Extec C-12 CRUSHER, Operator'S Manual

Page 1: ... Iss1 C 12 CRUSHER OPERATORS MANUAL Machine with Transport Bogie Folding Hopper EXTEC SCREENS CRUSHERS LTD HEARTHCOTE ROAD SWADLINCOTE DERBYSHIRE DE11 9DU ENGLAND Tel 44 0 1283 212121 Fax 44 0 1283 217342 0 ...

Page 2: ...tsrates Alle Direttive de Consigliodelle Comunita Europee Las directivas emitidas por el Consejo de Comunidades Europeas 89 392 CEE 91 368 CEE 93 44 CEE 93 68 CEE 89 622 CEE 98 37 EC CEE 92 58 EEC E M C 89 336 EEC 91 263 EEC 92 31 EEC European harmonised standards Aux Normes Europeennes Harmonisees Und den in Einklang stehenden Europäischen Normen Alle Norme europee armonizzate Estándares armoniza...

Page 3: ...d outside the working parameters specified by the manufacturers Every effort has been taken to ensure the accuracy of this manual nevertheless as operating conditions vary considerably all performance data contained herein is indicative only for plant operated in accordance with the conditions set out in this manual It is ESSENTIAL that the operator reads and observes the safety instructions in th...

Page 4: ...INE Page 13 14 SETTING UP MACHINE Page 15 18 ADJUSTING OUTPUT SIZE Page 19 21 OPERATING MACHINE CRUSHING Page 22 23 FEEDING MATERIAL INTO MACHINE Page 22 ADJUSTING FEEDER SPEED Page 23 REVERSE JAW OPERATION Page 24 JAW BRAKE PRESSURE ADJUSTMENT Page 25 MAINTENANCE Page 26 36 MAINTENANCE DAILY Page 26 27 MAINTENANCE WEEKLY Page 28 34 MAINTENANCE EVERY 250hrs Page 35 MAINTENANCE EVERY 1000hrs Page 3...

Page 5: ...chine without guards in place ii Make adjustments or clean moving parts whilst machine is running iii Reach into the machine to clean lubricate or adjust without first shutting off power to engine removing ignition key iv Operate the machine while under the influence of drink or drugs NOTE medicines prescribed by your medical advisor may make you unfit to operate machinery Always check before atte...

Page 6: ...RANSPORTATION DIMENSIONS TRANSPORTATION WIDTH 2743 9 ENSURE HOPPER DOORS INLET CHUTE COVER EXHAUST STACK SPRAY BAR ARE FOLDED DOWN FOR TRANSPORTATION BEFORE TRANSPORTING THIS MACHINERY ALL MEASUREMENTS OF THE MACHINE SHOULD BE CHECKED TO ENSURE THEY ARE WITHIN THE LEGAL TRANSPORT DIMENSIONS 5 ...

Page 7: ...s taken by Castle GA 101 701 meter calibrated on the 13 9 94 with all systems running sited on factory assembly line As stated in the Safety Instructions section of this manual ear protection is compulsory within 10 meters of the machine when the engine and other moving parts of the machine are in operation 7m 77 dB 10m 77 dB 7m 85 dB 7m 81 dB 7m 77 dB 10m 77 dB 7m 81 dB 7m 85 dB 6 ...

Page 8: ...d auxiliary equipment vi Ensure that the checks and prestart procedures outlined in the engine manufacturers instruction manual are complied with vii Check oil levels in engine and vibrating feeder viii Check that all drums and rollers turn freely This should be done by hand NEVER attempt to touch drums or rollers whilst machine is running ix Make sure that skirting rubbers and scrapers are in goo...

Page 9: ...n firm level ground before being operated Failure to comply with this or any other instructions in this manual may cause damage to the machine and may invalidate any warranty i Set speed control to No 1 position ii Turn key clockwise to on position All lights will flash for several seconds iii Turn key to start position and hold until engine starts iv Release key Key will return to on position v E...

Page 10: ...key to off position STOPPING MACHINE IN AN EMERGENCY THE MACHINE CAN BE STOPPED IN AN EMERGENCY BY PRESSING THE EMERGENCY STOP BUTTONS LOCATED ON THE ELECTRICAL CONTROL PANEL AND ALONG EACH SIDE OF THE MACHINE OR BY TURNING THE IGNITION KEY DIRECTLY TO OFF POSITION ENSURE THAT ALL PERSONNEL IN THE VICINITY OF THE MACHINE ARE FULLY AWARE OF THE LOCATIONS OF THE EMERGENCY STOPS 1 Emergency stop igni...

Page 11: ...Lower front Jacking Legs to raise fifth wheel neck by approximately 100 mm 4 Unlock bogie from machine 4 positions 5 Rear Jacking Legs lever 6 Lower rear Jacking Legs to raise machine clear of the bogie locking mechanism NOTE Before attempting to lower the jacking legs ALL of the leg transportation retaining screws MUST be removed Jack retention screw 10 ...

Page 12: ...onnections then tow away from machine 8 Retract both front and rear jacking legs so that weight of machine is taken on tracks 10 Raise R H hopper side 9 Raise L H hopper side Hopper back door being raised 11 Raise hopper back door Hopper side fully raised Hopper side being raised 11 ...

Page 13: ...5th wheel neck up into a vertical position to avoid damage when loading material into hopper 16 Reattach hose to rear door ram Fitting the bogie and attaching the tractor for transportation is a reversed procedure to that describe above IMPORTANT Before transporting with the bogie fitted ensure that the jacking legs are fully retracted and the leg transportation retaining screw have been refitted ...

Page 14: ...an be moved to desired position on site by following the instructions below Main conveyor in raised position 2 Press button Interlock On 3 Press button Main conveyor lift 4a Activate levers to raise front jacking legs 4b Activate levers to raise rear jacking legs 1 Press button Clamp On 13 ...

Page 15: ...at it is only moved over firm ground suitable for carrying the weight of the machine Prior to operating the machine it is ESSENTIAL that both tracks are in contact with firm level ground to avoid excessive vibration or rocking of the machine DO NOT MOVE THE MACHINE ACROSS EXCESSIVELY SLOPING GROUND NOTE i When operating the Yellow Remote Handset the directional arrows relate to the machines forwar...

Page 16: ...HER PREPARING THE CRUSHER FOR OPERATION Main conveyor in working position 5 Raise R H hopper side 2 Press button Interlock On 4 Raise L H hopper side 3 Press button main conveyor lower 1 Press button Clamp On 15 ...

Page 17: ...E CRUSHER FOR OPERATION Cont Hopper back door being raised 8 Fit hopper cross tie box secure with pins R clip 6 Raise hopper back door 7 Fit locking pins to hopper sides rear Hopper side fully raised Hopper side being raised 16 ...

Page 18: ...or locking pin 11 Activate lever marked Side Con Fold to lower side conveyor Side conveyor in working position 12b Fix main conv spray bar in working position 12a Raise main conv spray bar to working position Locking Pin 9 Fit tighten bolts at hopper leg chassis Both sides 17 ...

Page 19: ...achine is on a level surface before operating the jack leg levers b Lift the machine uniformly 13b Push safety gate firmly down into holes 13c Raise up rotating gate section NOTE while operator is using the platforms the safety gates MUST be closed 13d Rotate lower gate into position Repeat procedure on other side of machine 14 Lower jack legs by operating levers 18 ...

Page 20: ...ollowing procedure WARNING The machine MUST be stationary and the crusher turned off whilst this procedure is carried out 2 Restart machine as described on page 8 and leave speed switch at position No 1 1 Stop the machine as described on page 9 NOTE MACHINE MUST BE SHUT DOWN AND RESTARTED SEE STEPS 1 2 BEFORE JAW CAN BE OPENED CLOSED I g n i t i o n K e y 19 ...

Page 21: ...adjust on 4a Press button Jaw in to close up Jaw 4b Press button Jaw out to open up Jaw 5 Lock jaw when adjustment is complete USING REMOTE PENDENT FOR SETTING MATERIAL OUTPUT SIZE 1 Turn to remote 2 Remote pendent for opening jaw J A W C L O S E J A W O P E N STOP 20 ...

Page 22: ... not be operated at Closed Size Settings CSS of less than 75mm 3 without prior approval in writing from Extec Determining when the jaw is fully closed can be done by examining the position of the alignment arrow on the jawstock shaft end plate When the indicator arrow is pointing vertically up the jawstock is in its fully closed position This can be seen by looking through the slotted area on the ...

Page 23: ... the feeder STOP MACHINE and remove any large pieces of material with the appropriate equipment DO NOT use excavator to force any material into feeder as any damage occurred from this action will invalidate any EXTEC warrantees iii Material should be fed carefully not dropped onto feeder from about 300mm above feeder Ensure that feeder is evenly loaded over its entire length excluding grizzly this...

Page 24: ...eder when the pressure in the crusher chamber exceeds specified limits This reduces the chances of the crusher becoming choked with material as the machine will have more time to deal with what is in the crusher chamber Once the pressure in the crusher chamber drops to within specified limits the feeder will automatically restart to give an uninterrupted crushing process This system reduces the ch...

Page 25: ...se off vi Switch engine to No 2 position Restart all running systems see page 22 To resume normal crushing The above procedure may be repeated as often as necessary to try to release any blockages in the crusher box If the machine is unable to crush material that has become stuck in the jaw after the crusher reverse function has been activated the crusher may need to be cleared manually STOP MACHI...

Page 26: ...n position with the attached lock nut 6 The jaw will run for approximately 5 seconds when stopping SAFETY NOTICE FORWARD JAW BRAKE PRESSURE REVERSE JAW BRAKE PRESSURE Note jaw should only be run in reverse on speed No 1 1 Attach pressure gauge to pressure point as shown 2 Start crusher in reverse jaw on speed on No 1 then stop crusher pressure gauge should read 350 bar If required adjust pressure ...

Page 27: ...hilst operating or carrying out any maintenance on the machine All adjustments must ONLY be carried out by trained personnel All adjustments to modify hydraulic system must ONLY be carried out by trained Extec service engineers It is recommended that the following DAILY MAINTENANCE SCHEDULE be carried out If necessary refill diesel tank Refill if necessary Refer to the engine manufacturers handboo...

Page 28: ...sed air NOTE Service indicators are for showing when elements need to be replaced not cleaned Bleed diesel water trap Diesel Tap 2 Unscrew nut to remove cover 5 Replace elements and rear cover after cleaning 4 Remove inner element 3 Loosen nut Remove outer element 1 Air cleaner inside of Power Unit S e c u r i n g n u t cover Service indicator Check radiator water level refill if necessary Radiato...

Page 29: ...ace if necessary g Examine toggle plate to make sure that it is free from cracks and other defects Replace if necessary h Check toggle assembly for damage and clear any debris to ensure free movement of the hydraulic cylinders i Check toggle clamping ram link arm ram bearings for any damage or wear Replace if necessary j Examine liner plates inside crusher chamber for wear replace if necessary k C...

Page 30: ... iv Re tighten Nyloc nut RETAINING BOLT ADJUSTMENT 2 Remove oil filler plug Refill using EP220 GEAR OIL until oil comes out of level hole CHECKING FEEDER OIL LEVEL ALWAYS CHECK BOTH SIDES 1 Remove oil level plug If oil trickles out there is enough oil in feeder if not oil level needs to be topped up filler plug level plug drain plug If the service indicator is green it is time to replace the tank ...

Page 31: ... Conveyor Bearings 50 Grams 40 Hrs Grease EP2 Main Conveyor Bearings 50 Grams 100 Hrs Grease EP2 Main Conveyor Bearings 50 Grams 100 Hrs Grease EP2 Side Conveyor Bearings 50 Grams 100 Hrs Grease EP2 Side Conveyor Bearings 50 Grams 100 Hrs Grease EP2 Torque Arm Bearings 50 Grams 40 Hrs Grease LGHQ3 18 Frame Jawstock Bearings 40 Grams 8 Hrs Grease EP2 General Bearing Housings Main Conveyor lower bea...

Page 32: ...xing screws 1 Sealing rubber in correct position condition INSPECTING ADJUSTING BELT SEALING RUBBERS ADJUSTING BELT SCRAPER If required adjust head drum scraper by loosening bolts in rota springs adjusting scraper and re tightening bolts Both sides should be adjusted simultaneously 31 ...

Page 33: ...hen the water trap is taken off oil will spill out Use a suitable container to catch any waste oil expect between 3 and 5 litres Replace water trap as shown CLEAN UP ANY OIL SPILLS AFTER PERFORMING THESE OPERATIONS 2 Replace elements if service indicator is red 4 Close and secure cover plate 1 Lift up cover inspect service indicator 3 Replace cap ensuring O ring is in place service indicator O rin...

Page 34: ...EFORE REPLACING ELEMENTS 2 Replace element if service indicator is red 4 Lower oil cooler lift up cover inspect service indicator 1 Remove cover plate inspect service indicator 3 Replace cap ensuring O ring is in place service indicator O ring 5 Repeat stages 2 3 for second filter Close secure cover 6 Raise oil cooler and re attach cover plate stay bar service indicator HYDRAULIC FILTERS WITH OPTI...

Page 35: ...HER BOX LINER PLATES If when examining jaw plates it is found that they are excessively worn they must be either turned or replaced Jaw plates will wear more at the bottom of the crusher chamber as this is where most of the crushing action takes place The jaw plates can be turned around to maximise their useful life to change or turn jaws proceed as follows Do not allow jaw plate to become so badl...

Page 36: ...if the service indicator is red change it otherwise just clean all dust from the base of the filter e Run all systems for 4 hours with engine speed set to No 1 position DO NOT FEED MATERIAL INTO MACHINE DURING THIS OPERATION f Stop machine and replace flushing filters with new 25 micron hydraulic filters v Check for leaks on hydraulic pipes vi Inspect condition of conveyor belts and tracking vii I...

Page 37: ...g of waste oil must be done in a manner that complies with any relevant legislation To refill track gearbox with oil drive machine until either one of the drain plugs is at the top See Photo NOTE this will only be 1 4 turn of the track gearbox DO NOT drive machine any further until oil has been replaced in tracks Remove both drain plugs as shown in the photographs below Fill oil into the top drain...

Page 38: ...and fit the replacement toggle in the following way View on hydraulic control box 2 Stop the machine as described on page 9 solenoid valve 1 Close jaw up as described on page 19 to give a 30 to 40 mm gap 3 Using appropriate equipment support the toggle plate 4 Remove toggle support arm tie bar bush Note only one bolt shown toggle release valve accumulator 6 Restart machine as described on page 8 a...

Page 39: ...b Ensure that ALL guards are refitted and that the feeder crusher and conveyor belts are empty BEFORE restarting machine 15 Remove valve handle and lock back into position shown above 17 Adjust to the required closed size setting as described on page 21 relief valve 16 Restart machine press Jaw Lock ON button screw out relief valve until accumulator pressure gauge reads 155 170 bar push pull 12 Ra...

Page 40: ...ydraulic pipes leaking Check flywheel belt tension Check engine speed switch is at No 2 position Clean air filter diesel filter diesel sediment bowl NOTE A high pressure reading when crusher is empty would indicate a mechanical problem with the crusher such as an obstruction between jawstock and side of crusher box If this occurs STOP MACHINE INVESTIGATE IMMEDIATELY Flywheel slowing under load Che...

Page 41: ...uction pressure using a 0 6 bar pressure gauge this should be 1 2 bar min 1 1 2 bar max Check control pressure using a 0 100 bar pressure gauge This should be 40 bar at all times Check webtec is fully open Check pressure on at 4 station manifold using 0 250 bar pressure gauge See next page for detail Feeder not working Check clamp pressure is between 155 170bar Check operation of toggle cylinders ...

Page 42: ...d block on side of valve plate Check pressure at test points shown to check Feeder Magnet Side conveyor Main conveyor using a 0 250 bar pressure gauge Pressure readings when running empty should be i Feeder Cold start 100 bar this should drop to 50 bar when warm ii Magnet 30 bar iii Side conveyor 30 bar iv Main conveyor 50 bar Check belt tension Check that there is no build up of material undernea...

Page 43: ...efon 49 0 6628 9211 0 Telefax 49 0 6628 9211 11 Extec Inc PO Box 355 Essington PA 19029 0355 Tel 1 610 521 1448 Tel 1 800 44SCREEN Fax 1 610 521 1863 Extec Screens Crushers Ltd Hearthcote Rd Swadlincote Derbyshire DE11 9DU England Tel 44 0 1283 212121 Fax 44 0 1283 217342 42 ...