Extec Crusher C12+ Operating and Maintenance Manual Hydraulic Schematic 2007

Description

Contents:
Operating and Maintenance Manual
Introduction
Certificate of Conformity
Contents
Section 1 Safety Instructions
1.1 Notes
1.2 Alarms and Warnings
1.3 Warnings marked on the machine
1.3.1 Personnel Safety Warnings
1.3.2 Machine Safety Warnings
1.3.3 Machine Legend Plate
1.4 Component Safety Features
1.5 Features for Operator Safety
1.6 Environmental Safety
1.6.1 Consumable Materials
1.6.2 Machine Disposal
1.7 Personal Protective Equipment (PPE)
1.8 Measured Noise Level
1.9 Vibration Levels
1.10 Organisational Safety Measures
1.11 Personnel Qualification, Requirements and Responsibilities
1.12 Safety Advice Regarding Specific Operational Phases
1.12.1 Standard Operation
1.12.2 Blockage or Malfunction
1.12.3 Unguarded Areas
1.13 Special Work
1.13.1 Isolation
1.13.2 Maintenance Site Conditions
1.13.3 Replacement & Removal of Components
1.13.4 Climbing, Falling
1.13.5 Safety Consideration during Advanced Maintenance
1.13.6 Safety Considerations during Cleaning
1.13.7 Removal of Safety Devices and Guards
1.13.8 Surrounding Structures
1.13.9 Safety when Refuelling
1.14 Specific Hazards
1.14.1 Electrical Energy
External Considerations and Hazards
Machine – Electrical
Battery
1.14.2 Gas, Dust, Steam, Smoke and Noise
1.14.3 Welding or Naked Flames
1.14.4 Hydraulic Equipment
1.14.5 Hazardous Substances
Section 2 Transportation
2.1 Transport
2.2 Loading
2.3 Machine Transportation Dimension
Section 3 Description and Technical Information
3.1 Application & Limitations
3.2 Description
3.3 Operation Description
3.4 Key Features of the C-12+ Crusher
3.5 Common Applications
3.6 Machine Layout Indicating Main Components
3.7 Machine Layout Indicating Emergency Stop Positions
3.8 Data
Crusher
Feeder
Conveyors
Dimensions
Engine Details
Fuel Consumption Guide
3.9 Machine Dimensions
Section 4 Commissioning and Operation
4.1 Pre-Start Instructions
4.2 Main Control Devices
4.2.1 Electrical Control Box
4.2.2 Remote Control
4.3 Starting Procedure
4.4 Stopping the Machine
4.5 Stopping Machine in an Emergency
4.5.1 Emergency Stop Locations
4.6 Removing Tractor Unit and Bogie – (Where fitted)
4.7 Tracking Procedure
4.8 Preparing the Crusher for Operation
4.9 Setting Material Output Size
4.9.1 Using Remote Pendent For Setting Material Output Size
4.9.2 Setting Material Output Size
4.10 Operating The Machine (Crushing)
Loading Material Into Machine:
Feeder Cut-out:
4.11 Reverse Jaw Operation
4.12 Jaw Brake Pressure Adjustment
Forward Jaw Brake Pressure
Reverse Jaw Brake Pressure
Section 5 Machine Maintenance
5.1 Introduction
5.2 Daily Maintenance Schedule
5.2.1 Air Cleaner Servicing
5.3 Weekly Maintenance Schedule
5.3.1 Checking Feeder Oil Level
5.3.2 Checking/ Changing Hydraulic Tank Air Breather
5.3.3 Greasing Bearings
5.3.4 Vogel Pump Unit
5.3.5 Inspecting/ Adjusting Belt Sealing Rubbers
5.3.6 Adjusting Belt Scraper
5.3.7 Hydraulic Filter
5.3.8 Changing Hydraulic Water Trap
5.4 250 Hour Maintenance Schedule
5.5 1000 Hour Maintenance Schedule
5.5.1 Changing Oil in Tracks
5.6 Track Adjustment
5.6.1 Increasing The Track Tension
5.6.2 Releasing The Track Tension
5.7 Turning/ Changing Jaw Plates
5.7.1 Removing Swing Jaw Plates
5.7.2 Removing Fixed Jaw Plates
5.7.3 Replacing the Fixed Jaw Plate
5.7.4 Replacing the Swing Jaw Plate
5.7.5 Changing Crusher Box Liner Plates
5.8 Oils And Fluids
5.9 Toggle Plate Removal/ Replacement
5.10 Maintenance and Service Parts
Section 6 Trouble Shooting Guide
6.1 Test Procedures for Electronics
6.2 Checking Hydraulic Pressure
6.3 Checking 5 Station Manifold Pressure
6.4 Control Block Pressure
Appendix A Parts Manual
Contact Details
Parts Manual Contents
AA.1 Loose Items
AA.2 Chassis, Walkways and Tracks
AA.3 Hopper
AA.4 Magnetic Conveyor and Supports
AA.5 Feeder and Vibrator Box
AA.6 Transfer Chute
AA.7 Power Pack
AA.8 Power Pack – Hydraulics
AA.9 Control Boxes
AA.10 Diesel Tank
AA.11 Main Conveyor
AA.12 Side Conveyor
AA.13 Crusher – Assembly
AA.14 Crusher – Box
AA.15 Crusher – Torque Arm Assembly
AA.16 Crusher – Jaw Stock
AA.17 Crusher – Toggle Crossbeam
AA.18 Hydraulic Hoses
Complete Hydraulic Hose Kits
AA.19 Deflector Door – Optional
AA.20 Stickers – English
AA.21 Transport Bogie and Fifth Wheel – Optional
AA.22 Light Stand – Optional
AA.23 Water Pump – Optional
Appendix B Drawing Pack
HYDRAULIC DIAGRAM
LAMP DIAGNOSTICS
Appendix C OEM Manuals supplied with this machine
Appendix D Hazardous Substances associated with this machine
1. Exxon Unirex N 3 Grease 570317-00 UNIREX N 3
2. Shell Albida Grease EP2 ACIYK GB/eng/C 19/03/2005
3. Shell Rimula Super 15W-40 ACK9D GB/eng/C 26/11/2003
4. Shell Naturelle Fluid HF-M 46 ACKXR GB/eng/C 09/06/2004
5. Shell Tellus Oil 46 ACKQ6 GB/eng/C 29/04/2004
6. Shell Omala 220 Gear Oil ACH75 GB/eng/C 29/01/2003
7. Shell Safe Anti Freeze L84042 Revision 23 08 2004
8. Shell Agricultural Gas Oil F32002 Revision 02 10 2002
9. Exol Ethena EP90 Gear Oil 2nd October 2002
Appendix E Heavy Component Weights