CONVEYOR BELT ADJUSTMENT
6.8 TRIP WIRE SWITCH ADJUSTMENT
Refer to Section 5.1 and 5.2 for belt tension and tracking adjustment.
DANGER! Wrong adjustment can result in malfunction of the emergency stop and cause severe injury or death.
Proceed as follows a. Adjust the rigging screw so that there is no slack in the trip wire but not so tight as to activate the emergency stop switch. If there is not enough adjustment available, the length of the trip wire must be adjusted.
Figure 6-32 Adjust the trip wire
b. Adjust the trip wire length: - Turn the rigging screw so that the trip wire is in its most slack position. - Loosen clamps on the trip wire and adjust the trip wire to remove slack. - Tighten clamps securely. Adjust the trip wire as described above (detail a). c. Trip the wire few times to verify the functioning of the emergency stop switch. NOTE: The emergency stop trip wire switch must never be used except in case of emergency (e.g. should not be used to effect a routine shutdown, or as substitute for lockout).
6-14
CONVEYOR INSTRUCTION MANUAL
EN
11/06
CHAPTER 6 - REPAIRS
6.9 DRIVE DRUM LAGGING RENEWAL Inspect lagging on drive drum regularly. Replace the lagging when the grooves on the surface are just barely visible. As a rule of thumb, the lagging will likely be worn out when the belt is changed the 3rd time. The factory-applied lagging is a vulcanized rubber blanket. There are several options for lagging renewal according to services available locally. Or you can replace the drum with a factory lagged item. The old lagging must be removed by cutting or heating, and remaining residue removed by grinding. Use appropriate safety equipment. If relagging the drum, follow instructions and precautions supplied by the manufacturer for surface preparation and installation.
Figure 6-33 Drive drum lagging renewal
WARNING! When heated, lagging can catch fire and/or give off toxic fumes. Insure adequate ventilation and have the appropriate fire extinguisher at hand.
NOTE: Never attempt to operate, maintain or service the conveyor unless you understand all procedures necessary to safely and properly perform the task.
WARNING! Cold vulcanizing adhesives are toxic and have a narcotizing effect. The adhesive irritates eyes and skin, may cause cancer, has a possible risk of irreversible effects and its vapors may cause drowsiness and dizziness.
WARNING! Danger of fire. Cold vulcanizing adhesives can become highly flammable in use.
11/06
EN
CONVEYOR INSTRUCTION MANUAL
6-15
CHAPTER 6 - REPAIRS
6.11 PLOUGH REPLACEMENT
6.10 PRE CLEANER (Option)
2
1
The condition of the belt plough should be checked as part of the weekly conveyor inspection. The exploded view of plough is illustrated in the figure below.
5
7
3
4
6
Figure 6-34 Exploded view of scraper
Reference 1 2 3 4 5 6 7
Description Pre-cleaner blade Blade cassette Main frame Tensioner plate, small Spring locking ring End stop Main lock
Figure 6-35 Plough (Exploded view)
The condition of the pre-cleaner should be checked as part of the daily conveyor inspection. The scraper must be cleaned after every shift, especially in cold weather. Adjust the scraper tension as needed. When the scraper blade is sufficiently worn, it will not clean the belt any more and must be replaced. For further information about scraper repair, see separate Pre-cleaner installation instruction.
6-16
CONVEYOR INSTRUCTION MANUAL
EN
11/06
CHAPTER 6 - REPAIRS
6.12 TEST RUN AFTER REPAIR During a test run after repair, observe all applicable safety requirements and the following details
11/06
–
Belt centralization
–
Belt tension
–
Bearing overheating (none of the bearings is overheating)
–
Leakage (no leaks)
–
General functioning (no unusual noises)
–
Scraper functioning
–
Plough functioning
–
Roller functioning
–
Functioning of the rotation detector
–
Skirt rubber adjustment
–
Conveyor emergency stop functioning
EN
CONVEYOR INSTRUCTION MANUAL
6-17
CHAPTER 6 - REPAIRS
This Page Left Intentionally Blank.
6-18
CONVEYOR INSTRUCTION MANUAL
EN
11/06
REFERENCE TABLES
CHAPTER
7
7.1 TIGHTENING TORQUES, UNITS OF MEASUREMENT AND CONVERSION TABLES
Table 7-1 Conveyor lenghts and widths Conveyor width Conveyor width / meter / inch 0,5 19,7 0,6 23,6 0,65 25,6 0,7 27,6 0,8 31,5 0,9 35,4 1,0 39,4 1,1 43,3 1,2 47,2 1,3 51,2 1,4 55,1 1,5 59,1 1,6 63,0 1,7 66,9 1,8 70,9 1,9 74,8 2,0 78,7
Conveyor lenght / meter 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Conveyor lenght / foot 6,6 9,8 13,1 16,4 19,7 23,0 26,2 29,5 32,8 36,1 39,4 42,7 46,0 49,2 52,5 55,8 59,1
Conveyor lenght / meter 19 20 21 22 23 24 25
Conveyor lenght / foot 62,3 65,6 68,9 72,2 75,5 78,7 82
The accuracy used in the conversion in the table 1-1 is one decimal. The corresponding values are at the same line, e.g. 0,5 m corresponds 19,7 in.
Table 7-2 Conversion table, distance unit cm m cm 1 0.01 m 100 1 km 100000 1000 in 2.54 0.0254 ft 30.48 0.3048 yd 91.44 0.9144 mile 160930 1609.3 1 mm = 0.1 cm, 1 mm = 0.001 m
11/06
km 0.00001 0.001 1 0.000025 0.000304 0.000914 1.6093
EN
in 0.3937 39.37 39370.7 1 12 36 63360
ft 0.03281 3.2808 3280.8 0.08333 1 3 5280
yd 0.01094 1.0936 1093.6 0.02777 0.3333 1 1760
mile 0.000006 0.00062 0.62137 0.000015 0.000189 0.000568 1
CONVEYOR INSTRUCTION MANUAL
7-1
CHAPTER 7 - REFERENCE TABLES
Table 7-3 Conversion table, pressure unit
kp/cm2
bar
Pa=N/m2
kPa
kp/cm2 bar
1
0.98067
98066.5
1.01972
1
100000
Pa=N/m2
0.00001
0.001
1
kPa
0.01020
0.01
lbf/in2 (psi)
0.07032
0.0689
0.00047
0.00047
lbf/ft
2
lbf/in2 (psi)
lbf/ft2
98.0665
14.2233
2048.16
100
14.5037
2088.6
0.001
0.00015
0.02086
1000
1
0.14504
20.886
6894.76
6.89476
1
144
47.88028
0.04788
0.00694
1
2
kg/cm = 735.56 Torr (mmhg) = 0.96784 atm
Table 7-4 Conversion table, speed
7-2
unit
m/s
m/min
km/h
ft/s
ft/min
mph
m/s m/min km/h ft/s ft/min mph
1
60
3.6
3.28
196.85
2.24
0.016667 0.277778 0.3048 0.00508 0.44704
1 16.66667 18.288 0.3048 26.8224
0.06 1 1.09728 0.018288 1.609344
0.054681 0.911344 1 0.016667 1.466667
3.28084 54.68066 60 1 88
0.037282 0.621371 0.681818 0.011364 1
CONVEYOR INSTRUCTION MANUAL
EN
11/06
CHAPTER 7 - REFERENCE TABLES
Tightening torques, recommendations Table 7-5 Tightening torques State
Bolt
Nut
Lubrication
1
untreated
untreated
oil
2
bright-galvanized
untreated or bright-galvanized
oil or dry
3
hot-galvanized
untreated
oil or dry
Strenght class /
8.8
Size State
10.9
12.9
1
2
3
1
1
M6
11 Nm
9.8 Nm
12.5 Nm
16 Nm
19 Nm
M8
26 Nm
24 Nm
30 Nm
38 Nm
45 Nm
M10
52 Nm
47 Nm
59 Nm
74 Nm
89 Nm
M12
91 Nm
81 Nm
103 Nm
128 Nm
154 Nm
M16
220 Nm
198 Nm
250 Nm
313 Nm
375 Nm
M20
430 Nm
386 Nm
490 Nm
620 Nm
732 Nm
M24
750 Nm
668 Nm
848 Nm
1050 Nm
1270 Nm
M30
1480 Nm
1317 Nm
1672 Nm
2080 Nm
2500 Nm
M-thread
Table 7-6 Conversion table, torque Bolt M6 M8 M10 M12 M16 M20 M24 M30
Nm 11 26 52 91 220 430 750 1480
ft lbs 8.1 19 38 67 162 317 553 1092
Nm 9.8 24 47 81 198 386 668 1317
ft lbs 7.2 18 35 60 146 285 493 971
Torque Nm 12.5 30 59 103 250 490 848 1672
The attached table (1-6) gives an example of conversion the metric units into the imperial units.
11/06
EN
ft lbs 9.2 22 44 76 184 361 625 1233
Nm 16 38 74 128 313 620 1050 2080
ft lbs 12 28 55 94 231 457 774 1534
Nm 19 45 89 154 375 732 1270 2500
ft lbs 14 33 66 114 277 540 937 1844
1 Nm = 1,355818 x ft lbs
CONVEYOR INSTRUCTION MANUAL
7-3
CHAPTER 7 - REFERENCE TABLES
Units of measurement and their abbreviations Unit Newton meter Kilopond meter Millimeter Centimeter Meter Kilometer Second Minute Hour Pascal Kilopascal Inch Foot Yard Mile Pounds Pound-force
Pounds avoirdupois
7-4
Abbreviation Nm kpm mm cm m km sec min h Pa kPa in ft yd mile lb lbf lbs
CONVEYOR INSTRUCTION MANUAL
EN
11/06
CHAPTER 7 - REFERENCE TABLES
7.2 CONVEYING TERMINOLOGY
Drive drum / Drive pulley
A
Transmits the torque of the drive motor to the belt by friction. Bends the belt to the return side of the conveyor. Located at the discharge or head end of the conveyor.
Arching / Crown-faced Enlargement of the diameter in the middle of a pulley which helps to center the belt. Also referred to as crown-faced.
Drive drum bearing The number and location of the bearings varies according to the conveyor type. In some applications the drive motor can be used as a bearing.
B Back stop device Prevents the belt from running backwards if there is loss of power with material on the belt. Typically accomplished by adding a check valve into the hydraulic circuit.
Drive drum coating / Lagging The drive drum coating is a rubber coating on the surface of the drive drum. The coating can also be made of rubber discs or strips. Also referred to as lagging.
Belt Drive motor
The belt is used to convey the material.
A hydraulic driven motor, which rotates the drive drum. Belt speed The distance traveled in a given time
Dust cover A shield for preventing the dust spreading to the surroundings.
Belt tension mechanism A slide that allows for adjusting the belt tension by moving the head or tail pulley.
E Emergency stop D
Emergency stop push button or a switch with a trip line for stopping the conveyor.
Discharge area A point where the material drops off the conveyor. Discharge chute
G
Guides the outflowing material
Guide roller
Discharge height
Prevents the edge of the belt from hitting the conveyor’s structure.
Vertical free distance from the conveyor discharge end to the ground
11/06
EN
CONVEYOR INSTRUCTION MANUAL
7-5
CHAPTER 7 - REFERENCE TABLES
I
R
Impact beam / Impact bar
Return roller / Return idler
A beam, located at the charging point underneath the belt. Equalizes the impact of the dropping material.
Supports the belt on the return side. Guides the belt. Adjustment of the return idlers can correct belt tracking. Roller assembly / Idler assembly Supports the belt on the material flow side and guides the belt. Adjustment of the troughing idlers can correct belt tracking.
L Lifting angle An angle, which the conveyor lifts the material (Too steep of an angle may cause the material to roll downwards).
Rotation detector A sensor indicating the rotation of the conveyor.
Load point A point where the material drops on to the conveyor. The structure of the load point varies according to a stress of the dropping material flow. There may be several load points.
S Scraper Device used to clean residual material from the material side of the belt after the point of discharge.
M Skirt rubber
Maintenance hatch Maintenance and inspection accesses located along the conveyor frame
A longitudinal rubber seal located between the belt and the conveyor’s frame for preventing the overflow of the material. Slide bar / Slider bed
P
A beam, or an array of beams, along which the belt slides. Supports the belt on the material flow side. Similar to an impact bed.
Pinch guard / Nip guard Device designed to eliminate or reduce the possibility of injury by blocking the pinch/nip hazard.
T Plow / Plough
Tail pulley
A cleaning device located underneath the belt before the tail pulley. Prevents material from getting caught between the belt and the tail pulley.
Bends the belt back to the drive side. Located at the feed end of the conveyor.
Pre scraper / Pre cleaner Cleans the belt with a carved blade against the surface of the drive drum.
7-6
CONVEYOR INSTRUCTION MANUAL
EN
11/06
CHAPTER 7 - REFERENCE TABLES
W Water spray system A system for reducing the amount of fugitive dust by directing a fine water spray onto the material. Wing pulley A pulley with openings on the cylinder face. The dirt and stones that fall to to the return side of the belt can enter these openings and fall to the ground rather than being trapped and causing damage to the belt.
11/06
EN
CONVEYOR INSTRUCTION MANUAL
7-7
CHAPTER 7 - REFERENCE TABLES
This Page Left Intentionally Blank.
7-8
CONVEYOR INSTRUCTION MANUAL
EN
11/06
IC500 / IC600 INSTRUCTION MANUAL
IC500 / IC600 Instruction Manual
Introduction This Instruction Manual refers to the controller used in LT units, manufactured by Metso Minerals (Tampere) Oy. To obtain the best performance from this product, please read this manual carefully. It will guide you in operating the IC500 / IC600 system. This Instruction Manual is valid for IC500 / IC600 controller. Because of the continuous development of the product, the manufacturer reserves the right to alter the technical specifications written in this manual, without any advance information.
Version 2.5
2/93
IC500 / IC600 Instruction Manual TABLE OF CONTENTS 1
PRECAUTIONS ...............................................................................................................................................5 1.1 HANDLING INFORMATION ...............................................................................................................................5 1.1.1 Storage..................................................................................................................................................5 1.1.2 Transport ..............................................................................................................................................5 1.1.3 Function Keys.......................................................................................................................................5 1.2 WELDING OF THE UNIT ...................................................................................................................................5 1.3 BATTERY CHARGING ......................................................................................................................................5 1.3.1 Quick Chargers ....................................................................................................................................5 1.3.2 Jump Starting .......................................................................................................................................6 1.4 CLEANING THE DISPLAY .................................................................................................................................6
2
GENERAL.........................................................................................................................................................7 2.1 2.2 2.3 2.4
3
IC500 / IC600 SYSTEM ...................................................................................................................................7 RUN MODE .....................................................................................................................................................8 ADMINISTRATION MODE .................................................................................................................................8 SERVICE MODE ...............................................................................................................................................8
DISPLAY WINDOWS .....................................................................................................................................9 3.1 STRUCTURE AND ORDER OF THE DISPLAY WINDOWS .....................................................................................9 3.1.1 Tracks movement ................................................................................................................................10 3.2 GENERAL INFORMATION ...............................................................................................................................11 3.3 DISPLAY SCREEN ..........................................................................................................................................11 3.3.1 Choosing the Language......................................................................................................................12 3.3.2 Adjusting the Display Contrast and Brightness .................................................................................12
4
STARTING THE PROCESS.........................................................................................................................12
5
STOPPING THE PROCESS .........................................................................................................................13
6
MAIN WINDOW (RUN MODE WINDOW)...............................................................................................14 6.1
HELP-WINDOW ..............................................................................................................................................17
7
UNIT INFORMATION..................................................................................................................................18
8
FEEDER ..........................................................................................................................................................19
9
CRUSHER.......................................................................................................................................................20
10
ENGINE...........................................................................................................................................................22
11
HYDRAULICS ...............................................................................................................................................23
12
TIME COUNTERS.........................................................................................................................................24
13
PROCESS OPTIONS .....................................................................................................................................25
14
MANUAL CONTROL OF DEVICES ..........................................................................................................27 14.1 14.2 14.3 14.4
15
TRACK-DRIVING WINDOW (OPERATION IN SERVICE MODE ONLY)........................................31 15.1
16
STARTING THE PROCESS WITH MANUAL CONTROL (JAW CRUSHER / IMPACT CRUSHER) ..........................28 STOPPING THE PROCESS WITH MANUAL CONTROL (JAW CRUSHER / IMPACT CRUSHER)............................28 CONE CRUSHER MANUAL CONTROLS ........................................................................................................29 STOPPING THE PROCESS WITH MANUAL CONTROL WITH CONE CRUSHER ..................................................30
TRACK DRIVE SPEED.................................................................................................................................32
PARAMETERS / SERVICE WINDOW ......................................................................................................33 16.1 16.2
Version 2.5
EDITING CONTRAST, TIME, DATE OR UNITS ...............................................................................................34 PARAMETERS ...........................................................................................................................................34 3/93
IC500 / IC600 Instruction Manual 16.2.1 Service parameter adjustment ............................................................................................................34 16.2.2 User editable parameters ...................................................................................................................35 16.2.3 Parameters .........................................................................................................................................36 16.3 ALARM PARAMETER .................................................................................................................................58 16.4 THIS CHAPTER IS RESERVED FOR FUTURE USE ..........................................................................................58 16.5 CONE CRUSHER SETTING CALIBRATION WINDOW (CONE CRUSHERS ONLY) ..............................................59 16.6 DIAGNOSTICS ...........................................................................................................................................61 16.7 TRACK DRIVE DIAGNOSTICS ....................................................................................................................62 16.8 PUSH BUTTON TEST .................................................................................................................................63 17
LOG FILES.....................................................................................................................................................64 17.1 ALARM LOG .............................................................................................................................................65 17.1.1 Alarm list ............................................................................................................................................66 17.2 DIESEL DIAGNOSTIC TROUBLE CODES (ACTIVE AND STORED) ................................................................72 17.3 TEMPERATURE HISTORY LOG ..................................................................................................................73 17.4 PARAMETER LOG .....................................................................................................................................73 17.5 FACTORY PARAMETERS ............................................................................................................................74
18
MODULE PROGRAM VERSIONS .............................................................................................................75
19
READING INPUT/OUTPUT MODULES DATA .......................................................................................76
20
REPLACING A MODULE............................................................................................................................77 20.1 REPLACING A CONTROL MODULE .............................................................................................................77 20.2 REPLACING A DISPLAY MODULE (UCD) ...................................................................................................77 20.2.1 Updating the HUB and I/O modules ..................................................................................................77
21
TROUBLESHOOTING .................................................................................................................................78
Appendices
1 2
Engine diagnostics codes SAE J1939 Input/Output list
Version 2.5
79 87
4/93
IC500 / IC600 Instruction Manual
1
Precautions
1.1
Handling Information
1.1.1
Storage
Store the device control module (DCM), power supply unit and hub junction module (Hub), hydraulic control module (HCM) and engine control module (ECM) at a temperature between –50 oC and +85 oC (-58 oF and + 176 oF). Store the unit control display (UCD) at a temperature between –25 oC and +60 oC (-13 oF and +140 oF). (See Chapter 2.1 IC500 / IC600 system: Explanations of Abbreviations). 1.1.2
Transport
DCM, Hub, HCM and ECM: Dimensions: 147 x 136 x 46 mm. Weight: 0.7 kg (1.5 lbs) UCD: Dimensions: 182 x 120 x 53 mm Weight: 1.2 kg (2.6 lbs) 1.1.3
Function Keys
Always press the function keys with bare fingers. Do not press the keys with a screwdriver or any other sharp tool, as it will break the keys. Do not use gloves as you may by mistake press many buttons simultaneously. 1.2
Welding of the Unit
If any welding is to be done on the unit, care must be taken to protect the control system.
Stop the engine. Disconnect the earth cable from the batteries. Disconnect engine wire harness sockets from engine control module (Ref. Engine instructions) Fasten the earth cable of the welding device as close to the part to be welded as possible. Make sure that no welding current is able to pass through any bearings or electrical equipment.
1.3 1.3.1
Battery Charging Quick Chargers Do not use quick chargers or start boosters. The rough voltage control and interference of the above-mentioned devices may damage the components of the control system. If unit batteries need to be charged, remove the + and – cables from the batteries during charging.
Version 2.5
5/93
IC500 / IC600 Instruction Manual 1.3.2
Jump Starting
Jump-starting can be used to help the engine start if the batteries of the unit are unable to start the engine. Make sure that the power source voltage level corresponds to the control system (24 VDC).
Make sure the polarity is correct.
1.4
Cleaning the Display
Wipe the display with a damp, soft cloth.
Do not use material that may scratch or otherwise damage the surface of the window. Do not direct a jet of water on to the IC500 / IC600 display screen when washing the unit with a pressure washer.
Version 2.5
6/93
IC500 / IC600 Instruction Manual
2 2.1
General IC500 / IC600 System
The IC500 / IC600 controller is used to control LT functions. IC500 / IC600 is a computer system designed for field operation, and it consists of five components: • • • • •
Device Control Module (DCM) Power Supply Unit and Hub Junction Module (Hub) Hydraulic Control Module (HCM) Engine Control Module (ECM) Unit Control Display (UCD)
Figure 2.1.1 Layout of IC500 / IC600 control system IC500 / IC600 controls the devices of the LT unit. The devices are: • • • • • • • • •
Feeder (LC/LC-Feeder) Crusher Main conveyor Side conveyor Magnetic separator Screen module Engine Hydraulic system Tracks
Version 2.5
7/93
IC500 / IC600 Instruction Manual IC500 / IC600 has three modes: a running mode, an administration mode and a service mode. The running mode is active when the machine is running normally. The administration mode is active when the user is making changes to the system. The service mode is active when an authorized person has entered a password to be able to change service parameters. 2.2
Run Mode
In run mode the system continuously monitors the machine functions and controls the operating devices. All functions are performed automatically and you do not need to interfere in the operation. You are only expected to give instructions if there is an emergency or malfunction when the system is run down. 2.3
Administration Mode
In administration mode you have access to certain system parameters. You can bring devices into use (magnetic separator, side conveyor, etc.) and change the values of the system parameters. You may change some parameters while the process is running, but some parameters require the process to be off. 2.4
Service Mode
In service mode the authorized user has access to all system parameters. Access is given with a password or with a hardware keylock.
Version 2.5
8/93
IC500 / IC600 Instruction Manual
3 3.1
Display Windows Structure and Order of the Display Windows
Figure 3.1.1 Structure of display windows
Version 2.5
9/93
IC500 / IC600 Instruction Manual This structure will give you an idea of how the system is built. The figures refer to the number of windows. It will also show a path from one window to another. The explanations of the windows are given below: 0 1 1.1 1.2 1.3 1.4 1.5 1.6 2 3 3.1 3.1.1
Main window Unit information Feeder information Crusher information Engine information Hydraulics information Operation hour information Gearbox information (LT300HP) Help Process options Manual control Tracks movement
3.2 4
Manual control (LT300HP) Parameters: general, feeder, crusher, tracks, engine and hydraulics, update, alarms, language, supervisor access, contrast adjustment, time and units 5 Diagnostics / Troubleshooting 5.1 Track drive, control test (Radio button 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 (load/save) 5.4 Module program versions 5.5 HUB module 5.6 Device control module, XM1 input/output status 5.7 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 5.10 Engine control module XM2 input/output status 5.11 Engine control module XM3 input/output status 5.12 Hydraulic control module XM1 input/output status 5.13 Hydraulic control module XM2 input/output status 5.14 Hydraulic control module XM3 input/output status
Version 2.5
10/93
IC500 / IC600 Instruction Manual 3.2
General Information
UCD is mounted on the control panel of the unit. The UCD has a 16 bit, 4 MHz crystal display and five control keys (F1 – F5) which are used for the actual control operations. User interface gives you all the information you need about the system and the required actions.
F1 = Unit information
F2 = Help
F3 = Process options
F4 = Settings
F5 = Diagnostics/troubleshooting
Figure 3.2.1 Display The Help key function (F2) stays the same in every window. Thus you always obtain information on the window by pressing F2. 3.3
Display Screen
The system always opens to the main menu (window 0). The key symbols are displayed above the control keys. If the control key does not have any symbol above it, it does not have any function in that window. NOTE! The function of the control keys varies depending on the window you are in. In each display window you will find: • symbol of the window (excluding the main window) • running number of the window • time Use arrow keys F4 and F5 (not in the main window) to move to an action you want to. Choose or save the required information by pressing OK (F3). Version 2.5
11/93
IC500 / IC600 Instruction Manual 3.3.1
Choosing the Language
Select the language in the display window 4 (see chapter 15). You do this by pressing the F4 function key in the main window. 3.3.2
Adjusting the Display Contrast and Brightness
Adjust the display contrast and brightness in display window 4 (see chapter 15). You do this by pressing the F4 function key in the main window.
4
Starting the Process
First, switch the power on with the unit key switch. The control system starts up when the power is switched on (see Fig. 5.1.1). Before starting the engine wait until main window appears. Turn the key switch to "Start engine" position and keep it there until the engine is running. 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 has 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 are able to 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 Hydraulic main valve is open 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
12/93
IC500 / IC600 Instruction Manual
5
Stopping the Process
Stop the process by pressing the "Process stop" –button on the control panel of the unit. (NOTE: The "Process stop" –button is not in the UCD, see Fig. 5.1.1.) The “Process stop” sequence stops the devices of the unit in a specific order. The order is opposite to the start process sequence. The automatic stopping sequence ensures that the devices are stopped in the correct order. The delay between the shut down of each device varies from 5 to 45 seconds. If the process is disabled, the “Process stop” sequence is activated. For more information, please refer to chapter 5, "Starting and stopping", in the Instruction Manual of the unit.
Figure 5.1.1 Control center of the unit 1 2 3 4 5
Emergency stop Lubrication unit (option) Radio key Water pump (option) Display
Version 2.5
6 7 8 9 10
Process ON Key switch Signal horn Process OFF Work light
13/93
IC500 / IC600 Instruction Manual
6
Main Window (Run Mode Window)
When you start up the system the main window (run mode window) is displayed. In the main window you will see the key values of the crushing process. To access unit information, process options, settings or diagnostics, press the function key below the symbol. If you need more information about the main window press the help function key.
Figure 6.1.1 Main window with unit type LT95, LT105, LT1110, LT1213: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Feeder control % and control mode (M = manual, A = automatic) Crusher speed (rpm) Crusher pressure bar/psi Engine running speed (rpm) Engine load % Material capacity according to the belt scale (optional) Radio control / Drive box symbol Material level detector symbol visible when beam is blocked (C-Jaw only) Fuel amount Window number Time Unit information (=F1) Help (=F2) Process options (=F3) Settings (=F4) Diagnostics (=F5) Message field
Numbers 1 – 6 refer to the figures on the unit and on the window. Symbol field (7) shows whether the radio control or drive box is selected. If the crusher level sensor is blocked then that information is also shown in the symbol field. The message field (17) gives you information about the system status. Before the engine has started the message field informs you when the engine is ready for starting.
Version 2.5
14/93
IC500 / IC600 Instruction Manual
Figure 6.1.2 Main window with unit type: LT200HP and LT300HP Explanations: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Lifting conveyor feeder (LC-feeder) control % and control mode (M = manual, A = automatic) (LT300HP only) Lifting conveyor speed % (NOTE: M/A control method shown in position 1) Feed rate (Requested by the crusher cavity level * crusher speed, * crusher pressure) Crusher load kW Crusher setting mm / ‘’. Device pump pressure Radio control / Drive box symbol Cavity level symbol when high level Fuel amount Window number Time Unit information (=F1) Help (=F2) Process options (=F3) Settings (=F4) Diagnostics (=F5) Message field
Numbers 1 – 6 refer to the figures on the unit and on the window. Symbol field (7) shows whether the radio control or drive box is selected. If the crusher level sensor is blocked then that information is also shown in the symbol field. The message field (17) gives you information about the system status. Before the engine has started the message field informs you when the engine is ready for starting.
Version 2.5
15/93
IC500 / IC600 Instruction Manual
Display messages during normal “Process start” phase: • • • • • • • • • • •
Process enabled Process starting Engine rpm increase to work rpm (10 sec ramp) Starting screen module conveyors (if equipped with s-module) Starting screen (if equipped with s-module) Starting magnetic separator Starting main conveyor Starting crusher Starting discharge conveyor Starting feeder Process running
If a cold start is selected, all of the above messages are shown except that the feeder is not started. The system shows a message: •
Process cold start, waiting for the machine to warm up.
When the machine has warmed up the feeder is started and the "Process running" message is shown. Messages are visible for 3 seconds after the "|Process running" status is achieved. Display messages during normal process stop phase: • • • • • • • • • •
Process stop activated Feeder stopped Discharge conveyor stopped Crusher stopped Main conveyor stopped Magnetic separator stopped Screen stopped (if equipped with s-module) Screen module conveyors stopped (if equipped with s-module) Engine to idle rpm Process stopped
Version 2.5
16/93
IC500 / IC600 Instruction Manual 6.1
Help-window
This is the Help-window of the main window. Press F2 in the main window and you obtain Help. To obtain more information, scroll the screen with arrow keys F4 (down) and F5 (up). All windows have their own help to assist and guide in unit operations.
Figure 6.1.3 Help-window
Press F1 to return to the main window.
Version 2.5
17/93
IC500 / IC600 Instruction Manual
7
Unit Information
Press F1 in the main window to go to the unit information window.
Jaw
Impactor
Figure 7.1.1 Unit information (Jaw, Impactor, Cone)
Cone 1 2 3
4 5 6 7 8 9 10 11 12
Symbol of the window Feeder information (to the window 1.1) a) Jaw crusher information (to the window 1.2) b) Impact crusher information (to the window 1.2) c) Cone crusher information (to the window 1.2) Engine information (to the window 1.3) Hydraulic information (to the window 1.4) Time counters (to the window 1.5 ) Back (to the previous window) (F1) Help (F2) Enter (F3) Backwards (F4) Forwards (F5) Distribution gearbox information (LT300HP only)
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
18/93
IC500 / IC600 Instruction Manual
8
Feeder
Highlight the symbol of the feeder in the unit information window and press F3. You will obtain the feeder information window.
Jaw
Figure 8.1.1 Feeder information (Jaw, Impactor, Cone) 1
1c 2 3 4 5 6 7 8
9 9c 10 11 12 13
Impactor
Cone
Feeder speed ( LC-feeder) Symbol of the running status: = Stop = Running = Pause Lifting conveyor control voltage Manual/automatic operation Manual stop for feeder (start not enabled) Feeder speed decrease/increase Feeder valve control % Control voltage Crusher speed a) Number of material level alarms in a selected period of time (Automatic operation) (Jaw crusher only) b) Feed funnel up (Impact crusher only) c) Cone crusher material level in crushing chamber % (If digital sensor selected: level count / count time visible) Crusher pressure Crusher power kW Hydraulic oil temperature Feed rate % (generated by the IC600 ) Crusher high material level alarm count ( number of alarms / time period ) Secondary LT high load alarm
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
19/93
IC500 / IC600 Instruction Manual
9
Crusher
Highlight the symbol of the crusher in the unit information window and press F3. You will obtain the crusher information window.
Jaw
Impactor
Figure 9.1.1a Crusher information (Jaw, Impactor, Cone)
1 2 3 4 5 6 7 8 9 10 11
Version 2.5
Crusher speed Number of material level alarms in a selected period of time Crusher operating hours Clamping pressure (Return rod cylinder pressure) Setting sensor Crusher pressure Control current of the jaw crusher hydraulic pump Status of the service platform control buttons + / - (setting) Status of the service platform control buttons 0 / 1 (setting direction) Control current of the impact crusher hydraulic pump Control current of the impact crusher adjust motor (LT1110 only)
20/93
IC500 / IC600 Instruction Manual
Cone
Figure 9.1.1b Cone crusher information 1 12 13 14 15
16 17 18
Crusher speed Clamping pressure ( 1 = ok , 0 = crusher start / feed prevented) Cooler symbol visible when cooler running Release pressure ( 1 = ok, 0 = crusher start / feed prevented) Lubrication pump running status: Pump speed with hydraulically driven lubrication pump 0 or 1 with electrically driven lubrication pump –Lubrication tank oil temperature C / F. Symbol is blinking when heater is on. Return oil temperature C/ F Feed state: Symbol of the running status: = Stop = Running = Pause
19 20 21 22 23 24 25 26
Feed rate % Crusher power kW Material level in crushing chamber % Crusher setting Counter shaft pressure 0 ( off ) 1 ( on ) Main conveyor running state Crusher running state Message field ( same messages as in main view ) Note: Cooling fan symbol will appear only when the lubrication oil cooler is controlled on.
The crusher parameters shown in this window, are actual measured values. NOTE: The parameters can not be adjusted in this window. Return to the previous window with F1.
Version 2.5
21/93
IC500 / IC600 Instruction Manual
10 Engine Highlight the symbol of the engine in the unit information window and press F3. You will obtain the engine information window.
1 2 3 4 5 6
7 8 9 10 11 12
Figure 10.1.1 Engine information 1 2 3 4 5 6 7 8 9 10 11 12
Engine coolant temperature Engine load Engine oil pressure Engine operating hours Fuel consumption System voltage Engine speed, required Engine speed, actual Engine coolant level % (0 = no coolant, 1 = coolant) Engine intake air temperature Engine intake air restricted (Filter condition indicator) Cooler fan control current (LT200HP only)
These are the actual engine values. NOTE: The parameters can not be adjusted in this window. Return to the previous window with F1.
Version 2.5
22/93
IC500 / IC600 Instruction Manual
11 Hydraulics Highlight the hydraulics symbol in the unit information window and press F3. You will obtain the hydraulics information window.
1 2 3 4 5
6 7 8 9
Figure 11.1.1 Hydraulics information
1. 2. 3. 4. 5. 6. 7. 8. 9.
Hydraulic oil temperature (circuit # 1) Device pump pressure (pump # 1) Crusher pump pressure Hydraulic oil filter (0 = OK/ 1 = not OK) Hydraulic oil level (1 = OK/ 0 = not OK) Device pump pressure ( pump # 2) Lifting conveyor rpm Main conveyor rpm Screen discharge conveyor speed
Actual hydraulics information. NOTE: The parameters can not be adjusted in this window. Return to the previous window with F1.
Version 2.5
23/93
IC500 / IC600 Instruction Manual
12 Time Counters Highlight the time counters symbol in the unit information window and press F3. You will obtain the time counters information window.
Jaw
Figure 12.1.1 Time Counters (Jaw, Impactor, Cone) 1 2 3 4
Impactor
Cone
Tracks driving active hours Process operating hours Feeder operating hours a) Impact crusher operating hours b) Jaw crusher operating hours c) Cone crusher operating hours
These are actual operating hours.
NOTE: The time counters can not be adjusted.
Return to the previous window with F1.
Version 2.5
24/93
IC500 / IC600 Instruction Manual
13 Process Options Press F3 in the main window and you will obtain the process options window.
Jaw
Figure 13.1.1 Process options selection page (Jaw, Impactor, Cone)
Impactor
Cone (LT200HP, LT300HP)
1
Magnetic separator off/on Side conveyor off/on 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 10 Feed stop button (feeder & lifting conveyor stop) 11 Feed speed adjust buttons. (buttons work only if Manual feed mode is selected (ic5x0 parameter F5 = 0, IC6x0 F40=0) 12 Lubrication oil heating sequence activation / deactivation 13 Engine rpm adjusting when crusher is running (engine rpm can be adjusted between the limit CS92 - CS93) 14 Crusher rpm value
2 3
Version 2.5
25/93
IC500 / IC600 Instruction Manual Move in the window with F4 or F5. Confirm your selection with F3. For example, move with F4 or F5 to the magnetic separator off/on button and choose either one of them. Press F3 to save the information. In this way you are able to select whether the magnetic separator is on or not. NOTE: If you want to edit the process options during the process, their validation becomes active only on next “Process start” (e.g. if you want to run the process without the magnetic separator you are able to select the magnetic separator off (0), but the separator keeps running until the process is switched off.) (1)
Hydraulic driven generator for the cone crusher can be activated with this button. When oil temperature is above +20oC (+68oF), deactivate hydraulic output. (2) To edit target speed, please see crusher parameters C24, C25 and C26 in chapter 16.2 Press F1 to obtain the main window.
Version 2.5
26/93
IC500 / IC600 Instruction Manual
14 Manual control of devices Highlight the manual control symbol in the process options window and confirm your selection with F3. You will obtain the manual control window. Manual control for cone crusher, see chp. 14.3. The safety devices of the unit will stop devices when activated from the hard wiring side. The activation of the safety device will not disengage the control, which has been set in the on position. Special care must be taken when the manual control is used.
Jaw
Figure 14.1.1 Manual control 1 Main conveyor off/on 2 Side conveyor off/on 3 Magnetic separator off/on 4 Feeder off/on a) 5 Jaw crusher off/on b) Impact crusher off/on 6 Engine speed adjustment 7 Screen off/on 8 Screen conveyors (2 pieces) off/on 9 Tracks movement 10 Scalper off/on (impact crushers only) 11 Lifting conveyor off/on 12 By pass conveyor (visible only if in use) 13 Return conveyor (visible only if in use)
Impactor
Cone
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
27/93
IC500 / IC600 Instruction Manual
NOTE: No interlocking is valid when the system is running under manual control. The material level indicator is unable to control the feeder. The function of the manual control sets the selected output on/off according to the window 3.1.
14.1 Starting the process with manual control (Jaw crusher / impact crusher) Start the engine as instructed in chapter 5.2, “ Starting the Diesel Engine”, in the Instruction Manual of the unit. 1
2 3 4 5 6 7 8 9
Increase the engine rpm to maximum (CAT C9 & C13 value 2100 rpm / Cummins 5,9 value 2300 rpm) by highlighting the + button on the left side of the engine symbol (see Fig. 14.1.1 number 6). Press F3 as long as the engine is running with the requested rpm. If the unit has a screen module, start the screen module conveyors (see Fig. 14.1.1, number 8). Highlight button 1 and activate it by pressing F3. Start the screen (see Figure 14.1.1, number 7). Highlight button 1 and activate it by pressing F3. Start the main conveyor (see Figure 14.1.1, number 1). ). Highlight button 1 and activate it by pressing F3. Start the crusher (see Fig. 14.1.1, number 5a/b). Highlight button 1 and activate it by pressing F3. Start the magnetic separator (see Fig. 14.1.1, number 3). Highlight button 1 and activate it by pressing F3. Start the side conveyor (see Fig. 14.1.1, number 2). Highlight button 1 and activate it by pressing F3. Start the feeder (see Fig. 14.1.1, number 4). Highlight button 1 and activate it by pressing F3. Start the scalper (see Fig. 14.1.1, number 10). Highlight button 1 and activate it by pressing F3. (Only when LT1110/LT1213 impact crusher is selected).
14.2 Stopping the process with manual control (Jaw crusher / impact crusher) 1 2 3 4 5 6 7 8 9
Stop the scalper (see Fig. 14.1.1, number 10). Highlight button 0 and activate it by pressing F3. (Only when LT1110/LT1213 impact crusher is selected). Stop the feeder (see Fig. 14.1.1, number 4). Highlight button 0 and activate it by pressing F3. Stop the side conveyor (see Fig. 14.1.1, number 2). Highlight button 0 and activate it by pressing F3. Stop the magnetic separator (see Fig. 14.1.1, number 3). Highlight button 0 and activate it by pressing F3. Stop the crusher (see Fig. 14.1.1, number 5). Highlight button 0 and activate it by pressing F3. Stop the main conveyor (Figure 14.1.1, number 1). ). Highlight button 0 and activate it by pressing F3. Start the screen (Figure 14.1.1, number 7). Highlight button 1 and activate it by pressing F3. Stop the screen module conveyors (see Fig. 14.1.1, number 8). Highlight button 0 and activate it by pressing F3. Decrease the engine rpm to minimum by highlighting the - button on the left side of the engine symbol (see Fig. 14.1.1 number 6) and stop the engine as instructed in chapter 5, “Starting and Stopping", in the Instruction Manual of the unit.
Version 2.5
28/93
IC500 / IC600 Instruction Manual
14.3 Cone crusher manual controls Highlight the cone crusher manual control symbol in the process options window and confirm your selection with F3. You will obtain the manual control window.
1 2 3 4
6 7 8
5
Figure 14.1.2 Cone crusher functions 1 2 3 4 5 6 7 8
Lubrication oil heating off / on Lubrication oil pump off / on Lubrication oil cooler off / on Cone crusher off / on Engine rpm control off / on Dust removal fan, can be activated only if dust removal vibrator is not running (visible only dust removal is in use,) Dust removal vibrator, can be activated only if dust removal fan is not running (visible only dust removal is in use) Vibration chute (visible only if in use)
Return to the previous window (process options) with F1.
Version 2.5
29/93
IC500 / IC600 Instruction Manual
14.4 Starting the process with manual control with cone crusher Start the engine as instructed in chapter 5.2, “ Starting the Diesel Engine”, in the Instruction Manual of the unit. 1
2
3
4 5
6
7 8
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 in Lt300HP(if rpm´s are not fully up, the electrical components will not start). Activate lubrication oil heating if oil temperature is below 20 °C/ 68 °F. Lubrication tank electrical heaters can operate internally with hydraulic driven generator or by external power source. Activate hydraulic driven generator separately. When lubrication oil temperature is above 20 °C/ 68 °F)/ 68 °F start the crusher lubrication pump. Highlight button 1 of the item #2 and activate it by pressing F3. Deactivate hydraulic driven generator. Start the main conveyor (see Figure 14.1.1, number 1). ). Highlight item #1 button 1 and activate it by pressing F3. Start the crusher (see Fig. 14.1.2, number 4). Highlight item # 4 button 1 and activate it by pressing F3 ( Note: the lubrication must be on going at least 2 min before starting the crusher ) Start screen module (see fig 14.1.1) highlight the item #7 button 1 and activate is by pressing F3 & screen module conveyors (see fig 14.1.1) highlight the item #8 button 1 and activate is by pressing F3. Start the LC feeder and / or lifting conveyor (see Fig. 14.1.1, number 4). Highlight items 1/11 button 1 and activate it by pressing F3. Start the cooling fan when lubrication oil temperature has exceeded 40 °C/ 104 °F
14.4 Stopping the process with manual control with cone crusher 1 2 3 4 5 6 7
8
Stop the material feed by disabling the feed lifting conveyor or LC feeder & lifting conveyor. Highlight items 1/11 button 0 and activate it by pressing F3. wait until crusher is free from crushed material Stop the crusher (Fig 14.1.2). Highlight the item #4 button 0 and activate by pressing F3 Keep lubrication on at least two minutes to cool down the bearing surfaces. Stop the crusher lubrication pump. (Fig 14.1.2). Highlight the item #2 button 0 and activate by pressing F3 Stop the cooling fan. Highlight the item #3 button 0 and activate by pressing F3 Stop screen module (see fig 14.1.1) highlight the item #7 button 0 and activate is by pressing F3 & screen module conveyors (see fig 14.1.1) highlight the item #8 button 0 and activate is by pressing F3. Stop main conveyor. (See Figure 14.1.1, number 1). ). Highlight item #1 button 0 and activate it by pressing F3
Version 2.5
30/93
IC500 / IC600 Instruction Manual
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. Stay away from the moving tracks! Special care must be taken when manual control is used. NOTE!Driving the tracks from the display is possible only in service mode (service lock open).
Figure 15.1.1 Track driving 1 2 3 4
Left track backwards Left track forward Right track backwards Right track forward
Left and right are defined from the feeder end of the unit. The “forward” instruction moves the unit in the direction of the main conveyor (the same direction as the crushing material moves in the unit). If you press the button continuously, the LT unit will move in the direction you want. You cannot use the forwards and backward functions simultaneously. Only minimum driving speed is possible when the unit is driven from this page. Return to the previous window (process options) with F1.
Version 2.5
31/93
IC500 / IC600 Instruction Manual 15.1 Track drive speed Slow speed is active when the process is running and track driving is allowed. It is also active when the engine rpm is below the T6 parameter (CAT C9 & C13: 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 & C13 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
32/93
IC500 / IC600 Instruction Manual
16 Parameters / service window Press F4 in the main window and you will obtain the parameter adjustment window.
Jaw
Figure 16.1.1 Parameters (Jaw, Impactor, Cone) 1 2 3
4 5 6 7 8 9
10 11 12 13 14 14c 15 16
Impactor
Cone
General parameters Feeder parameters a) Jaw crusher parameters b) Impact crusher parameters c) Cone crusher parameters Tracks parameters Engine parameters Alarm parametrization UPD (Module update) Language Service code: -lock open: access to user and service parameters -lock closed: access to user parameters Contrast adjustment Time Date Units (metric/imperial) Hydraulic overload parameters Cone crusher setting calibration page Lubricating unit and gearbox parameter Engine and hydraulics parameters
Version 2.5
33/93
IC500 / IC600 Instruction Manual 16.1 Editing contrast, time, date or units Highlight the required parameter with F4 or F5 arrow keys and select it by pressing F3 (OK). Adjust the parameter with F4 or F5 and confirm with F3 (OK).
16.2 Parameters There are two types of parameters: user editable parameters and supervisor access parameters.
NOTE: If a parameter has an "S" with it, it means that it is a service parameter and only an authorized person has access to it.
16.2.1 Service parameter adjustment • •
To adjust the Service parameters you will need to have the service lock opened The lock can be opened either with a code or with a service key
Version 2.5
34/93
16.2.2 User editable parameters •
The parameter can be adjusted by first pressing parameter is shown
•
The parameter values background color changes dark and the adjustment buttons appear
•
When the value is changed it is accepted by
•
Press
when the desired
a sufficient amount of times to return to main-page
IC500 / IC600 Instruction Manual 16.2.3 Parameters GENERAL GS1 DELAY BETWEEN DEVICE START. In the process start sequence the devices of the unit are started in certain order. This parameter is used to set the delay between device starts in the sequence. G2 DELAY AFTER THE FEEDER IS STOPPED WITH THE PROCESS STOP SEQUENCE. When the process stop sequence is started the feeder is stopped immediately. This parameter will affect the feeder stop delay after which the stop sequence continues to the next device. The delay is used to ensure that the devices are empty when they are stopped. GS3 DELAY BETWEEN THE SHUT DOWN OF THE DEVICES In the process stop sequence the devices of the unit are stopped in certain order. This parameter is used to set the delay between the stoppings of the devices in the sequence. GS4 VIBRATION CHUTE NOT IN USE This parameter is used to select the vibration chute in use. The vibration chute is under the crusher. It feeds main conveyor with the material coming from crusher. G5 GENERATOR IN USE This parameter is used to select the generator in use. If the unit is equipped with a fixed generator, it must be selected in use in order to enable all functions. The optional hydraulicdriven generator connected to a hydraulic power take off is not related to this parameter. G6 BYPASS CONVEYOR NOT IN USE G7 DUST REMOVAL IN USE This parameter is used to select the dust removal in use. G8 DUST REMOVAL FAN TIME This parameter is used to set the duration of the suction phase in the dust removal sequence. G9 DUST REMOVAL VIBRATING TIME This parameter is used set the duration of the vibration phase in the dust removal sequence. G10 RETURN CONVEYOR NOT IN USE This parameter is used to select the return conveyor in use. GS11 UNIT TYPE SELECTION. This parameter is used to select the type of the machine. In IC500: 1 = LT95 / LT105, 2 = LT1110 / LT1213 In IC600: 3 = LT200HP, 4 = LT300HP, 7 = LT300HP(B) GS12 RADIO TYPE SELECTION This parameter is used to select the type of radio, which is used. 0 = I/O-radio, 1 = CAN-radio. Used only in: IC500 Version 2.5
36/93
IC500 / IC600 Instruction Manual
GS13 LC-FEEDER IN USE This parameter is used to select the Lifting Conveyor Feeder in use. (1), not in use (0) Used in: LT300HP GS14 HYDRAULIC OUTLET IN USE This parameter is used to select the hydraulic output in use. GS15 SCALPER NOT IN USE The optional two stage feeder consists of a feeder and a scalper. The scalper can be equipped with either a vibrating grizzly or a roller grizzly. This parameter is used to select the vibration chute or the roller grizzly in use. The main difference in the control of these devices is the automatic jam removal sequence of the roller grizzly. G16 MAGNETIC SEPARATOR NOT IN USE This parameter is used to select the magnetic separator in use. When the separator is selected into use, the process selection button for the separator appears in window 3. G17 SIDE CONVEYOR NOT IN USE This parameter is used to select the side conveyor in use. When the conveyor is selected into use, the process selection button for the conveyor appears in window 3. Used with: jaw and impact crushers GS18 SEPARATE CRUSHER AUTOMATION (IC70) GS19 DUST REMOVAL WITH HYDRAULIC USE
Version 2.5
37/93
IC500 / IC600 Instruction Manual
Feeder speed control is used to control the production of the unit. In high- or overload situations the feeder is slowed down, paused (restarted automatically) or stopped, depending on the situation. Continuous stopping and starting of the feeder wastes power, consumes more fuel and causes extra stops in crushing process. Thus a steady material feed (a correct feeder control value and proper unit loading) is a key factor when optimizing the production rate. Feeder speed and control modes The feeder has two control modes: Manual and Automatic (selected with parameter F5). In manual mode the control percent can be adjusted by operator from the service platform, IC display or optional radio control. When the feeder automatic mode is selected the IC calculates the feeder control according to: - Crusher drive pressure F8 – F9 & high pressure time delay FS10 (in C-jaw & NP) - Device pump pressure H1 (all) - Device pump 2 pressure H13 (LT300HP only) - Crusher speed FS11 – FS12 & Low speed time delay (in C-jaw & HP) - Hydraulic oil temperatures FS14 (all except HP), FS15 (all units), F33 (HP) - Secondary unit alarms F18 (all units) - High cavity level F16 (all), F43 – F45 (HP only) Feeder control mode affects only the control percent (=speed) - pause and stop conditions are utilized in both modes. Feeder speed varies between the minimum and maximum feeder speeds, which can be adjusted with the parameters F1-F2 (in C-Jaw & NP) and F26-F27 & F35-F36 (in HP). The feeder speed range is divided into a control range from 0 % to 100 %, where 0 % control corresponds to minimum speed parameter and 100 % control corresponds to maximum speed parameter. The control percent is displayed on the display in windows 0 and 1.1. The control range is set with the parameters mentioned above. Every time the feeder starts from stop, the feeder is always started with the minimum speed and it will run at that for a time set by the parameter FS17. After this time the feeder speed is raised to correspond to the active control value.
Version 2.5
38/93
IC500 / IC600 Instruction Manual
Pause state When the feeder goes into the pause state, IC restarts the feeder automatically when the reason for the pause has disappeared. The feeder can be paused for the following reasons: - Crusher power draw is high; Over parameter F48 (HP only) - Crusher level detector (C-Jaw) If high material level is detected the feeder is set to the minimum speed. If the level is high longer than the delay, parameter F16, the feeder is paused. The level detector is taken into use with parameter F6.
NOTE: If the learning level detector is selected into use, the feeder speed is only decreased / increased by steps in a certain time period - Secondary LT pause request (All units) If a secondary machine is interlocked, the request to pause the primary feeder will set the primary feeder to minimum speed. If the request is active longer than the delay, parameter F18, the feeder is paused.
- Crusher low speed (C-Jaw only) If the crusher speed decreases under the crusher speed low limit (parameter FS12) the feeder is set to the minimum speed. If the feeder speed is low longer than the delay, parameter FS13, the feeder is paused. The feeder is restarted when the speed of the crusher rises over the limit FS12.
- Screen module conveyors low speed (if equipped with S-module) If the speed of product conveyor (main discharge belt) drops under the low limit (F42) the feeder is paused. If screen discharge conveyor speed is zero for a 3 seconds the process is disabled.
Stop state When the feeder goes into stop state, the user must restart the feeder manually. The feeder can only be restarted after the reason for stopping has disappeared. The feeder can be restarted either from the service platform or from optional radio control. The feeder can be stopped for the following reasons: - The user stops the feeder from the service platform, radio control or display - Secondary machine alarm Interlocked secondary unit sends an stop alarm message - Device pump pressure alarm If the pressure of the device pump 1 or 2 rises over the alarm limit, the feeder is stopped
- Hydraulic feed gate opening (NP) When the unit is equipped with scalper the feed gate opening uses the same valve with feeder. Therefore the feeder is paused while the feed gate is opened.
- Hydraulic oil temperature rises over the hydraulic oil temperature high limit (FS15) - Fuel level is at alarm limit (E3). Version 2.5
39/93
IC500 / IC600 Instruction Manual - Parameter F68 is used to set whether the scalper also pauses with the feeder. When the scalper is paused with the feeder it is paused when the feeder is paused - not when the feeder goes to minimum speed. When the feed is restarted the scalper is started first and then the feeder.
Feeder automatic mode In the feeder automatic mode the IC controls the feeder control percent. Control is carried out in linear fashion (except in learning level detector mode). In other words the control is continuous. In the learning level detector situation the control range between minimum and maximum speed is divided into steps with parameter F56 - Crusher pressure (NP) - Level detector (C-Jaw & HP) {Learning level detector mode} - Hydraulic oil temperature (C-Jaw & NP) - Feed rate calculation (HP) - Secondary unit (interlock)
F1 FEEDER MINIMUM SPEED This parameter will affect the minimum speed of the feeder. The higher the value, the higher the actual feeder running speed. 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. 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. Note: If the parameter value is set to 0 (zero), the self-learning feeder speed control will not be used. 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. F5 AUTOMATIC FEEDER SPEED CONTROL / ON – OFF SELECTION This parameter is used to select the feeder automatic/manual control mode. Used with: jaw and impact crushers. Automatic feeder speed control = 1 Manual feeder speed control = 0 Note: If you want to use the automatic speed control, set the level detector as “on". Check that the material level detector is functioning. Version 2.5
40/93
IC500 / IC600 Instruction Manual
F6 CRUSHER MATERIAL LEVEL DETECTOR This parameter is used to select the crusher level detector in use. Level sensor ON = 1 Level sensor OFF = 0 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. F8 CRUSHER PRESSURE OK LIMIT. The feeder stays at full speed until the crusher pressure OK limit is achieved (if anything else does not limit the capacity). If the material to be crushed is very hard, you may lower this value in order to affect the feeder speed before the jaw crusher drops the speed (flywheel energy). F9 CRUSHER PRESSURE HIGH LIMIT. At this pressure level the feeder is stopped FS10 CRUSHER PRESSURE HIGH LIMIT TIME DELAY. The length of time the feeder will wait before feeder stop case of crusher high pressure. FS11 CRUSHER SPEED OK LIMIT. When the crusher speed goes below this rpm limit, the feeder will start to reduce speed FS12 CRUSHER SPEED LOW LIMIT. If the speed of the crusher falls down to the crusher speed low value the feeder is stopped. FS13 CRUSHER SPEED LOW LIMIT TIME DELAY. The length of time the feeder will run at a before stopping in case of crusher low speed. FS14 HYDRAULIC OIL TEMP OK LIMIT. The feeder stays at full speed until the hydraulic oil temperature OK limit is achieved (if anything else does not limit the capacity). When the hydraulic oil temperature achieves the value set by parameter FS14 the feeder speed will start to ramp down. FS15 Hydraulic oil temp HIGH limit. When the hydraulic oil reaches the temperature set by parameter FS15 the feeder will stop. If the hydraulic oil temperature rises +2 oC over the value set by parameter FS15 the process is disabled. F16 THE LENGTH OF TIME WHICH THE CRUSHER LEVEL MAY BE OVER THE HIGH LEVEL LIMIT BEFORE THE FEEDER IS PAUSED This parameter is used to set the delay that defines how long the feeder is running with a minimum speed before pausing when the crusher material level is high. FS17 FEEDER START MINIMUM SPEED TIME. The feeder is always started at minimum speed. F18 CRUSHER LEVEL HIGH ALARM TIME OF THE POSSIBLE SECONDARY LT
Version 2.5
41/93
IC500 / IC600 Instruction Manual This parameter is used to set the delay that defines how long the feeder is running with the minimum speed before pausing when the secondary machine load is high. If the secondary machine pause request is active longer than the delay, the feeder is paused. FS19 THE LENGTH OF THE FEEDER ACCELERATION AND DECELERATION RAMP IN SECONDS. FS20 FEEDER-HOPPER ANALOG LEVEL DETECTOR Distance in millimeters from the end of the sensor What corresponds the 4 mA output signal FS21 FEEDER-HOPPER ANALOG LEVEL DETECTOR Feeder hopper analog level detector range 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 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 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. 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. F28 FEED HOPPER ANALOG LEVEL DETECTOR IN USE Feeder hopper analog level detector in use / off F30 METAL DETECTOR STOP TIME Used to stop the metal exactly in the collecting point. If the value is set to zero the detector is not in use. 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. F33 HYDRAULIC OIL SLOW DOWN LIMIT Feed rate is reduced if the hydraulic oil temperature exceed parameter value F34 LIFTING CONVEYOR SPEED ALARM Optional lifting conveyor speed detector can be activated & adjusted to detect belt slip F35 LC FEEDER MINIMUM SPEED Version 2.5
42/93
IC500 / IC600 Instruction Manual This parameter will affect the minimum speed of the LC feeder. The higher the value, the higher the actual feeder running speed. 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. F38 STOP DELAY BETWEEN LC FEEDER AND LIFTING CONVEYOR How long does the LC-feeder run after LC has stopped F40 LC-FEEDER CONTROL MODE 0 = Manual, 1 = Automatic F41 LC FEEDER MINIMUM SPEED START TIME LC-Feeder minimum running speed time 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 Conveyor speed can be observed from the hydraulic information page (page 1.4) F43 CRUSHER CAVITY LEVEL SENSOR Sensor type is selected with this parameter 0 = not in use, 1 = Analog sensor, 2 = Digital sensor F44 CAVITY LEVEL SENSOR CURRENT AT 0% Sensor polarity & range adjustments F45 CAVITY LEVEL SENSOR CURRENT AT 100% Sensor polarity & range adjustments F46 FEED POWER MODE Cone crusher power draw controls the material feed to the crusher F47 CRUSHER POWER OK LIMIT Cone crusher power limit when the material feed starts to derate. F48 CRUSHER POWER HIGH LIMIT Material feed is paused when power high limit is achieved 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 F50 CRUSHER LOW SPEED ALARM LIMIT If the crusher speed is too low the process is stopped. F89 CRUSHER LOW SPEED ALARM LIMIT When the crusher speed goes below this parameter limit the stopped
Version 2.5
43/93
IC500 / IC600 Instruction Manual
CS1 CRUSHER MAX CURRENT The current control value of the crusher speed CS2 CRUSHER MINIMUM CURRENT. CS3 THE OVERLOAD PROTECTION TYPE SELECTION. This parameter is used to set whether the crusher has hydraulic or mechanic setting adjustment system. With hydraulic adjustment system the control system controls and monitors the pressure of the clamping cylinder. - Hydraulic setting adjustment (0) - Hydraulic overload protection (1) - Mechanical setting adjustment (2) CS4 CLAMPING CYLINDER MINIMUM PRESSURE. CS5 CLAMPING CYLINDER MAXIMUM PRESSURE. If the crusher is equipped with a hydraulic setting adjustment system (parameter CS3), the control system controls and monitors the pressure of the clamping cylinder. The clamping cylinder clamps the rotating jaw from the bottom to the setting adjustment mechanism. The control system tries to keep the pressure between the minimum and maximum clamping pressure. When the pressure drops to the minimum value the control system pressurizes the cylinder. The pressurization is stopped when the maximum clamping pressure is reached. These parameters are used to set the minimum and maximum clamping pressures. NOTE! The maximum value must be higher than the minimum. The cut off point for the charging of the return rod cylinder (clamping cylinder) circuit is set with this parameter. (The return rod creates a force which holds the pitman and the toggle plate clearance free against the frame). CS6 CRUSHER STARTING LOW PRESSURE ALARM LIMIT. If the crusher drive circuit does not raise the pressure above the set pressure limit, the jaw is disabled. By this function you are able to detect if the crusher v- belts or the crusher drive pump are damaged. CS7 CRUSHER STARTING LOW PRESSURE ALARM DELAY. The time for how long the system can start the crusher before it sets an alarm due to low pressure in the hydraulic drive circuit. CS8 CRUSHER STARTING HIGH PRESSURE ALARM LIMIT. The crusher starting pressure is observed and if the pressure is above the value of parameter CS8 the crusher is stopped.
Version 2.5
44/93
IC500 / IC600 Instruction Manual CS9 CRUSHER STARTING HIGH PRESSURE ALARM DELAY. The time for how long the system can start the crusher before it sets an alarm due to high pressure in the hydraulic drive circuit. This delay makes it possible to start an empty crusher. If the delay is set too long it is possible that the crusher v-belts will lose their grip and the v-belt will burn. CS10 LOW CLAMPING PRESSURE ALARM LIMIT. If the crusher is equipped with a hydraulic setting adjustment system (parameter CS3), the control system controls and monitors the pressure of the clamping cylinder. The clamping cylinder clamps the rotating jaw from the bottom to the setting adjustment mechanism. This parameter is used to setthe low clamping ressure limit. If the pressure drops under the limit, the crusher is stopped immediately, process is disabled, and alarm 4 is launched. CS11 CRUSHER OVER PRESSURE ALARM DELAY. The process is disabled if the crusher pressure draw is above the alarm limit (CS12) longer than the time set by parameter CS11. CS12 CRUSHER OVER PRESSURE ALARM LIMIT. The process is disabled if the crusher pressure draw exceeds the pressure set by this parameter and stays higher longer than the time set by parameter CS11. CS13 CRUSHER START RAMP TIME. When the crusher is started by the process or from the service platform the crusher acceleration is rather slow. (The crusher swing function uses a different ramp). The parameter CS13 is the time for how long the crusher drive pump current will accelerate from the parameter C2 (start current value) to the crusher running current value parameter C1. CS14 CRUSHER STOP RAMP TIME. The time for how long the current set in parameter C1 will decelerate before it reaches the value set in parameter C2. CS15 ULTRASONIC SETTING SENSOR (NOT AVAILABLE) Setting sensor 4 mA value (mm). Used with hydraulic overload protection. CS16 ULTRASONIC SETTING SENSOR (NOT AVAILABLE) Setting sensor signal range (Ultrasonic) Used with hydraulic overload protection. CS17 CRUSHER OVERLOAD WHEN SETTING IS N% OF FULLY OPEN The crusher and process are disabled if the setting value opens more than the value set by parameter CS17. CS18 NORMAL SETTING MOVEMENT DURING CRUSHING. This parameter defines the allowed setting measurement hysteresis before correction in mm. The hydraulic overload will return to this setting if it is changed. C19 CRUSHER SPEED SENSOR ON (1) / OFF (0). Version 2.5
45/93
IC500 / IC600 Instruction Manual If the crusher speed sensor is damaged it can be temporarily bypassed by taking it out of use with this parameter. C24 CRUSHER TARGET SPEED 1 The target speed 1 of the crusher can be adjusted with this parameter. Default: Depends on the unit type. Please refer to the parameters help file. C25 CRUSHER TARGET SPEED 2 The target speed 2 of the crusher can be adjusted with this parameter. Default: Depends on the unit type. Please refer to the parameters help file C26 CRUSHER TARGET SPEED 3 The target speed 3 of the crusher can be adjusted with this parameter. Default: Depends on the unit type. Please refer to the parameters help file CS27 CRUSHER SPEED SENSOR PULSES PER ROUND. This parameter is used to set the value of how many pulses the speed sensor sends when the crusher rotates one round. CS28 CRUSHER PUMP ZERO SPEED 1. When selected crusher target speed 1 is in use the crusher drive pump control current will accelerate to this parameter value. As soon as the value is achieved the control system observes the crusher speed and if the sensor is functional the target speed control will be used. NOTE: If the parameter C36 is selected to 0 or if the crusher speed sensor is damaged the crusher drive pump control current remains in the value given with this parameter CS29 ADJUST CRUSHER MOTOR ZERO SPEED 1. This parameter is only used in LT1110. When selected crusher speed 1 is in use and the crusher has been accelerated to pump zero speed 1 (parameter 28) the adjustment motor keeps the crusher speed stabile with this parameter. The IC system then monitors and if necessary changes the adjustment pump angle to maintain the correct crusher auto speed. NOTE: If the parameter C36 is selected to 0 or if the crusher speed sensor is damaged the crusher drive pump control current remains in the value given with this parameter CS30 CRUSHER PUMP ZERO SPEED 2. When selected crusher target speed 2 is in use the crusher drive pump control current will accelerate to this parameter value. As soon as the value is achieved the control system observes the crusher speed and if the sensor is functional the target speed control will be used. NOTE: If the parameter C36 is selected to 0 or if the crusher speed sensor is damaged the crusher drive pump control current remains in the value given with this parameter
CS31 ADJUST CRUSHER MOTOR ZERO SPEED 2. Version 2.5
46/93
IC500 / IC600 Instruction Manual This parameter is only used in LT1110. When selected crusher speed 2 is in use and the crusher has been accelerated to pump zero speed 2 (parameter 30) the adjustment motor keeps the crusher speed stabile with this parameter. The IC system then monitors and if necessary changes the adjustment pump angle to maintain the correct crusher auto speed. NOTE: If the parameter C36 is selected to 0 or if the crusher speed sensor is damaged the crusher drive pump control current remains in the value given with this parameter CS32 CRUSHER PUMP ZERO SPEED 3. When selected crusher target speed 3 is in use the crusher drive pump control current will accelerate to this parameter value. As soon as the value is achieved the control system observes the crusher speed and if the sensor is functional the target speed control will be used. NOTE: If the parameter C36 is selected to 0 or if the crusher speed sensor is damaged the crusher drive pump control current remains in the value given with this parameter CS33 ADJUSTMENT CRUSHER MOTOR ZERO SPEED 3. This parameter is only used in LT1110. When selected crusher speed 3 is in use and the crusher has been accelerated to pump zero speed 3 (parameter 32) the adjustment motor keeps the crusher speed stabile with this parameter. The IC system then monitors and if necessary changes the adjustment pump angle to maintain the correct crusher auto speed. NOTE: If the parameter C36 is selected to 0 or if the crusher speed sensor is damaged the crusher drive pump control current remains in the value given with this parameter CS34 CRUSHER SPEED CHANGE HYSTERESIS When crusher is running with auto speed control, the crusher actual speed can vary between hysteresis limits. If the crusher actual rpm value exceeds the limit (+/- this parameter value) crusher speed will be adjusted CS35 CRUSHER TARGET SPEED RAMP When crusher speed is changing, the reaction time can be adjusted with this value C36 CRUSHER AUTO SPEED Autospeed in use = 1 Autospeed not in use = 0 CS37 CRUSHER IDLING POWER LIMIT Idling power is used to detect that he crusher is empty of material before stopping the crusher
CS38 HYDRAULIC MOTOR SIZE Value is used to calculate power Version 2.5
47/93
IC500 / IC600 Instruction Manual CS39 CRUSHER HYD. MOTOR V-BELT PULLEY DIAMETER Value is used to calculate power CS40 CLAMPING FAULT DELAY Alarm delay time before the clamping fault alarm appears CS41 RELEASE FAULT DELAY Alarm delay time before the release fault alarm appears CS42 CRUSHER EXCESSIVE POWER ALARM LIMIT Power limit by with the process stops to protect the cone crusher CS43 CRUSHER EXCESSIVE POWER ALARM DELAY Alarm delay time before the release fault alarm appears CS44 CRUSHER SOFT START TIME CS45 CRUSHER STARTER DELAY CS46 HP-SETTING CHANGE PER TOOTH Value how much does the setting change by one tooth step CS47 CRUSHER DRIVE TYPE This selection is used to select the correct drive type, depending on the machine CS48 DIESEL ENGINE SIZE This value defines the diesel engine power (kW) CS49 UNIT POWER DRAW WITHOUT CRUSHER This value defines the diesel engine power (kW) draw without crusher CS50 HYDRAULIC PUMP SIZE This value defines the hydraulic pump size CS60 CRUSHING HOURS TO NOTIFY USER ABOUT BEARINGS LUBRICATION. This parameter is used to set the interval between the service notifications on the lubrication of crusher bearings. After the crusher has been running for this time, the system lauches the alarm 131 to remind the operator. CS61 CRUSHING HOURS TO NOTIFY USER ABOUT COUNTER WEIGHT LINER AND ARM LINERS CLEANING. CS62 CRUSHER TARGET SPEED CHANGE ALLOWED ”0” = not allowed, “1” allowed
Version 2.5
48/93
IC500 / IC600 Instruction Manual
Tracks can be driven from the drive box, (optional) radio control, and the display. If radio operation is selected from the main control panel, other controls cannot be used for driving. If the drive box is connected and radio control is not selected, the drive box can be used to drive the unit. The display can be used for driving in service mode when other driving devices are not present and process is stopped. Driving is prevented if: - Hand valves are activated - Screen module is connected and process has been activated - There is a problem with track drive outputs and feedbacks Driving with a long main conveyor (unit without vibration chute) With a long main conveyor the bottom side of the conveyor has to be lifted before driving. The conveyor is lifted after engine start when a driving device is either connected or track control is activated. Track driving is possible after the conveyor has been lifted for five seconds. The conveyor descends when it is started. During process the conveyor is not lifted. The hydraulic power take off is controlled with the same valve as main conveyor lifting, and these functions cannot be used simultaneously. The hydraulic power take off is deactivated when main conveyor is lifted. For safety reasons the user must restart the hydraulic power take off himself window [3]. Driving speeds There are three different drive speeds for tracks. Slow speed is active when process is not stopped or when engine rpm is less than the value of parameter T6. Parameters T8 - T11 are used to adjust the track speed so that the machine moves straight forward/backward with proper speed. Normal speed is active when engine speed is higher than the value of parameter T6. Fast speed is active when engine speed is higher than the value of parameter T5 AND both tracks are driven in the same direction. In other words the fast speed is no longer active when the unit is turning.
Version 2.5
49/93
IC500 / IC600 Instruction Manual
T1 MIN VALUE FOR RIGHT TRACK BACKWARD How much the spool moves from central point when engine rpm's are below the normal speed and right drive lever pulled backwards T2 MIN VALUE FOR RIGHT TRACK FORWARD How much the spool moves from central point when engine rpm's are below the normal speed and right drive lever pulled forward. T3 MIN VALUE FOR LEFT TRACK BACKWARD How much the spool moves from central point when engine rpm's are below the normal speed and left drive lever pulled backward. T4 MIN VALUE FOR LEFT TRACK FORWARD How much the spool moves from central point when engine rpm's are below the normal speed and left drive lever pulled forward. From T1 to T4: Adjust the value so that the track motion is 0,25m/sec.
T5 FAST SPEED TRACKING RPM LIMIT This parameter is used to define the engine speed at which fast track driving speed is automatically activated. Fast speed is not active while the unit is turning or screen module is connected. The parameter value has to be greater than T6. Used with: jaw and impact crushers T6 NORMAL SPEED TRACKING RPM LIMIT This parameter is used to define the engine speed at which normal track driving speed is automatically activated. The parameter value has to be lower than T5. T7 TRACK STOP RAMP The stop time of the unit can be adjusted with this parameter. The ramp is not in use when driving at slow speed. TS13 FAST SPEED ALLOWED / NOT ALLOWED This parameter prevents the fast drive to activate, e.g. if screen module is connected, "0" = not allowed, "1" = allowed
Version 2.5
50/93
IC500 / IC600 Instruction Manual
E1 ENGINE MIN SPEED This parameter sets the minimum speed for the engine. ES2 ENGINE MAX SPEED This parameter is used to set the maximum speed for the engine. For example, hydraulic pumps can set requirements for maximum speed in addition to the engine. E3 FUEL LEVEL ALARM LIMIT When the fuel level drops below the alarm limit, the alarm is displayed and material feed is immediately shut down. The user can restart the feed from service platform or radio control. The fuel level indication will not prevent the unit from running out of fuel. ES4 FUEL LEVEL SENSOR MINIMUM OUTPUT VOLTAGE. This parameter is used to set the voltage of the fuel level sensor when fuel tank is empty. Note the operation voltage of the fuel sensor is 5 VDC. ES5 FUEL LEVEL SENSOR MAXIMUM OUTPUT VOLTAGE. This parameter is used to set the voltage of the fuel level sensor when fuel tank is full. ES6 MINIMUM PWM VALUE FOR THROTTLE CONTROL. If the engine speed is not controlled with J1939 it is possible to use PWM control. PWM control is not used in LT 105(S). ES7 MAXIMUM PWM VALUE FOR THROTTLE CONTROL. If the engine speed is not controlled with J1939 it is possible to use PWM control. PWM control is not used in LT 105(S).
ES8 COOLER CONTROL IN USE Engine cooler control observes engine coolant and charge air temperatures and adjusts the fan speed depending on the need. The control value is calculated for both temperatures and the one which demands more cooling is taken in use. If the control is not in use the fan rotates with maximum speed. Parameters ES9 - ES15 set the limits for the control. This parameter is used to select the cooler control in use. ES9 COOLER MAXIMUM MA-VALUE (MINIMUM SPEED) The cooler fan minimum running speed is adjusted with this parameter. ES10 COOLER MINIMUM MA-VALUE (MAXIMUM SPEED) The cooler fan maximum running speed is adjusted with this parameter.
Version 2.5
51/93
IC500 / IC600 Instruction Manual
ES11 COOLANT TEMPERATURE OK LIMIT ES12 COOLANT TEMPERATURE HIGH LIMIT When the coolant temperature rises over the ok limit the cooling fan speed starts to rise from the minimum speed. The speed is raised relative to the temperature until the temperature reaches the high limit, in which point the fan is running with maximum speed. When the temperature drops, the fan is decelerated in a similar way. These parameters are used to set the ok and high limits for the coolant temperature. ES13 CHARGE AIR TEMP TEMPERATURE OK LIMIT ES14 CHARGE AIR TEMP TEMPERATURE HIGH LIMIT When the charge air temperature rises over the ok limit the cooling fan speed starts to rise from the minimum speed. The speed is raised relative to the temperature until the temperature reaches the high limit, in which point the fan is running with maximum speed. When the temperature drops, the fan is decelerated in a similar way. These parameters are used to set the ok and high limits for the charge air temperature. ES15 COOLER RAMP SPEED FASTNESS MA / SEC The fastness of the cooling fan control change can be set with this parameter. ES16 DIESEL ENGINE TYPE “0” CAT, “1” Cummins,
Version 2.5
52/93
IC500 / IC600 Instruction Manual
HYDRAULIC PARAMETERS H1 DEVICE PUMP PRESSURE ALARM LIMIT This parameter is used to set the high pressure limit for the device pump 1.
HS2 HYDRAULIC OIL TEMPERATURE SENSOR GAIN(MV/100°C) This parameter is used to set how much [mV] the voltage value of the hydraulic oil temperature sensor changes when the temperature changes 100 °C. HS3 HYDRAULIC OIL TEMPERATURE SENSOR ZERO POINT This parameter is used to set the voltage value of the hydraulic oil temperature sensor which corresponds to 0 °C temperature.
HS4 HYDRAULIC OIL TEMPERATURE LIMIT FOR MONITORING OIL FILTER The hydraulic oil filter condition observation is based on the pressure measurement of the filter. In addition to accumulated dirt, also the viscosity of the hydraulic oil affects the pressure. Hydraulic oil viscosity varies according to the oil temperature.With cold oil the pressure of the filter might give the impression that the filter is clogged even though the reason for the high pressure was stiff oil. This parameter is used to set the limit for hydraulic oil temperature over which the filter is monitored. If hydraulic oil is changed to an oil with different viscosity grading, the value of the parameter has to be changed respectively. Used with: jaw and impact crushers ISO 32 ------ 10 oC ISO 46 ------ 20 oC ISO 68 ------ 30 oC HS5 CRUSHER PRESSURE SENSOR 4 MA VALUE This parameter is used to set the pressure value that corresponds with the 4 mA output from the pressure sensors of the pumps. With this parameter you are able to trim the sensor’s zero-point HS6 CRUSHER PRESSURE SENSOR RANGE This parameter is used to set range for the pressure sensor. HS7 CLAMPING PRESSURE SENSOR 4 MA VALUE This parameter is used to set the pressure value that corresponds with the 4 mA output from the pressure sensors of the pumps. With this parameter you are able to trim the sensor’s zero-point HS8 CLAMPING PRESSURE SENSOR RANGE This parameter is used to set range for the clamping pressure sensor. HS9 DEVICE PUMPS AND LIFTING CONVEYOR PRESSURE SENSOR 4 mA VALUE This parameter is used to set the pressure value that corresponds with the 4 mA output from the pressure sensors of the device pumps.
HS10 DEVICE PUMPS AND LIFTING CONVEYOR PRESSURE SENSOR RANGE This parameter is used to set the range for the pressure sensors of the device pumps. HS11 TOGGLE PRESSURE SENSOR 4 MA VALUE This parameter is used to set the pressure value that corresponds with the 4 mA output from the pressure sensors of the pumps. With this parameter you are able to trim the sensor’s zero-point Version 2.5
53/93
IC500 / IC600 Instruction Manual
HS12 TOGGLE PRESSURE SENSOR RANGE This parameter is used to set range for the pressure sensor. H13 DEVISE PUMP #2 PRESSURE LIMIT This parameter is used to set the high pressure limit for the device pump 2. Used with: jaw and impact crushers H14 MAIN CONVEYOR SPEED ALARM This parameter is used to set the low speed limit for the main conveyor. Process is disabled when the speed drops below the limit.
H16 DEVICE PUMP 1/2/3 PRESSURE HIGH Feed stopped (0) / paused (1) HS17 HYDRAULIC OIL COOLER START TEMP The hydraulic oil cooler is started when the hydraulic oil temperature rises over the start limit. This parameter is used to set the start limit. Used with: jaw and impact crushers HS18 HYDRAULIC OIL COOLER STOP TEMP The hydraulic oil cooler is stopped when the hydraulic oil temperature drops under the stop limit. This parameter is used to set the stop limit. Used with: jaw and impact crushers H19 HYDRAULIC OIL COOLER AUTOMATIC CLEANING This parameter is used to set the automatic hydraulic oil cooler cleaning to use. -When selected in use, the automatic cleaning sequence rotates the hydraulic oil cooling fan to the reverse direction for 10 seconds during process start. HS22 LC-FEEDER OIL VOLUME FLOW HS23 LC-FEEDER IDLE PRESSURE HS24 SCREEN MODULE OIL VOLUME FLOW HS25 SCREEN MODULE IDLE PRESSURE HS26 PUMP1 IDLE PRESSURE HS27 PUMP 1 OIL VOLUME FLOW
Version 2.5
54/93
IC500 / IC600 Instruction Manual
These parameters are used only with: LT200HP, LT300HP LS1 LUBRICATION TANK OIL TEMPERATURE SENSOR 4MA VALUE This parameter is used to set the temperature value that corresponds with the 4 mA output of the lubrication oil temperature sensor. LS2 LUBRICATION TANK OIL TEMPERATURE SENSOR RANGE This parameter is used to set the range for the lubrication oil temperature sensor. If the parameter value is set to zero the sensor is not in use. LS3 LUBRICATION RETURN OIL TEMPERATURE SENSOR 4MA VALUE This parameter is used to set the temperature value that corresponds with the 4 mA output of the lubrication oil temperature sensor. LS4 LUBRICATION RETURN OIL TEMPERATURE SENSOR RANGE This parameter is used to set the range for the lubrication oil temperature sensor. If the parameter value is set to zero the sensor is not in use. LS5 LUBRICATION TANK OIL HEATERS, HEATERS OFF LIMIT This is the temperature limit on which the lubrication oil heaters are turned off LS6 LUBRICATION RETURN OIL TOO HOT, FEED STOP LIMIT This is the temperature limit on which the feeder is stopped because lubrication oil is too hot LS7 LUBRICATION RETURN OIL TOO HOT, CRUSHER ALARM LIMIT This is the temperature limit on which the crusher is stopped because lubrication oil is too hot LS8 COUNTER SHAFT PRESSURE ALARM DELAY This delays the countershaft lubrication pressure alarm LS9 LUBRICATION PUMP LOW SPEED LIMIT This limit is the lowest allowed speed for lubrication pump LS10 LUBRICATION OIL COOLER ON TEMPERATURE LIMIT LS11 LUBRICATION OIL COOLER OFF TEMPERATURE LIMIT. LS12 LUBRICATION PUMP MOTOR TYPE “0” =hydraulic motor, “1” =electric motor, default “0” LS13 LUBRICATION TANK TEMP PROCESS ENABLED LIMIT LS14 LUBRICATION PUMP RUNNING TIME AFTER CRUSHER HAS STOPPED Version 2.5
55/93
IC500 / IC600 Instruction Manual
LS15 LUBRICATION PUMP SPEED SENSOR DETECTED PULSES PER ONE ROUND LS16 LUBRICATION OIL COOLER MOTOR TYPE “0” hydraulic, “1” electric motor, LS17 OIL HEATING HYDRAULIC PUMP RAMP TIME. IF SET TO ZERO NOT IN USE, LS18 LUBRICATION PUMP SPEED ALARM DELAY This delays the lubrication pump speed low alarm
These parameters are used only with: LT300HP KS1 DELAY BEFORE NEW START ATTEMPT IS POSSIBLE This parameter is used to set a delay between crusher start attempts. Frequent starting is prevented to avoid the clutch from being damaged. KS2 GEARBOX OIL TEMPERATURE ALARM LIMIT When the gearbox oil temperature rises over the alarm limit, the process is disabled and alarm 100 is launched. This parameter is used to set the alarm limit. K3 GEARBOX OIL TEMPERATURE WARNING LIMIT This parameter is used to set the warning limit of the gearbox oil temperature. When the limit is exceeded a warning message is shown. KS4 ENGINE RPM AT CLUTCH ACTIVATION This parameter is used to set the engine speed at which the clutch is activated during the crusher start sequence. During crusher start the control system controls the engine speed and the hydraulic valves of the gearbox. The parameter value must be higher than engine minimum speed + 20 rpm. KS5 CHOKE TIME This parameter is used to set the duration of the crusher soft start. In other words it sets the time how long the choke is active. During crusher start the control system controls the engine speed and the hydraulic valves of the gearbox. KS6 DELAY BEFORE CLUTCH SLIP % IS CHECKED DURING CRUSHER START Clutch slip is checked twice during the crusher start sequence: after soft start (after choke deactivation) and after the engine speed has been raised to the selected operating speed. This parameter is used to set the time period after both cases before the slip is checked. KS7 CLUTCH SLIP % ALARM LIMIT If the clutch slip percent rises over the alarm limit and stays there longer than the delay set by parameter (KS15), the clutch is released, the process is disabled, and alarm 101 is launched. The clutch slip percent is calculated by comparing the crusher drive axle (in the gearbox) speed and engine speed. Crusher speed does not have an effect on the clutch slip percent. This parameter is used to set the alarm limit.
Version 2.5
56/93
IC500 / IC600 Instruction Manual KS8 CRUSHER DRIVE AXLE SPEED SENSOR This parameter is used to set the crusher drive axle speed sensor in use. KS9 CLUTCH LOW PRESSURE ALARM LIMIT If clutch pressure drops under the alarm limit, the clutch is released, process is disabled, and alarm 103 is launched. This parameter is used to set the alarm limit. KS10 GEARBOX OIL TEMPERATURE SENSOR 4mA VALUE This parameter is used to set the temperature value that corresponds with the 4 mA output of the gearbox oil temperature sensor. KS11 GEARBOX OIL TEMPERATURE SENSOR RANGE This parameter is used to set the range for the gearbox oil temperature sensor. If the parameter value is set to zero the sensor is not in use. KS12 CLUTCH PRESSURE SENSOR 4MA VALUE This parameter is used to set the pressure value that corresponds with the 4 mA output of the clutch pressure sensor. KS13 CLUTCH PRESSURE SENSOR RANGE This parameter is used to set the range for the clutch pressure sensor. If the parameter value is set to zero the sensor is not in use. KS14 CRUSHER DRIVE AXLE SPEED SENSOR DETECTED PULSES PER ONE ROUND This parameter is used to set how many pulses the speed sensor sends when the crusher drive axle rotates one round. KS15 DELAY FOR CLUTCH SLIP % ALARM WHEN GEARBOX IS RUNNING This parameter is used to set the time how long the clutch slip percent can be higher than the alarm limit (parameter KS7) before the alarm is launched.
Version 2.5
57/93
IC500 / IC600 Instruction Manual
16.3 Alarm parameter In the Alarm parameter 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
58/93
IC500 / IC600 Instruction Manual 16.5 Cone crusher setting calibration window (Cone crushers only) Due to material wear the crusher actual setting will enlarge during the crushing process. Calibration of the setting is recommended at least in every 40 h of operation. Fast and correct setting changes are easily done when the actual setting is maintained in the setting calibration window.
2 1
3 4 5
Figure 16.5 Cone crusher calibration page 1 2 3 4 5
Setting value Operating hours after the last setting calibration Time & date of last setting calibration kWh consumed after the last setting calibration Calibration window
16.5.1 Setting calibration With the new liners (liner contact method) 1 Make sure that the process is switched off. 2 Install the crusher control panel on the service platform 3 Make sure that the crushing chamber is clean. 4 Activate the crusher lubrication as instructed in chap.14.3 4 Turn the bowl to setting decrease direction 5 When the crusher head turns stop turning the bowl. 0-mm setting is achieved. 6 Return to the control panel and open page 4.1 7 Activate calibration by pressing F3 button. 8 Adjust the new measured actual crusher setting value to the calibration window by adjusting the actual value with buttons F4 & F5. (See fig 16.5 item 5) 9 Confirm the new value to the control system by pressing button F3. 10. Set the desired setting from the crusher control panel. NOTE: Check the allowed minimum setting from the instruction manual Nordberg 100, 200, 300,400,500 cone crushers.
Version 2.5
59/93
IC500 / IC600 Instruction Manual
(Used liners: No liner contact before the A-limit according to chapter 3.13 of the instruction manual Nordberg 200 and 300 cone crushers) 1 2 3 4 5 6 7
Check the setting according to instruction manual Nordberg 200 and 300 cone crushers / chapter 3.11. Compare the measured setting to the setting value #1 in window 4.1. If a difference is noticed in actual setting and display value, calibrate the setting. Activate calibration by pressing F3 button. Adjust the new measured actual crusher setting value to the calibration window by adjusting the actual value with buttons F4 & F5. Confirm the new value to the control system by pressing button F3. Set the desired setting from the crusher control panel.
NOTE: Check the allowed minimum setting from the instruction manual Nordberg 200 and 300 cone crushers.
Version 2.5
60/93
IC500 / IC600 Instruction Manual 16.6 Diagnostics You obtain the diagnostics window by pressing F5 in the main window. This is the main window for diagnostics. In this window you can select whether you want to view basic diagnostics (tracks, buttons and log files) or detailed diagnostics (connectors of each module). For example, the tracks symbol (Fig. 17.1.1, number 1) opens the track drive diagnostics window.
Figure 17.1.1 Diagnostics
1 2 3 4 5 6 7 8 9
Tracks (window 5.1) Control keys window 5.2) Log files (window 5.3) Module program versions (window 5.4) CAN2 bus parameters Status of information by each connector of the device control module Status of information by each connector of Hub junction module Status of information by each connector of engine control module Status of information by each connector of hydraulics control module
Move with F4 and F5 to the box that you want to see and select it with F3. Return to the main window with F1.
Version 2.5
61/93
IC500 / IC600 Instruction Manual 16.7 Track Drive Diagnostics You can obtain the track drive diagnostics window by selecting the tracks symbol in the diagnostics main window.
Figure 17.1.2 Track drive diagnostics 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Version 2.5
Drive box / radio control Left track "forward" control received (radio/drive box) Left track "backward" control received (radio/drive box) Right track "forward" control received (radio/drive box) Right track "backward" control received (radio/drive box) Left track control percentage Left track control voltage percentage Right track control percentage Right track control voltage percentage Left track forward output. When activated, the triangle is black. Left track backward output. When activated, the triangle is black. Right track forward output. When activated, the triangle is black. Right track backward output. When activated, the triangle is black. Engine rpm down or feeder off with radio control received Engine rpm up or feeder on with radio Engine rpm down output. When activated, the triangle is black. Engine rpm up output. When activated, the triangle is black. Tracking controls active in radio Crushing controls active in radio Feeder speed down control received from radio Feeder speed up control received from radio
62/93
IC500 / IC600 Instruction Manual This window shows you the most important data for track driving. The window is also the diagnostics window for the drive box. The selected control (drive box or radio) is shown in this window (see Fig. 17.1.2, number 1). You will also see the control percentages for the proportional valves, as well as the control voltage area. Engine rpm and increasing/decreasing of the engine speed are also indicated. 16.8 Push Button Test You will obtain the push button test window by selecting the control button symbol in the diagnostics main window.
Figure 17.2.1 Push button test (depending on selected LT unit) 1 2 3 4 5 6 7 8 9
Feeder off/on / Feed on/off Feeder speed decrease / increase Feed decrease / increase Crusher off/on (jaw crusher only) Crusher swing clockwise / counter clockwise (jaw crusher only) Crusher setting increase / decrease (jaw crusher only) Engine key switch, start, running status Process key switch off/on Radio control off/on Feed funnel up (impact only)
This window allows you to check whether the buttons in the remote control function normally. For instance, if you press feeder on/off button of the service platform, the function is indicated by a highlighted feeder on (number 1) symbol at this window. To carry out the service platform test you need an assistant to activate the button in the service platform, as the button needs to be pressed and its status read simultaneously. Return to the previous window by pressing F1.
Version 2.5
63/93
IC500 / IC600 Instruction Manual
17 Log Files In window 5 selecting symbol "log files" (figure 17.1.1, number 3) you will obtain the log files window (5.3).
Figure 18.1.1 Log files 1 2 3 4 5
Alarm history Diesel diagnostics trouble codes Temperature history log Factory settings Parameter log
From window 5.3 you have access to windows: 5.3.1 (Alarm log) 5.3.2 (Diesel diagnostics trouble codes) 5.3.3 (Temperature history log) 5.3.4 (Parameter log) 5.3.5 (Factory settings). Return to the previous window by pressing F1.
Version 2.5
64/93
IC500 / IC600 Instruction Manual 17.1 Alarm log In the log files window select number 1 to obtain the alarm log window.
Figure 18.1.2 Alarm log When a malfunction occurs, the system shows an alarm message window and saves the information about the alarm in the alarm log database. The database consists of the date, time, alarm code and number of alarms. If the same alarm occurs sequentially, only the first and last alarms and the number of alarms are saved. The maximum number of alarms in the database is 100. The date of the last reset is saved. How to use the alarm messages and the alarm log: When the system gives out an alarm message, read it and try to understand it. If you do not understand the meaning of the alarm or do not know how to fix the problem, you can get additional information by pressing F2 (help) to access the alarm message’s help view window while the alarm message is active. You can find a list of alarms (the number of alarms depends on the selected unit type) by going to the Parameters/service window (4) and choosing the Alarm icon (Fig 16.1.1, number 6) by highlighting it and pressing OK. Here the alarm help view can be accessed by pressing the F2 button. Example on how to use the alarm log: Problem: A malfunction occurs that stops the process. You know the approximate time when the malfunction occurred but you do not know what alarms occurred before and after the malfunction. Solution: From the alarm log you can find out the dates, times, alarm codes and the number of times the alarms have occurred. Use the alarm log to look up all the alarms that occurred near the time the malfunction occurred, this way you can narrow down the cause. If you need further information on how to deal with the problem, refer to chapter 16.3. The complete list of alarms and their corresponding alarm codes can be found in chapter 17.1.1. Return to the previous window by pressing F1.
Version 2.5
65/93
IC500 / IC600 Instruction Manual 17.1.1 Alarm list 1-active, 0-passive, not shown Alarm # 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Crusher over pressure Crusher pressure rising too fast on start Clamping pressure Toggle plate condition Crusher pressure rising too slow on start Crusher speed rising too slow on start Crusher speed slow Hydraulic oil temperature high feeder stopped Fuel level low No connection to diesel engine Engine red stop Engine amber warning Hydraulic oil level low Hydraulic oil filter clogged Hydraulic oil main valve closed Hydraulic oil temperature high Main conveyor safety switch left Main conveyor safety switch right Crusher critical Overload Conveyor maintenance safety switch Screen over size conveyor safety switch Screen under size conveyor safety sw. Side conveyor safety switch left side Side conveyor safety switch right side Drive box remote stop Radio remote stop Emergency stop pressed from control panel Emergency stop pressed from service platform Emergency stop pressed from engine module Emergency stop pressed from hydraulic centre Wrong program in one of the I/O-modules Ultrasonic sensor not in range Setting pressure sensor not in range Device pump pressure sensor not in range Toggle plate pressure sensor not in range ECM-module missing HCM-module missing DCM-module missing Device pump pressure high Crusher pressure sensor not in range Setting sensor detected overload
Version 2.5
LT1110 / LT1213
LT95/LT105
LT200HP
1 0 0 0 0 0 1 1
1 1 1 1 1 1 1 1
0 0 0 0 0 0 0 1
1 1 1 1 1 1 1 1 1 1 0 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 0 1 1 1 1 1 1 1 1 1
1
1
1
1
1
1
1 0 0 1 0 1 1 1 1 1 0
1 1 0 1 0 1 1 1 1 1 1
1 0 0 1 0 1 1 1 1 1 1 66/93
IC500 / IC600 Instruction Manual 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82
Toggle plate failure Bypass conveyor safety Bypass conveyor motor overload Return conveyor safety switch Return conveyor motor overload Generator voltage Generator thermistor Generator frequency Cone crusher feedback Vibration chute motor overload Feeder hopper level sensor not in range Metal detected Engine air filter clogged Lifting conveyor safety Device pump 2 oil pressure high Belt tensioning failure, controlled output HCM XM1.1 is not active! Belts are loosened or pre-tensioning is ongoing Side conveyor motor overload Crusher stop without ramp Feed authorization lost Lifting conveyor speed low Device pump 2 oil pressure sensor out of range Impactor crusher slow speed alarm Impactor cover open alarm Impactor speed fault or jammed crusher FB fault Cone crusher in service mode Process disabled: cone crusher alarm Connection between IC570 and IC70 is lost Wintermode with internal power supply is activated. Main conveyor low speed Engine cooler current feed back fault! Cooler to the max speed. Charger fault, System voltage low Screen discharge conveyor jammed or speed sensor fault Lubrication oil tank temperature sensor not in range process disabled: Lubrication tank oil too cold Lubrication return oil temperature sensor not in range Lubrication oil too hot Crusher speed sensor fault or crusher jammed HP crusher slow speed
Version 2.5
1 0 0 1 1 0 0 0 0 0 0 0 0 0 0 0
1 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0
1 1 1 1 1 1 1 1 0 1 1 1 0 1 1 0
0
0
0
1 1 0 0 0
0 1 0 0 0
1 0 0 1 1
1 1 1 1 0 0 0 0
0 0 0 1 0 0 0 0
0 0 0 0 0 0 0 0
1 1
1 1
1 1
1 1
1 1
1 1
0
0
1
0
0
1
0
0
1
0 0
0 0
1 1
0
0
1 67/93
IC500 / IC600 Instruction Manual 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126
HP crusher hydraulic pump feedback fault HP crusher excessive power limit alarm Clamping pressure fault Release pressure fault countershaft pressure fault lubrication oil level low lubrication pump low speed alarm Analog cavity level sensor not in range Lubrication pump safety device tripped setting sensor A fault setting sensor B fault clutch pressure switch alarm Lubrication oil cooler safety device tripped Oil heating alarm due to lifting conv. safety or conv. maintenance switch Too short time since last start attempt Clutch pressure sensor not in range Clutch pressure sensor is not in use Gearbox oil temperature high Clutch slip % too high Crusher axle speed sensor fault Clutch pressure alarm Dust removal motor overload Electric outlet motor protection Engine: coolant temperature Engine: oil pressure Engine: coolant level Engine: fuel filter blocked Device pump 3 pressure high Device pump 3 pressure sensor not in range Magnetic separator motor overload Hand valves active Gearbox oil temperature sensor not in range Crusher drive axle speed sensor not in use. Clutch slip % cannot be monitored! Uncontrolled crusher movement: Possible gearbox failure! Gearbox start failed Gearbox start failed again. Frequent starts may damage the clutch! Gearbox oil temperature sensor is not in use Clamping pressure sensor not in range Clamping pressure high Crusher must be stopped (0 rpm) before belts can be loosened Additional emergency stop 1 pressed Additional emergency stop 2 pressed Track driving failure, uncontrolled HCMoutput is active! Left track feedback fault
Version 2.5
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
1 1 1 1 1 1 1 1 1 1 1 1 1 1
0 0 0 0 0 0 0 0 0 1 1 1 1 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 1 1 1 1 0 0 0 0 0 0
1 1 1 1 1 1 1 1 0 1 1 1 1 0 0 0 0 1 1
0
0
1
0 0
0 0
1 1
0 0 0 0
0 0 0 0
1 0 0 0
0 0 0
0 0 0
0 0 0
0
0
0 68/93
IC500 / IC600 Instruction Manual 127 128 129 130 131 132 133 134 135 136 137 138
139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160
Right track feedback fault Distribution gearbox failure, uncontrolled output ECM XM2.1 is active! Main conveyor motor overload Vibration chute motor overload SERVICE NOTIFICATION: Check autolube / lubricate crusher bearings Crusher idling power high Crusher speed low too long, clutch is released Engine speed low Roller grizzly jammed Feeder feedback fault Feed stop, crusher setting adjusting activated SERVICE NOTIFICATION: Clean accumulated material from counter weight liner and arm liners Screen under size conveyor left safety switch Screen under size conveyor right safety switch Screen left side conveyor left safety switch Screen left side conveyor right safety switch Screen left side conveyor jammed or speed sensor fault Screen right side conveyor left safety switch Screen right side conveyor right safety switch Screen right side conveyor jammed or speed sensor fault Screen return conveyor left safety switch Screen return conveyor right safety switch Screen return conveyor jammed or speed sensor fault Screen conveyors maintenance switch Screen feedback fault Screen under size conveyor feedback fault Screen side conveyor feedback fault Screen module disconnected Crusher dust seal air blower circuit monitoring fault Control centre dust seal air blower circuit monitoring fault Water pump circuit monitoring fault Setting sensor signal not in range Crusher main shaft in highest allowed position Crusher main shaft in lowest allowed position
Version 2.5
0 0
0 0
0 0
0 0 1
0 0 1
0 1 1
0 0
0 0
1 0
0 0 0 0
0 0 0 0
1 0 0 1
0
0
1
0
0
0
0
0
0
0 0 0
0 0 0
0 0 0
0 0
0 0
0 0
0
0
0
0 0 0
0 0 0
0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0
0
0
0 0 0
0 0 0
0 0 0
0
0
0 69/93
IC500 / IC600 Instruction Manual 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196
Minimum setting reached Setting not changing Adjusting pump circuit monitoring fault Crusher high pressure Crusher high power Crusher stopped, lubrication pump not running Crusher stopped, excessive temperature fault from switch Crusher stopped, excessive adjusting pressure Crusher stopped, excessive crusher power Crusher stopped, crusher not idling within 5 minutes Crusher stopped, pressure and power measurement fault Lubrication return oil temperature switch fault Excessive lubrication return oil temperature Crusher stopped, excessive lubrication return oil temperature Crusher stopped, excessive low crusher speed Crusher stopped, low crusher speed Crusher adjusting pressure sensor signal not in range Crusher power calculation fault Uncontrolled crusher movement Crusher drive belts has slipped Bypass conveyor circuit monitoring fault Engine stopped, excessive high hydraulic oil temperature Crusher Maximum power Crusher Maximum pressure Generator Frequency measurement fault Generator Voltage measurement not in range Lubrication oil pressure rise fault Lubrication oil pressure fault Lubrication pump circuit monitoring fault Lubrication oil pressure switch device fault Lubrication oil filter clogged Adjustment oil filter clogged Dust removal fan motor circuit monitoring fault Dust removal vibration motor circuit monitoring fault Heater 1 circuit monitoring fault Heater 2 circuit monitoring fault
Version 2.5
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0
0
0
0
0
0
0 0
0 0
0 0
0
0
0
0
0
0
0 0
0 0
0 0
0
0
0
0 0
0 0
0 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0 0 0 0
0 0 0 0 0 0 0
0 0 0 0 0 0 0
0
0
0
0 0
0 0
0 0 70/93
IC500 / IC600 Instruction Manual 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212
213
Lubrication oil cooler slow speed circuit monitoring fault Lubrication oil cooler fast speed circuit monitoring fault Engine excessive temperature. Return conveyor circuit monitoring fault Side conveyor circuit monitoring fault Process stopped, external power supply connected Winter mode OFF: Power supply not connected Winter mode Off: Manual control activated Winter mode advised to be used: Lubrication return oil excessive cold Contact calibration sequence interrupted Contact calibration not possible, liners too worn. ACM module missing Engine derated High fuel temperature High inlet air temperature Engine rpm must be at working rpm before generator can supply power for the electric motors Material in crusher on start! Clutch or drive belts may damage.
0
0
0
0
0
0
0 0 0 0
0 0 0 0
0 0 0 0
0
0
0
0 0
0 0
0 0
0 0
0 0
0 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0 1
0
0
0
The list of alarms can also be found in the Parameters/service window (4) by highlighting and choosing the Alarm icon.
Version 2.5
71/93
IC500 / IC600 Instruction Manual 17.2 Diesel Diagnostic Trouble Codes (Active and Stored) In the log files window select number 2 to obtain the engine trouble code log window.
Figure 18.2.1 Diesel diagnostic trouble codes This window shows you the engine trouble codes. By pressing the function key F3 you will be able to select whether to see the active trouble codes (DM1) or previously active (stored) trouble codes (DM2). By default the window always shows the DM1 page first. With F4 and F5 you will be able to scroll the screen. Return to the previous window by pressing F1. Example on how to use the Diesel diagnostic trouble codes: In the DM1 window you can see all active trouble codes concerning the diesel engine. By crossreferencing the SPN and FMI to the list in Appendix 2 you can determine what the problem is. The count tells you how many times a specific trouble code has been active. SPN 111 Translation: SPN FMI Cnt
FMI 1
Cnt 1
= Coolant level = Data valid but below normal operational range - most severe level = Trouble code has been active one (1) time
Engine diagnostic codes according to SAE J1939 are shown in Appendix 2. SPN: Suspect parameter number FMI: Failure mode identifier Refer to Engine Instruction manual.
Version 2.5
72/93
IC500 / IC600 Instruction Manual 17.3 Temperature History Log In the log files window select number 3 to obtain the temperature log window.
Figure 18.3.1 Temperature history log The number of module temperatures that are below –40 oC (-40 oF) or above +70 oC (158 oF) is registered in this window by each module. Also, the number of hydraulic oil temperatures that exceed –25 oC (-13oF) and +85 oC (185 oF) is registered. Return to the previous window by pressing F1. 17.4 Parameter Log In the log files window select number 4 to obtain the parameter log window.
Figure 18.4.1 Parameter log In the parameter log window you can see the changed parameters and the date and time when they were changed. You can also see the old and new values. Using the arrow keys you will be able to scroll the screen. Return to the previous window by pressing F1.
Version 2.5
73/93
IC500 / IC600 Instruction Manual 17.5 Factory parameters In the log files window select number 5 to obtain the factory parameter window.
Figure 18.5.1 Factory parameters
Select load/save with arrow keys F4 or F5. Confirm your selection by pressing F3 (OK). The Load function will reset the factory parameters.
Saving and loading are only allowed in service mode.
Return to the previous window by pressing F1.
Version 2.5
74/93
IC500 / IC600 Instruction Manual
18 Module Program Versions In the diagnostics main window select number 4 (Module program versions) to obtain this window.
Figure 19.1.1 Module program versions
This window shows you the module program versions and the date of the program. In this window you cannot enter any information. 1 2 3 4 5
Device control module Engine control module hydraulic control module Hub junction module Display control unit
Return to the previous window by pressing F1.
Version 2.5
75/93
IC500 / IC600 Instruction Manual
19 Reading Input/Output Modules Data Select the Hub XH4 connector of the modules shown in window 5 and this window will be opened.
Figure 20.1.1 Input/output data by connectors 1 2 3
Module Number of the terminal / pin Input/output value
The window shows all pins in the selected connector. A detailed list can be found in the Help file. Value is either 0 (no voltage in the input/output), 1 (input/output active, voltage sent or received), mA-value or V-value.
Help file will contain information on all terminals. You can also use unit electrical diagrams to locate terminals.
Return to the previous window by pressing F1.
Version 2.5
76/93
IC500 / IC600 Instruction Manual
20 Replacing a module 20.1 Replacing a control module If a defected control module is found it can be replaced with a new one. After it is replaced and the control system is restarted, the UCD will download the operating program into the module. NOTE: This function is recommended only to be used by Metso Minerals Service
After the control module replacement has been completed, all parameter values must be checked. Remember that supervisor parameters can only be edited in service mode! Please contact Metso Minerals for further information. 20.2 Replacing a display module (UCD) If the new module has a different program or program version it will automatically propose to update the HUB and I/O modules. (Refer to instructions in chapter 20.3) The UCD must be programmed before it is sent to the site. 20.2.1 Updating the HUB and I/O modules Activate the module update function by highlighting the start button and operating the OK key (Fig. 2.3.1.1). This function will take approximately 20 min.
WARNING: DO NOT INTERRUPT the downloading process after the update function has started by turning off the power. This might lead to uncontrollable situations in the I/O modules.
Version 2.5
77/93
IC500 / IC600 Instruction Manual
21 Troubleshooting In a fault situation IC helps the user to solve the problem. The alarms and the corresponding help texts give more information on the problem, which makes it easier to find the cause. If the pop-ups of the alarms have already been acknowledged, the lauched alarms can be viewed through the alarm log. In that case the help texts of the alarms can be accessed through the alarm parametrization window. The message field in the main window also offers information when the system prevents a function. In engine-related problem cases the engine trouble code list (SPN/FMI) helps. The buttons of the service platform, main control panel, drive box, and radio controller, related inputs, and some of the outputs can be easily tested in the button test window and the track drive diagnostics window. The statuses of the inputs and outputs of other controls can be viewed in the diagnostic windows of the I/O modules. The purpose of the pins is presented in the help windows and in Appendix 2 of this manual. The electric diagrams of the unit can also be used to locate the correct pinns. Chapter 17.1.1 presents list of all alarms. If the IC-system does not start at all, check the battery voltage, main switch and related fuses.
Version 2.5
78/93
IC500 / IC600 Instruction Manual Engine diagnostic codes
Appendix 1 / 1 (8)
ENGINE DIAGNOSTIC CODES SPN ( Suspected Parameter Number ) PID 0 1(1) 2(1) 3(1) 4 5(1) 6(1) 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 Version 2.5
Parameter Single data character length parameters Request parameter Invalid data parameter (see appendix A) Transmitter system status (see appendix A) Transmitter system Diagnostic (see appendix A) Reserved - to be assigned Underrange warning condition (see appendix A) Overrange warning condition (see appendix A) Axle # 2 lift air pressure Brake system air pressure low warning switch status Axle lift status Axle slider status Cargo securement Brake stroke status Entry assist position/deployment Entry assist motor current Fuel supply pump inlet pressure Suction side fuel filter differential pressure Engine oil level remote reservoir Extended range fuel pressure Extended range engine oil pressure Extended range engine coolant pressure Engine ECU temperature Extended engine crankcase blow-by pressure Generator oil pressure Generator coolant temperature Air conditioner system status # 2 Estimated percent fan speed Percent Exhaust gas recirculation valve # 1 position Percent accelerator position # 3 Percent accelerator position # 2 Crankcase blow-by pressure Transmission range position Transmission splitter position Clutch cylinder position Clutch cylinder actuator status Shift finger actuator status # 2 Clutch plates wear condition Transmission tank air pressure Second fuel level (right side) Tire pressure check interval Engine retarder switches status Cruise control switches status Pressure switch status Ignition switch status Attention/warning indicator lamps status 79/93
IC500 / IC600 Instruction Manual Engine diagnostic codes 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95
Version 2.5
Appendix 1 / 2 (8)
Inlet air heater status Vehicle wet tank pressure Retarder status Extended range barometric pressure ABS control status Air conditioner system clutch status/command # 1 Throttle position Engine intercooler temperature Transmission synchronizer clutch value Transmission synchronizer brake value Shift finger actuator status # 2 Transmission range switch status Transmission actuator status # 2 Shift finger actuator status Shift finger gear position Shift finger rail position Parking brake actuator status Retarder inhibit status Transmission actuator status # 1 Direction switch status Service brake switch status Vehicle enabling component status Shift request switch status Torque limiting factor Two speed axle switch status Parking brake switch status Idle shutdown timer status Blower bypass value position Auxiliary water pump pressure Maximum road speed limit Steering axle temperature Axle # 1 lift air pressure Forward rear drive axle temperature Rear rear-drive axle temperature Road surface temperature Washer fluid level Particulate trap inlet pressure Air start pressure Road speed limit status Road speed Cruise control status Cruise control set speed Cruise control high-set limit speed Cruise control low-set limit speed Power takeoff status PTO oil temperature Percent accelerator pedal position Percent engine load Output torque Fuel delivery pressure Fuel filter differential pressure
80/93
IC500 / IC600 Instruction Manual Engine diagnostic codes 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145
Version 2.5
Appendix 1 / 3 (8)
Fuel level Water in fuel indicator Engine oil level Engine oil filter differential pressure Engine oil pressure Crankcase pressure Boost pressure Turbo speed Turbo oil pressure Intake manifold temperature Air inlet pressure Air filter differential pressure Barometric pressure Coolant pressure Engine coolant temperature Coolant level Coolant filter differential pressure Governor droop New battery current Alternator current Brake application pressure Brake primary pressure Brake secundary pressure Hydraulic retarder pressure Hydraulic retarder oil temperature Engine retarder status Engine retarder percent Clutch pressure Transmission oil level Transmission oil level high/low Transmission filter differential pressure Transmission oil pressure Double data character length parameters Component-specific request Injector metering rail # 2 pressure Power specific fuel economy Exhaust back pressure Mass air flow Average fuel rate Wheel speed sensor status Extended range fuel delivery pressure (absolute) Auxiliary vacuum pressure reading Auxiliary gage pressure reading # 1 Auxiliary absolute pressure reading Tire pressure control system channel functional mode Tire pressure control system solenoid status Trailer # 1, tag # 1, or push channel # 1 tire pressure target Drive channel tire pressure target Steer channel tire pressure target Trailer # 1, tag # 1, or push channel # 1 tire pressure Drive channel tire pressure
81/93
IC500 / IC600 Instruction Manual Engine diagnostic codes 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193(1) 194
Version 2.5
Appendix 1 / 4 (8)
Steer channel tire pressure Average fuel economy (natural gas) Instantaneous fuel economy (natural gas) Fuel mass flow rate (natural gas) PTO engagement control status ATC control status Number of ECU resets Crankcase pressure Auxiliary input and output status # 2 Auxiliary input and output status # 1 Injector timing rail pressure Injector metering rail pressure Battery potential (voltage) - switched Gas supply pressure Main shaft speed Input shaft speed Transmission range selected Transmission range Attained Injection control pressure Compass bearing Rated engine power Alternator potential (voltage) Battery potential (voltage) Cargo ambient temperature Cab interior temperature Ambient air temperature Air inlet temperature Exhaust gas temperature Fuel temperature Engine oil temperature Turbo oil temperature Transmission # 1 oil temperature Front axle weight Rear axle weight Trailer weight Cargo weight Trip fuel Fuel rate (instantaneous) Instantaneous fuel economy Average fuel economy Power takeoff speed Power takeoff set speed Idle engine speed Rated engine speed Engine speed Transmission output shaft speed Variable and long data character length parameters Multisection parameter Transmitter system diagnostic table (see appendix A) Transmitter system diagnostic code and occurrence count table
82/93
IC500 / IC600 Instruction Manual Engine diagnostic codes 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245
Version 2.5
Appendix 1 / 5 (8)
Diagnostic data request/clear count Diagnostic data/count clear response Connection management Connection mode data transfer Traction control disable state Reserved - to be assigned Reserved - to be assigned Reserved - to be assigned Reserved - to be assigned Reserved - to be assigned Reserved - to be assigned Reserved - to be assigned Reserved - to be assigned Reserved - to be assigned ABS control status, trailer Tire temperature (by sequence number) Tire pressure (by sequence number) Tire pressure target (by sequence number) Wheel end assembly vibration level Vehicle wheel speeds Brake temperature Wheel bearing temperature Fuel tank/nozzle identification State line crossing Current state and country Engine torque history Anti-theft request Anti-theft status Auxiliary A/D counts Immobilizer security Reserved for text message acknowledged Reserved for text message to display Reserved for text message display type Speed sensor calibration Total fuel used (natural gas) Total idle fuel used (natural gas) Trip fuel (natural gas) DGPS differential correction Unit number (power unit) Software identification Total idle hours Total idle fuel used Vehicle identification number Velocity vector Vehicle position Change reference number Tire pressure by position Tire temperature by position Component identification Trip distance Total vehicle distance
83/93
IC500 / IC600 Instruction Manual Engine diagnostic codes 246 247 248 249 250 251 252 253 254 255
256 (0) 257(1) 258(2) 259(3) 260-361 362(106) 363(107) 364(108) 365(109) 366(110) 367(111) 368(112) 369(113) 370(114) 371(115) 372(116) 373(117) 374(118) 375(119) 376(120) 377(121) 378(122) 379(123) 380(124) 381(125) 382(126) 383(127) 384(128) 385-405 406(150) 407(151) 408(152) 409(153) 410(154) 411(155) 412(156) 413(157)
Version 2.5
Appendix 1 / 6 (8)
Total vehicle hours Total engine hours Total PTO hours Total engine revolutions Total fuel used Clock Date Elapsed time Special parameters Data link escape Extension Single data character length parameters (modulo 256 value identified in parentheses) Request parameter Cold restart of specific component Warm restart of specific component Component restart response Reserved (page 2) to be assigned Percent exhaust gas recirculation valve # 2 position Hydraulic retarder control air pressure HVAC unit discharge temperature Weighing system status command Engine oil level high/low Lane tracking system status Lane departure indication Distance to rear object (reverse) Trailer pneumatic brake control line pressure Trailer pneumatic supply line pressure Remote accelerator Center rear drive axle temperature Alternator AC voltage Fuel return pressure Fuel pump inlet vacuum Compression unbalanced Fare collection unit status Door status Articulation angle Vehicle use status Transit silent alarm status Vehicle acceleration Double data character length parameters Component-specific request Reserved (page 2 ) -to be assigned HVAC blower motor speed Axle group full weight calibration Axle group empty weight calibration Axle group weight Extended range road surface temperature Recirculated engine exhaust gas differential pressure Recirculated engine exhaust gas temperature Net vehicle weight change
84/93
IC500 / IC600 Instruction Manual Engine diagnostic codes 414(158) 415(159) 416(160) 417(161) 418(162) 419(163) 420(164) 421(165) 422(166) 423(167) 424(168) 425(169) 426(170) 427(171) 428(172) 429(173) 430(174) 431(175) 432(176) 433(177) 434(178) 435(179) 436(180) 437(181) 438(182) 439(183) 440(184) 441(185) 442(186) 443(187) 444(188) 445(189) 446(190) 447(191) 448(192) 449(193) 450(194) 451-497 498(242) 499(243) 500(244) 501(245) 502(246) 503(247) 504(248) 505(249) 506(250) 507(251) 508(252) 509(253)
Version 2.5
Appendix 1 / 7 (8)
Air conditioner Refrigerant low side pressure Air conditioner refrigerant high side pressure Evaporator temperature Gross vehicle weight Transmission # 2 oil temperature Starter circuit resistance Starter current (average) Alternator/generator negative cable voltage Auxiliary current Extended range net battery current DC voltage Auxiliary frequency Alternator/generator field voltage Battery resistance change Battery internal resistance Starter current peak Starter solenoid voltage Starter negative cable voltage Starter motor voltage Fuel shutoff solenoid voltage AC voltage Cargo ambient temperature (by location) Trip sudden decelerations Trailer # 2, tag # 2, or push channel # 2 tire pressure target Trailer # 2, tag # 2, or push channel # 2 tire pressure Extended range boost pressure # 1 Extended range boost pressure # 2 Auxiliary temperature # 1 Auxiliary temperature # 2 Auxiliary gage pressure reading # 2 Battery # 2 potential (voltage) Cylinder head temperature bank B (right bank) Cylinder head temperature bank A (left bank) Passenger counter Variable and long data character length parameters Page 2 multisection parameter Reporting interval request Bridge filter control Reserved (page 2) -to be assigned Send keypress command Driver interface unit (DIU) object/form command Intersection preemption status and configuration Signage message Fare collection unit - point of sale Fare collection unit - service detail Annunciator voice message Vehicle control head keyboard message Vehicle control head display message Driver identification Transit route identification Mile post identification
85/93
IC500 / IC600 Instruction Manual Engine diagnostic codes
Appendix 1 / 8 (8)
Special parameters 510(254) Page 2 data link escape 511(255) Page 2 extension (1) = these PIDs are superseded by PIDs 194, 195 and 196
FMI (Failure Mode Identifier) 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 – 30 31
Version 2.5
Data valid but above normal operational range - most severe level Data valid but below normal operational range - most severe level Data erratic, intermittent or incorrect Voltage above normal or shorted to high source Voltage below normal or shorted to low source Current below normal or open circuit Current above normal or grounded circuit Mechanical system not responding or out of adjustment Abnormal frequency or pulse width or period Abnormal update rate Abnormal rate of change Root cause not known Bad intelligent device or component Out of calibration Special instructions Data valid but above normal operating range - least severe level Data valid but above normal operating range - moderately severe level Data valid but below normal operating range - least severe level Data valid but below normal operating range - moderately severe level Received network data in error Reserved for SAE assignment Not available or condition exists
86/93
IC500 / IC600 Instruction Manual I/O List
Appendix 2 / 1 (7)
Input/Output List
HUB Input/Output data
Terminal/no = explanation XH4/1 = +24V (System supply) XH4/2 = +24V (System supply) XH4/3 = Not in use XH4/4 = Not in use XH4/5 = Not in use XH4/6 = Not in use XH4/7 = Not in use XH4/8 = Not in use XH4/9 = Ground XH4/10 = Ground XH4/11 = Emergency stop, control centre XH4/12 = Emergency stop, service platform XH4/13 = Emergency stop, engine module XH4/14 = Emergency stop, hydraulic module XH4/15 = BSL XH4/16 = CAN2 H XH4/17 = CAN2 L XH4/18 = RS485 H XH4/19 = RS485 L XH4/20 = Not in use (additional e-stop) XH4/21 = Not in use (additional e-stop) XH4/22 = Ref + XH4/23 = Ref -
Terminology: AI = Analog input AO = Analog output PI = Pulse input FB = Feedback O/ = Output O-PWM = Pulse Width Modulation output BSL = Boot sequence line
Version 2.5
87/93
IC500 / IC600 Instruction Manual I/O List
Appendix 2 / 2 (7)
DCM Input/Output data
Terminal/no = explanation XM1/1 = O/Primary feeder authorization pause XM1/2 = O/ Dust removal unit vibrator XM1/3 = O/ Dust removal unit fan XM1/4 = Key switch on start position XM1/5 = Not in use XM1/6 = Not in use XM1/7 = Process start button XM1/8 = Process stop button XM1/9 = Ground XM1/10 = Ground XM1/11 = Ground XM1/12 = Fuel level sensor /AI XM1/13 = (+24 V) output to sensors/switches etc. XM1/14 = Metal detector alarm XM1/15 = O/ screen support legs up XM1/16 = O/Crusher running XM1/17 = Not in use XM1/18 = Sound alarm horn XM1/19 = Not in use (electric outlet protection OK) XM1/20 = Radio operation selected XM1/21 = Feeder support legs are down (LT300HP only) XM1/22 = O/Primary feeder authorization XM1/23 = Lifting conveyor safety switch
XM2/1 = Hydraulic hammer operating switch XM2/2 = Not in use XM2/3 = Not in use XM2/4 = Not in use XM2/5 = Secondary LT level high, feeder paused XM2/6 = Secondary LT level alarm, feeder stopped XM2/7 = Feeder bottom heater (not available) XM2/8 = Not in use XM2/9 = Secondary LT connected XM2/10 = Feeder speed + (service platform) XM2/11 = (+24 V) Not in use XM2/12 = Feeder speed – (service platform) XM2/13 = Ground XM2/14 = Ground XM2/15 = Ground XM2/16 = Feeder start (service platform)
Version 2.5
88/93
IC500 / IC600 Instruction Manual I/O List
Appendix 2 / 3 (7)
XM2/17 = Feeder stop (service platform) XM2/18 = Setting increase (service platform) Feed funnel down (service platform) XM2/19 = Setting decrease (service platform) Feed funnel up (service platform) XM2/20 = Crusher off (service platform) XM2/21 = Crusher on (service platform) XM2/22 = Crusher swing normal direction (service platform) XM2/23 = Crusher swing reverse direction (service platform
XM3/1 = +12 V XM3/2 = +5 V XM3/3 = Ground XM3/4 = Ground XM3/5 = Drive box right track forward XM3/6 = Drive box left track forward XM3/7 = Drive box right track backward XM3/8 = Module identification /AI XM3/9 = +12 V XM3/10 = +5 V XM3/11 = Ground XM3/12 = Ground XM3/13 = Drive box left track backward XM3/14 = Crusher setting sensor /AI XM3/15 = BSL XM3/16 = Crusher speed /PI XM3/17 = Crusher level high XM3/18 = LT200HP lifting conveyor rotation detector XM3/19 = Drive box engine rpm + XM3/20 = Drive box engine rpm – XM3/21 = Drive box connected XM3/22 = Drive box remote stop XM3/23 = Not in use
Terminology: AI = Analog input AO = Analog output PI = Pulse input FB = Feedback O/ = Output O-PWM = Pulse Width Modulation output BSL = Boot sequence line
Version 2.5
89/93
IC500 / IC600 Instruction Manual I/O List
Appendix 2 / 4 (7)
ECM Input/Output data
Terminal/no = explanation XM1/1 = O/ Flash alarm XM1/2 = O/ Vibration chute XM1/3 = O/ Distribution gearbox “choke” XM1/4 = By pass conveyor electric motor protective switch ok XM1/5 = FB/ Engine cooler control XM1/6 = Not in use XM1/7 = Generator voltage protection circuit alarm XM1/8 = Air filter condition XM1/9 = Ground XM1/10 = Ground XM1/11 = Ground XM1/12 = AI / Cone crusher analog / digital cavity level XM1/13 = (+24 V) XM1/14 = O/ Lubrication tank oil temperature ok. / Return conveyor XM1/15 = O/ HP crusher XM1/16 = O/ HP crusher soft start XM1/17 = Not in use XM1/18 = Counter shaft pressure XM1/19 = Lubrication oil level XM1/20 = Not in use (RADIO) XM1/21 = Electric driven lubrication pump protective switch ok XM1/22 = Side conveyor electric motor protective switch ok XM1/23 = Return conveyor electric motor protective switch ok
XM2/1 = O/ Crusher speed normal direction (current in mA) O/ Impact crusher hydraulic pump valve ………….O/ distribution gearbox clutch valve XM2/2 = O/Crusher speed reverse direction (current in mA) O/Impact crusher hydraulic adjust motor valve XM2/3 = FB/Crusher speed both directions (current in mA) FB/Impact crusher hydraulic pump valve XM2/4 = FB/Impact crusher hydraulic adjust motor valve XM2/5 = O/Engine start XM2/6 = O/Engine stop solenoid XM2/7 = O/Horn XM2/8 = Generator frequency alarm XM2/9 = Generator thermistor alarm XM2/10 = O/ hydraulic cooler fan / lubrication oil cooler fan XM2/11 = (+24 V) XM2/12 = Hydraulic oil temperature /AI XM2/13 = Ground XM2/14 = Ground XM2/15 = Ground XM2/16 = Hydraulic oil filters
Version 2.5
90/93
IC500 / IC600 Instruction Manual I/O List
Appendix 2 / 5 (7)
XM2/17 = Hydraulic oil level XM2/18 = Hydraulic oil main valve XM2/19 = Clamping pressure switch XM2/20 = Release pressure switch XM2/21 = Distribution gearbox clutch pressure switch XM2/22 = PWM / Engine cooler control XM2/23 = O/ cone crusher lubrication pump
XM3/1 = +12 V XM3/2 = +5 V XM3/3 = Ground XM3/4 = Ground XM3/5 = Cone crusher lubrication tank oil temperature XM3/6 = Crusher pressure /AI XM3/7 = Cone crusher lubrication oil return oil temperature XM3/8 = Module identification /AI XM3/9 = +12 V XM3/10 = +5 V XM3/11 = Ground XM3/12 = Ground XM3/13 = AI/ Distribution gearbox clutch pressure XM3/14 = Not in use XM3/15 = BSL XM3/16 = PI/ crusher speed XM3/17 = PI/ Cone crusher setting sensor A XM3/18 = PI/ Cone crusher setting sensor B XM3/19 = PI/ Crusher drive shaft speed XM3/20 = PI/ Speed of hydraulic driven lubrication pump XM3/21 = Vibrating chute motor protective switch ok XM3/22 = Hydraulic pump safety device XM3/23 = Electric driven lubrication oil cooler fan motor protective switch ok
Terminology: AI = Analog input AO = Analog output PI = Pulse input FB = Feedback O/ = Output O-PWM = Pulse Width Modulation output BSL = Boot sequence line
Version 2.5
91/93
IC500 / IC600 Instruction Manual I/O List
Appendix 2 / 6 (7)
HCM Input/Output data
Terminal/no = explanation XM1/1 XM1/2 XM1/3 XM1/4 XM1/5 XM1/6 XM1/7
= O/Screen hydraulic valve CW (clockwise) = O/Screen hydraulic valve CCW (counter-clockwise) = O/Screen conveyors hydraulic valve = Side conveyor safety switch, right side = Not in use = Not in use = O/LS pressure discharge valve O/Impact magnetic separator or side conveyor on XM1/8 = O/Hydraulic power take off (PTO) valve XM1/9 = Ground XM1/10 = Ground XM1/11 = Ground XM1/12 = Not in use XM1/13 = (+24 V) XM1/14 = O/Hand valves hydraulic valve XM1/15 = O/Main conveyor hydraulic valve XM1/16 = O/Magnetic separator hydraulic valve XM1/17 = O/Side conveyor hydraulic valve XM1/18 = Screen module connected XM1/19 = Screen module safety switch, oversize conveyor XM1/20 = Screen module safety switch, undersize conveyor XM1/21 = Side conveyor safety switch, left side XM1/22 = Main conveyor safety switch, right side XM1/23 = Main conveyor safety switch, left side
XM2/1 XM2/2 XM2/3 XM2/4 XM2/5
= O/Fast track drive hydraulic valve = O/Scalper / Lifting conveyor = Not in use = Not in use = O/Feeder valve power-line O/Impact funnel up with scalper valve power-line XM2/6 = O/Left track valve power-line XM2/7 = O/Right track valve power-line XM2/8 = O-PWM/Feeder control value O-PWM/Impact funnel up with scalper control value ………….O/ PWM LC feeder XM2/9 = O-PWM/Left track control value XM2/10 = O-PWM/Right track control value XM2/11 = (+24 V) XM2/12 = AI/ Hydraulic oil temperature circuit #2 XM2/13 = Ground XM2/14 = Ground XM2/15 = Ground
Version 2.5
92/93
IC500 / IC600 Instruction Manual I/O List
Appendix 2 / 7 (7)
XM2/16 = O/ Setting increase hydraulic valve O/ Impact funnel up if not scalper ………….O/ return conveyor XM2/17 = O/Setting decrease hydraulic valve …………..O/ by pass conveyor XM2/18 = Conveyors maintenance switch XM2/19 = Not in use XM2/20 = Not in use XM2/21 = Hand valves XM2/22 = O/Clamping cylinder – pressurize, hydraulic valve XM2/23 = O/Clamping cylinder – unpressurize, hydraulic valve …………..PWM / Lifting conveyor
XM3/1 = +12 V XM3/2 = +5 V XM3/3 = Ground XM3/4 = Ground XM3/5 = Belt scale /AI (FUTURE PLAN) XM3/6 = Toggle pressure /AI (FUTURE PLAN) …………..AI / Feed hopper level sensor XM3/7 = AI/ Component pump pressure XM3/8 = Module identification XM3/9 = +12 V XM3/10 = +5 V XM3/11 = Ground XM3/12 = Ground XM3/13 = Not in use XM3/14 = Clamping pressure /AI XM3/15 = BSL XM3/16 = Feeder speed /PI XM3/17 = Main conveyor speed /PI XM3/18 = Toggle plate condition XM3/19 = PI/ Screen discharge conveyor speed XM3/20 = Return conveyor safety switch XM3/21 = Impact crusher cover open limit switch / by pass conveyor safety switch XM3/22 = Lifting conveyor feeder motor protective switch ok XM3/23 = Not in use
Terminology: AI = Analog input AO = Analog output PI = Pulse input FB = Feedback O/ = Output O-PWM = Pulse Width Modulation output BSL = Boot sequence line
Version 2.5
93/93
Remote Sensor Series Description Operation mode and max sensing range: Thru beam: Dependant on amplifier Diffuse proximity: Dependant on amplifier Optional sensor monitor LED Wide variety of housings High tolerance to hostile environments Cable or plug connections
The remote sensor series, which consists of a transmitter LT and receiver LR, is made to operate in conjunction with a Telco photoelectric amplifier from the PA or MPA programmes.
The series is available with optional power-(LR) and output-(LT) monitor LEDs for use with any Telco photoelectric amplifier which has the sensor LED drive feature incorporated.
The remote sensors are available in a wide range of housings, with either cable or plug connection, and may be used in thru beam or diffuse proximity mode.
Technical Data LT
LR
Transmitter Diode
Ga Al As, (880 nm)
–
Photo Transistor
–
Silicon NPN
2 x 0,25 mm2
1 x 0,25 mm2 + shield
Cable Ø 4mm PVC Sleeves Min. cable bending radius
45 mm
Environmental Data Vibration
10 – 55 Hz, 0,5 mm
Shock Light immunity, @ 20° incidence
30 g 101 Series 100 Series 110/120 Series
>50 000 lux >80 000 lux >100 000 lux
Temperature, operation
– 25 to +65 °C
Temperature, storage
– 40 to +80 °C
Sealing Class Approvals
IP 67 a
1 3
Remote Sensor Series Available Types Series
Optical Angle
Connection Housing Material
Transmitter
Polycarbonate Nickel Plated Brass +/– 8°
ABS
101
Receiver
Polycarbonate Nickel Plated Brass
Polyester
Transmitter
Polycarbonate
Receiver
Polycarbonate
LT 101 AP25 15
LT 101 AP25 T3
–
LT 101 TP25 T3
–
LT 101 TB25 5
LT 101 TB25 15
LT 101 TB25 T3
–
LT 101 TS25 5
LT 101 TS25 15
LT 101 TS25 T3
–
LT 101 SG 5*
LT 101 SG 15*
LT 101 SG T3
–
LT 101 S22 5*
LT 101 S22 15*
–
–
Ø10
LR 101 AP25 5
LR 101 AP25 15
LR 101 AP25 T3
–
LR 101 TP25 5
LR 101 TP25 15
LR 101 TP25 T3
–
M12 x 1
LR 101 TB25 5
LR 101 TB25 15
LR 101 TB25 T3
–
LR 101 TS25 5
LR 101 TS25 15
LR 101 TS25 T3
–
LR 101 SG 5*
LR 101 SG 15*
LR 101 SG T3
–
LR 101 S22 5*
LR 101 S22 15*
M12 x 1 9,5 x 11,5 Ø12,7 (Snap Housing)
9,5 x 11,5 Ø12,7 (Snap Housing)
Ø10
M12 x 1
Ø10
+/– 9° Nickel Plated Brass
M12 x 1
Transmitter
Stainless Steel
Polycarbonate
Ø10
+/– 8° Nickel Plated Brass
M12 x 1
Stainless Steel
Receiver
+/– 3°
Transmitter
110
+/– 4°
Polycarbonate Nickel Plated Brass
Ø10
M12 x 1
Stainless Steel
120
Nickel Plated Brass +/– 2,5°
4 pin, M12 Plug
LT 101 TP25 15
Stainless Steel
100
3 pin, M8 Plug
Order Reference LT 101 AP25 5
+/– 6° Nickel Plated Brass
15 m Cable
LT 101 TP25 5
Stainless Steel
ABS
Receiver
Ø10
Stainless Steel Polyester
+/– 9°
5 m Cable
Housing Size
–
–
LT 100 AP38 5
LT 100 AP38 15
LT 100 AP38 T3
–
LT 100 TP38 5
LT 100 TP38 15
LT 100 TP38 T3
–
LT 100 TB38 5
LT 100 TB38 15
LT 100 TB38 T3
LT 100 TB58 J
LT 100 TS38 5
LT 100 TS38 15
LT 100 TS38 T3
LT 100 TS58 J
LR 100 AP38 5
LR 100 AP38 15
LR 100 AP38 T3
–
LR 100 TP38 5
LR 100 TP38 15
LR 100 TP38 T3
–
LR 100 TB38 5
LR 100 TB38 15
LR 100 TB38 T3
LR 100 TB58 J
LR 100 TS38 5
LR 100 TS38 15
LR 100 TS38 T3
LR 100 TS58 J
LT 110 AP38 5
LT 110 AP38 15
LT 110 AP38 T3
–
LT 110 TP38 5
LT 110 TP38 15
LT 110 TP38 T3
–
LT 110 TB38 5
LT 110 TB38 15
LT 110 TB38 T3
LT 110 TB58 J
LT 110 TS38 5
LT 110 TS38 15
LT 110 TS38 T3
LT 110 TS58 J
LR 110 AP38 5
LR 110 AP38 15
LR 110 AP38 T3
–
LR 110 TP38 5
LR 110 TP38 15
LR 110 TP38 T3
–
LR 110 TB38 5
LR 110 TB38 15
LR 110 TB38 T3
LR 110 TB58 J
LR 110 TS38 5
LR 110 TS38 15
LR 110 TS38 T3
LR 110 TS58 J
LT 120 TB45 5
LT 120 TB45 15
–
–
LR 120 TB45 5
LR 120 TB45 15
–
–
M18 x 1
Note: If the applicable amplifier has sensor LED-drive, add ‘L’ after the series number for sensor monitor LED eg. LT/LR 101L AP25 5. Sensors marked * do not have this optional feature. Photo amplifiers to be ordered separately.
2 4
Remote Sensor Series Applicable Photoelectric Amplifiers and Ranges Photoelectric Amplifiers Operation Modes
Series
101 100 110 120
PA 01
PA 10
PA 09
PA 11
A
B
MPA 41
MPA 21
MPA 81
A/B
C/D
A/B
C/D –
Thru-beam
8m
5m
11 m
–
–
–
–
–
–
Diffuse Proximity
65 cm
45 cm
90 cm
–
–
–
–
–
–
–
Thru-beam
10 m
–
–
15 m
18 m
10 m
8m
4m
8m
4m
Diffuse Proximity
75 cm
–
–
1,1 m
1,1 m
75 cm
65 cm
35 cm
65 cm
35 cm
Thru-beam
23 m
–
–
35 m
40 m
25 m
18 m
9m
18 m
9m
Diffuse Proximity
1,6 m
–
–
2m
2m
1,6 m
1,3 m
70 cm
1,3 m
70 cm
Thru-beam
45 m
–
–
60 m
70 m
45 m
35 m
18 m
35 m
18 m
Diffuse Proximity
3,5 m
–
–
4m
5m
3,5 m
3m
2m
3m
2m
Note: For ranges using fibre optics, please refer to page 45.
Connections Cable
M8 Plug/Cable
M12 Plug/Cable
Transmitter Signal
Red
Pin 1/Brown
Pin 1/Brown
Transmitter Ground
Black
Pin 3/Blue
Pin 3/Blue
Receiver Signal
Yellow
Pin 4/Black
Pin 4/Black
Receiver Ground
Shield
Pin 3/Blue
Pin 3/Blue
3 pin, M8 Sensor Plug (Male)
4 pin, M12
Cable Plug (Female)
Sensor Plug (Male)
Cable Plug (Female)
Black 4 1
4 3
3
1
Brown 1
Brown
1 4
2
4
3
2 3
White Blue
Blue
Black
Dimensions and Descriptions Series 101
28,5 25 14
LED
28,5
5 LED
5 16
16
Ø 10 M12 x 1 25
10
8,7
8,7
3
17
AP25 5/15
10
TP/TB/TS25 5/15
36
Ø9
41
36 25 14
Ø 10
Ø9
41 60
60
Ø 3,5
Ø 3,5
M8 x 1 M12 x 1 25
17
AP25 T3
22
M8 x 1
15
15
7
LED 3
LED
LED
M8 x 1
TP/TB/TS25 T3
SG 5/15
SG T3
15,5
17,5 S22 5/15
(Units in mm)
3 5
Remote Sensor Series Dimensions and Descriptions Series 100/110 41,5
41,5 38 26
LED
58 38 LED
Ø 10
M12 x 1
M12 x 1
M12 x 1 38
17 3
17
AP38 5/15
3
LED
TB/TS58 J
TP/TB/TS38 5/15
49 38
49
26 Ø 10
M8 x 1 M12 x 1
M8 x 1
LED
38
17
3
LED
AP38 T3 TP/TB/TS38 T3 (Units in mm)
Series 120 55 45 28
LED
M18 x 1
24
4
TB45 5/15 (Units in mm)
Telco reserves the right to change specifications without notice.
4 6
PA 11
Amplifier Series Photoelectric Amplifier Series Description Operation mode and max sensing range: Thru beam: 0-70 m Diffuse proximity: 0-5 m 230 V ac, 115 V ac, 24 V ac or 24 V dc supply voltage Manual sensitivity adjustment Sensor LED-drive Automatic sensor test Adjustable on/off time delay 1 relay and/or 1 transistor output Switch selectable light or dark function Switch selectable long or short range Power, output and signal level indicators 11-pole DIN socket connection
The PA 11 is to be used in conjunction with a set of remote transmitter LT and receiver LR from the series 100, 110 and 120. This amplifier series offers manual sensitivity adjustment via integral potentiometers located on the front panel of the amplifier. Output can be selected from either a relay and NPN or NPN and PNP transistor outputs with or without a 0-10 sec on/off time delay. Light or dark function and long or short range is switch selectable.
The microprocessor controlled sensor test ensures that the system will automatically detect and indicate a faulty transmitter or receiver – cable break or electrical failure – during operation, through the relevant LED located on the front panel. The sensor LED drive powers the optional monitor LEDs available on the remote sensors – output (LT) and power (LR).
Technical Data Supply voltage
24 V dc, 24 V ac, 115 V ac or 230 V ac
Voltage tolerance
+/– 15 %
Power consumption Output
Max. 3,5 VA Relay Transistor
1 open / 1 close, 250 V ac / 3 A, 120 V ac / 5 A 60 mA / 30 V dc
Power on indicator
Green LED
Output indicator
Yellow LED
Signal level indicator
Green LED
LR sensor failure indicator
Red LED
LT sensor failure indicator
Red LED
Sensor monitor LED drive
The green monitor LED on the receiver indicates ‘Power ON’ The yellow monitor LED on the transmitter indicates ‘PA 11 output activated’
Hysteresis
Approx. 45 %
Operation frequency
20 Hz
Response time tON / tOFF Delay tON / tOFF Housing material
35 ms / 35 ms PA 11 A
Adjustable 0 – 10 sec Noryl
Environmental Data Temperature, operation
–10 to +50 ºC
Temperature, storage
– 40 to +80 ºC
Sealing class Approvals
IP 40 a b c
1 13
PA 11
Amplifier Series
Available Types Model
Supply Voltage
Connection
24 V dc
24 V ac
Output Relay and NPN
PA 11 A On/Off delay 11-pole DIN socket PA 11 B
115 V ac
230 V ac
Order Reference PA 11 A 303T
PA 11 A 302T
PA 11 A 301T
PA 11 A 300T
NPN and PNP
PA 11 A 403T
PA 11 A 402T
PA 11 A 401T
PA 11 A 400T
Relay and NPN
PA 11 B 303T
PA 11 B 302T
PA 11 B 301T
PA 11 B 300T
NPN and PNP
PA 11 B 403T
PA 11 B 402T
PA 11 B 401T
PA 11 B 400T
Note: Remote sensors and 11-pole DIN socket to be ordered separately.
Applicable Remote Sensors and Ranges Series
Thru Beam
Diffuse Proximity
100
18 m
1,1 m
110
40 m
2m
120
70 m
5m
Wiring Diagrams Load Supply Supply Voltage
2
10
LT
Relay
Black
C
NO NC
1
3
Load Supply
LR Yellow
Red
Black
Shield NPN
NPN
4
LT
Supply Voltage
7
9
5
6
8
2
10
LR Yellow
Red
Shield
PNP
9
1
3
Relay output
7
5
6
8
Transistor output
Dimensions and Descriptions
Power on indicator On delay adjustment
Power on indicator
76
Off delay adjustment Sensitivity adjustment Signal status indicator Output indicator Long/short switch Light/dark switch
LT/LR sensor test indicator
LT LR
LT/LR sensor test indicator
35
13
78
76
Sensitivity adjustment Signal status indicator Output indicator Long/short switch Light/dark switch
LT LR
35
PA 11 A
13
78
PA 11 B (Units in mm)
(Units in mm)
Telco reserves the right to change specifications without notice.
2 14