Jaw Crusher R800 -MAN NUAL

Serial number:

Side 0

CONTENT:
I Preface I. P f II. Intended use III Safety Safety hazard symbols p g instructions Operating Maintenance work IV.Technical data Overview Building groups V. Start up V Operation devices Transport System set up Gap adjustment VI. Operation VI O ti Special operating information Procedure crusher operation VII. Maintenance Hydraulic system Di Diesel l motor t Vibration feeder Caterpillar crawler Crawler gear Conveyor belts V belts V-belts Jaw crusher Welding preparations Oil level monitor Service plan Recommended oil qualities VIII. Standard forms Rockster warranty registration CAT warranty registration Warranty claim Terms and conditions Sid 2 Side Side 4 Side 6 Side 7 Side 13 Side 24 Side 26 Side 27 Side 28 Side 33 Side 34 Side 40 Side 42 Side 45 Sid 46 Side Side 47 Side 49 Side 51 Side 52 Sid 53 Side Side 53 Side 54 Side 54 Side 55 Side 55 Side 56 Side 57 Side 60 Side 62 Side 64 Side 65 Side 66 Side 67 Side 68 Side 69

CONTENT
R800 JAW CRUSHER
Side 1

CONTENT:
I Preface I. P f II. Intended use III Safety Safety hazard symbols p g instructions Operating Maintenance work IV.Technical data Overview Building groups V. Start up V Operation devices Transport System set up Gap adjustment VI. Operation VI O ti Special operating information Procedure crusher operation VII. Maintenance Hydraulic system Di Diesel l motor t Vibration feeder Caterpillar crawler Crawler gear Conveyor belts V belts V-belts Jaw crusher Welding preparations Oil level monitor Service plan Recommended oil qualities VIII. Standard forms Rockster warranty registration CAT warranty registration Warranty claim Terms and conditions Sid 2 Side Side 4 Side 6 Side 7 Side 13 Side 24 Side 26 Side 27 Side 28 Side 33 Side 34 Side 40 Side 42 Side 45 Sid 46 Side Side 47 Side 49 Side 51 Side 52 Sid 53 Side Side 53 Side 54 Side 54 Side 55 Side 55 Side 56 Side 57 Side 60 Side 62 Side 64 Side 65 Side 66 Side 67 Side 68 Side 69

I PREFACE I. E
R800 JAW CRUSHER
I. PREFACE
Side 2

PREFACE: This Operator's Manual applies for the track-m mounted crushing plants R800 manufactured by Kormann Rockster Recycler GmbH. The crushers are designed fo or the processing of virgin stone and recycling material. The technical specifications specifications, drawings drawings, photos, and other information contained in this manual are non-binding and may be changed, revised or updated due to further technical developments at any time without obligation. The machine owner/operator is responsible to supplement the information contained in this manual with any and all applicable local guidelines and regulations for safety prevention and environmental protection. This Operator's Manual must be available and accessible at the operation site at all times. All persons who operate, maintain, repair or tra ansport the crusher plant must first read and understand this Operator's Operator s Manual and must conscientiously o observe and follow the guidelines and regulations.

M Manufacturer: K Kormann Rockster Recycler GmbH W Wirtschaftszeile West 2, A-4482 Ennsdorf / Austria P Phone: +43 (0) 7223 81000 Fax: +43 (0) 7223 81000-329 e e-Mail: office@rockster.at Homepage: www.rockster.at

I. PREFACE

Side 3

CONTENT:
I Preface I. P f II. Intended use III Safety Safety hazard symbols p g instructions Operating Maintenance work IV.Technical data Overview Building groups V. Start up V Operation devices Transport System set up Gap adjustment VI. Operation VI O ti Special operating information Procedure crusher operation VII. Maintenance Hydraulic system Di Diesel l motor t Vibration feeder Caterpillar crawler Crawler gear Conveyor belts V belts V-belts Jaw crusher Welding preparations Oil level monitor Service plan Recommended oil qualities VIII. Standard forms Rockster warranty registration CAT warranty registration Warranty claim Terms and conditions Sid 2 Side Side 4 Side 6 Side 7 Side 13 Side 24 Side 26 Side 27 Side 28 Side 33 Side 34 Side 40 Side 42 Side 45 Sid 46 Side Side 47 Side 49 Side 51 Side 52 Sid 53 Side Side 53 Side 54 Side 54 Side 55 Side 55 Side 56 Side 57 Side 60 Side 62 Side 64 Side 65 Side 66 Side 67 Side 68 Side 69

II INTENDED USE II. U

R800 JAW CRUSHER
II. INTENDED USE
Side 4

INTENDED USE:

The machine is constructed in compliance with h prevailing technical standards and safety regulations. Nonetheless, the operation or use of the machine may be co onnected with hazards which may endanger personal safety or lead to material damage to the machine and/or other o objects. objects Operate the machine only in good order and co ondition and only in the intended manner of use. Observe all safety regulations and accident-prevention guidelines s according to this Operator's Manual and applicable local regulations. Circumstances or technical defects which may y pose a threat to operational safety must be immediately remedied or repaired. The machine is intended solely for the purpose e of crushing, screening, or sorting recycling material. Use of the machine for any other purpose is contrary to th he manufacturer's intended purpose. The manufacturer/dealer is not liable for damages arising from such contrary u use. The customer/operator assumes sole risk and responsibility for costs and damages which may result from suc ch contrary use. Use of the machine according to the manufact turer's intended purpose explicitly includes the observation of and compliance with all parts of the Operator's Man nual and the adherence to inspection and maintenance regulations.

II. INTENDED USE

Side 5

CONTENT:
I Preface I. P f II. Intended use III Safety Safety hazard symbols p g instructions Operating Maintenance work IV.Technical data Overview Building groups V. Start up V Operation devices Transport System set up Gap adjustment VI. Operation VI O ti Special operating information Procedure crusher operation VII. Maintenance Hydraulic system Di Diesel l motor t Vibration feeder Caterpillar crawler Crawler gear Conveyor belts V belts V-belts Jaw crusher Welding preparations Oil level monitor Service plan Recommended oil qualities VIII. Standard forms Rockster warranty registration CAT warranty registration Warranty claim Terms and conditions Sid 2 Side Side 4 Side 6 Side 7 Side 13 Side 24 Side 26 Side 27 Side 28 Side 33 Side 34 Side 40 Side 42 Side 45 Sid 46 Side Side 47 Side 49 Side 51 Side 52 Sid 53 Side Side 53 Side 54 Side 54 Side 55 Side 55 Side 56 Side 57 Side 60 Side 62 Side 64 Side 65 Side 66 Side 67 Side 68 Side 69

III SAFETY III. Y

R800 JAW CRUSHER
III. SAFETY
Side 6

SAFETY HAZARD SYMBOLS:

Many of the following symbols appear frequently in these operating instructions; they call special attention to hazardous situations which may arise when op perating the machine.

Danger of entrapment. Do not reach into open machinery. s. Entrapment may cause serious or fatal injuries Body parts can be drawn in and crushed or tor rn. Be sure that all machinery has come to a comp plete standstill before opening or removing protective covers. Keep in mind the necessary run-down time for r rotating/sliding/reciprocating machinery (rotor, jaws, belt pulleys, V-belts, flywheel, vibro plate, grizzly, pre-scree ener, centrifugal weights, etc.).

Danger of entrapment. Do not reach into open machinery. Entrapment in rotating parts may cause serious or fatal injuries. Body parts can be drawn in and crushed or tor rn. Be sure that all machinery has come to a comp plete standstill before opening or removing protective covers covers. Ignition key and battery switch have to be pulle ed off, the machine has to be protected against start-up by external persons.

III. SAFETY

Side 7

SAFETY HAZARD SYMBOLS (continued): Crush hazard. Caution is required at points wh here hands and/or feet can be crushed. Never use feet, hands, fingers, or other body parts p to support or hold machine parts. Always use the provided anchors and/or mech hanical supports.

Danger of falling/flying material. Do not enter loading/discharging zones. Doing g so may cause serious or fatal injuries. A hard hat must be worn in the immediate vicin nity of the machine.

Personal hearing protection must be worn.

Never stay, work or go under suspended / hanging load. Any stay is prohibited without exception. Use only tested and certified lifting equipment

III. SAFETY

Side 8

SAFETY HAZARD SYMBOLS (continued):

Wide or loose clothing may be drawn into or ca aught in moving machinery. Wear EN/ANSI tested, tested correctly fitting protectiv ve clothing clothing. Personal protective gear includes hard hat, goggles, hearing protection, close-fitting overalls, steel-toed boots, flourescent safety vest and protective gloves. Do D not wear jewellery.

The operator's manual must be read and unde erstood before operating the machine. Read and observe the various warning symbol ls on the machine. Only specially schooled and trained personnel may operate or work with the machine.

Turn off the motor and remove the key y from the ignition g before beginning g g maintenance or adjustment j work. Ignition key and battery switch have to be pulle ed off, the machine has to be protected against start-up by external persons. The key and battery switch must be kept on yo our person during maintenance or repair work. We recommend, to never work alone.

III. SAFETY

Side 9

SAFETY HAZARD SYMBOLS (continued):

Danger of falling: do not climb onto or stand on n the machine when it is moving or in operation. Only use the intended upward mobility ladder ladder on the catwalk catwalk . An appropriate work platform must be used wh hen working at heights exceeding 2 m.

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

Beware of escaping p g hydraulic y oil. Pressurized hydraulic oil can penetrate the skin and lead to poisoning. ginning maintenance or adjustment work. The system must be depressurized before beg If hydraulic oil has penetrated the skin it must be b surgically removed. Seek professional medical care immediately.

III. SAFETY

Side e 10

SAFETY HAZARD SYMBOLS (continued):

Personal safety hazard: acids acids, chemicals chemicals, und caustic fluids fluids.

Personal safety hazard: magnetic field. Do not allow persons with pacemakers or othe er electronic medical devices to enter the danger zone. Personal safety hazard: electrical current. Danger of serious or fatal injuries. Never perform work on the electrical system if you are not thoroughly familiar with all technical details and specifications. p Only qualified electricians may perform work on o the electrical system. Use only tested and certified lifting equipment

III. SAFETY

Side e 11

SAFETY HAZARD SYMBOLS (continued):

These symbols call attention to various regulat tions and prohibitions to prevent damage and avoid hazardous situations, as well as highlight special manufac cturer's instructions for correct machine operation.

III. SAFETY

Side e 12

OPERATING INSTRUCTIONS (continued):

Personal protective equipment must be worn in n compliance with the regulations to the extent necessary. In the event of changes to the operating state of o the machine (insofar as these are safety-relevant), safety-relevant) the system must be stopped and brought to a standstill an nd the fault reported to the person responsible; the latter must immediately rectify the fault or have it rectified, , and return the system to its correct operating state. No changes and assembly or conversion work k may be carried out on the machine without authorisation by the manufacturer. This applies in particular for mec chanical, electrical and hydraulic safety devices as well as for welding work on load-bearing components.

Replacement and wearing parts must correspo ond to the technical requirements specified by the manufacturer. This is always guaranteed for original and wearing parts. p Specified schedules and/or those cited in the operating o instructions for recurrent tests must be adhered to.

III. SAFETY

Side e 13

OPERATING INSTRUCTIONS

The operating instructions must always be with hin easy access at the site of operation of the machine. Universally applicable statutory and other binding regulations/laws concerning accident prevention and environmental protection (supplementary to the e operating instructions) must be observed/complied with. These obligations can also concern handling hazardous h materials; or providing and wearing protective equipment as well as road transport regulations. The operating instructions must be supplemen nted by instructions including supervisory and reporting obligations with regard to special operational circumstance es, for example with reference to workflows, work organisation, staff employed etc. All persons authorised for work on the machine e must have read and understood the operating instructions before commencing work. This applies in particular fo or individuals who only occasionally work with the machine, for example during maintenance or assembly work on the machine. Regularly Reg larl check that the personnel are working orking g with ith an a awareness areness of the safet safety and ha hazard ard aspects in compliance with the operating instructions. All safety and hazard indications must be easil ly visible and legible and must be observed. Removal of the safety and hazard instructions from the system y is strictly y prohibited. p Personnel must tie back long hair and may not t wear loose clothing or jewellery (also rings). There is risk of injury, for example, if the hair or clothing becomes ca aught or pulled into the machine. Personnel authorised for work on the machine are personally responsible for complia ance with the regulations.

III. SAFETY

Side e 14

OPERATING PERSONNEL:

Operating personnel must be instructed in corr rect and safe operation of the system and its accompanying accessories. Work on/with the machine may only be carried d out by reliable, trained and instructed personnel who have experience in working with machines. Observe e the statutory minimum age. Clearly specify areas of responsibility for perso onnel in regard to operation, assembly, maintenance, commissioning etc. Ensure that only authorised personnel work on n the machine. Also specify responsibilities for machine transp portation drivers in respect to road-transport road transport regulations, and ensure that drivers do not receive instructions contrary y to safety by third parties. Personnel who are to be trained or instructed or o who are currently receiving general training may only work on the machine under continuous supervision by an experienced e person. Work on the electrical system of the machine may m only be carried out by qualified electricians or by instructed personnel under the guidance and supervision n of a qualified electrician in accordance with the regulations concerning electrical engineering. Work on the hydraulics of the machine may on nly be carried out by personnel with specialist knowledge of hydraulic systems.

III. SAFETY

Side e 15

BEFORE COMMENCING WORK OPERATING PERSONNEL MUST:

...be instructed in the work to be performed by means of a specialist training. be advised of the dangers. ...check all safety relevant covers and casings on their correct position ...be informed about safety functions, like f.i. th he EMERGENCY OFF switch, in order to be able to use them in any case of emergency. be familiar with all moving parts of the system, in order to beware of these. ...have have read and understood the operating inst tructions together with all warning/safety instructions in the operating instructions as well as all other saf fety-relevant warning/safety instructions for the product. ...take sufficient time to examine in detail and become b familiar with the warning instructions, their significance and consequence.

III. SAFETY

Side e 16

HYDRAULIC SYSTEMS AND THEIR COMPO ONENTS:

Only persons with special knowledge and expe erience may work on the hydraulic units. Return all control valves to the neutral position n (discharge system pressure) pressure). Switch off the motor before disconnecting or removing hydraulic pipes, tan nk covers, hydraulic filters or couplings. Disconnect the power supply. Replaced hydraulic components must correspo ond to the same standard and quality. Ensure that the parts are correctly mounted.

Beware of leaking hydraulic pipes. Pressurised d hydraulic oil can penetrate through the skin or cause injury to the eyes. Leaks in pressure pipes may not be visib ble to the naked eye. Never check leaks with your hands or fingers. Use an aid, such as cardboard for example. Always wear goggles. If hydraulic oil comes int to contact with the eyes, seek medical advice immediately. Immediately replace defective hydraulic pipes. Fires can result from leakages. Ensure that the replaced hydraulic pipes correspond to the specifications of the original. riginal Ensure that the hydraulic pipes are correctly mounted and laid laid. Never exceed safety limits. Never set overpres ssure valves higher than the default settings. Never exceed safety limits. Never set overpres ssure valves higher than the default settings.

III. SAFETY

Side e 17

ELECTRICAL SYSTEMS AND MOTORS: In case of electric incidents of safety relevant components, c immediately switch off the diesel engine, the battery switch and protect the machine against re-star rt by external persons. Never carry out work on the electrics of any co omponents without familiarising yourself with these. Only qualified electricians may carry out work on o the electrical system of the machine. If work on the live parts is necessary, a second d person must be present who can operate the EMERGENCY OFF or main i switch it h with ith shunt h t release l i in th the event t of f an emergency. Only O l use voltage-insulated lt i l t dt tools. l

Electrical equipment within the system must be e checked regularly. Damaged cables or loose connections must be repaired p immediately. y Use original g fuses of the e specified p length g and p power. Lead connections or connections containing le ead are contained in the battery poles and accessories. These materials are carcinogenic. Observe the manufacturers instructions of the battery. Always wash your hands. Never short short-circuit circuit the battery poles poles. A short-ci short ci ircuit can cause fires and damage the electrical system system.

Battery acid can cause injuries. Avoid contact with w the skin or eyes. Always wear gloves and goggles. Exhaust E h t gases contain t i harmful h f l combustion b ti pro oducts. d t Work W k with ith th the system t in i an open environment i t or di divert t th the exhaust gases into the open air. ve the motor and exhaust system sufficient time to cool down before Do not touch the motor and exhaust parts. Giv starting g maintenance and repair p work. Never refuel while the motor is running. Do not t smoke while refuelling. Ensure that there are no exposed light sources in the vicinity. Do not spill any fuel or completely fill the tank tank. Spilt fuel must be removed properly and immediately immediately.

III. SAFETY

Side e 18

MAGNETIC FIELDS: There is a risk of magnetic radiation in systems s which are equipped with magnetic separators. This affects: o o o Persons with hea art pacemakers Electronic device es Electronic storag ge media

Entry into the hazard zone can cause damage to health or irreparable damage to electronic appliances. Personnel must be informed of these hazards accordingly during instruction. Explain this hazard to persons outside the com mpany. Keep persons with heart pacemakers away fro om the system.

DUST, VAPOUR AND SMOKE: Grinding, b Grinding burning rning or welding elding work ork ma may onl only be e carried o out t on the machine if this is e expressly pressl a authorised thorised (danger of explosion). a flammable substances and ensure sufficient ventilation before Clean the system and its environment of dust and burning, g welding g or g grinding g( (danger g of explosi p ion). ) Safety guards must be fitted on the devices so o that dust/materials cannot harm the machine user or persons in the immediate surroundings. Ensure that no dust enters e the air when loading, adjusting or removing the material to be crushed. Recommended procedures for eliminating dust are: o o Dust protection and a dust extraction Dust removal wit th water

III. SAFETY

Side e 19

NOISE: The noise protection equipment must be in the e protective position during operation. Wear the specified personal ear protection protection.

OILS, GREASES AND OTHER CHEMICAL SUBSTANCES: S Observe the safety regulations applicable for the product when working with oils, greases and other chemical substances. p materials (burning or scalding hazard). Caution when working with hot operating and process

BLASTING: The use of wireless remote control is strictly yp pr rohibited even during gp preparation p work for blasting. g Acute danger g of explosion. The use of a wireless remote control device is prohibited during blasting owing to the danger of explosion. The machine must be removed from the hazar rd zone before blasting blasting. Ensure that no explosive material can enter the e system.

III. SAFETY

Side e 20

FIRE FIGHTING: FIRE FIGHTING:

If the slightest signs of fire occur, proceed as follows, depending on the situation: o o o o o o o Warn persons who o are in the vicinity. Shut down the ma achine. Turn off the power r with the main switch. Ensure that there is no hazard for persons, and lead everyone in the vicinity to a safe place. Begin fire fighting and, if necessary, call the fire brigade. Remove the mach hine from the hazardous area, if possible. Fire fighting.

If the unit has already caught fire, proceed as fo ollows, depending on the situation: o o o o o T rn off the machine Turn ine. Warn persons who o are in the vicinity. seek shelter Ensure that there is no hazard for persons, and lead everyone in the vicinity to a safe p place. Call the fire depar rtment, firefighting

III. SAFETY

Side e 21

OPERATING THE SYSTEM: Only specialists or trained/instructed personne el may operate the system. Refrain from carrying out any work steps that m may pose a risk to safety. safety Before positioning the machine and bringing it into operating position, the work environment must be carefully checked for possible obstructions. The load bearing cap pacity of the ground and traffic arrangement must also be checked. The operating instructions must have been rea ad and understood before commissioning. Several labels are on the system; spare some time to become familiar with w the warning instructions. Note that the system has sharp corners and ed dges as well as rough surfaces in part. Check and ensure that all system parts are fully functional. o Check for defective and missing g parts. Immediately repair or replace these parts. o Ensure that all panelling is alwa ays correctly mounted and that all EMERGENCY OFF switches are functioning. o Dail maintenance work Daily ork m must st b be carried o out t in accordance with ith the ser service ice plan plan. For a detailed list, see the service plan. Walk round the machine before starting work, and ensure that no person(s) are on or under the system or in its vicinity or in danger g areas. All p persons who are in the immediate environment are to be informed if the system y is to be started. Only start the machine if no persons are on or under the system or in its vicinity. All doors must be closed and locked. Keep all handles, steps, railings, platforms, sta ages and ladders free of dirt, in particular ice, snow, oils and greases. Never climb onto, onto over and/or under running co onveyor belts belts. Always use the ascending aids and catwalks designed and provided for this. The belt and chain tension must never be chec cked while the system is running.

III. SAFETY

Side e 22

OPERATING THE SYSTEM (continued): Do not work or linger in the vicinity/environmen nt of system parts; these can rise or lower. Never stay in the loading or unloading zone as s long as the system is being loaded or unloaded unloaded. Always wear a protective helmet, for example as protection against stones falling/flying from the machine. Always observe all safety regulations. Operate e all buttons and levers gently. Avoid jerky movements or sudden changes in direction. Only press EMERGENCY OFF switches in em mergencies or during safety exercises. Check the machine for external signs of damag ges and defects at least once per shift. Immediately report changes that may have occurred to the person responsible. If required, immediately switch off the machine. s occur. Faults must be rectified immediately. The system must be shut down if malfunctions On and off s switching itching processes as well ell as mon nitoring displa displays s must m st be observed obser ed in accordance with ith the operating instructions. Parts of the power transmission system, such as the pulley of the drive shaft, flywheels, switches, V-belt pulley, V-belts etc, must be p provided with safety yg guards so that nobody y is endangered g by y rotating gp parts. Never remove material blockages if the machin ne is running. Before ending work, it must be ensured that th he feeding hopper, crusher feed and conveyor belts are free of material. Never leave material on the machine machine. Otherwis se the system will be overloaded on restarting restarting.

III. SAFETY

Side e 23

MAINTENANCE WORK: Only specialists or trained/instructed personne el may operate the system. Maintenance and repair work should always be e carried out by at least two persons. persons We recommend to never work alone. Take personal safety precautions. Always wear a helmet, goggles, ear protection and other requisite protective equipment. Do not wear wide and baggy clothing and jewe ellery. This can become caught and/or pulled into the machine. Tie back long hair.

Move the system to an even and firm surface. Turn off the motor and remove the starter key. Depressurise the hydraulics. Secure hydraulic components. Disconnect the power supply before commenc cing maintenance work. Never carry out adjustment or repair work while the motor is running. Pay attention to the overrun of rotating parts. Only remove panelling which actually blocks access. Remove oil or grease that has escaped. Never leave the system unattended if the pane elling is removed and the housing is open. Keep bystanders away from the system. Raised system parts must always be properly secured. Never work below system parts that have not been secured. If you are working at a height over than 2 m, yo ou must wear an EN/ANSI tested safety harness. Use the catwalks, work platforms or other such h safety (EN/ANSI) tested ascending aids and work platforms. provided for this. Do not use ascending aids or r work platforms that have not been secured and/or approved.

III. SAFETY

Side e 24

MAINTENANCE WORK (continued):

Only operate the motors in a well ventilated en nvironment toxic hazard resulting from exhaust gases. Caution when looking for leakages in the hydra aulic systems. Pressurised hydraulic oil can penetrate through the skin or cause injury to the eyes. Leaks in pressure pip pes may not be visible to the naked eye. Never check leaks with your hands or fingers; use an aid, such as cardboar rd for example. Always wear goggles. If hydraulic oil comes int to contact with the eyes, seek medical advice immediately. Damaged, illegible or missing warning signs must m be replaced or cleaned. Special attention must be paid to the moving p parts during maintenance work; these must be checked. Any damaged, worn or incomplete parts can fall out. This can lead to injury or death. Before finishing the maintenance work, all bolts, connections and joins must be tightened. All panelling must be mounted. Replace or repair damaged covers or o panelling. Only fill or refill pressure systems with the spec cified fluids. Start the motor and check for leakages. Activate all control levers and ensure that the system s functions correctly. After completing p g the tests, check the system y fo or missing g spring p g cotter p pins, washers, lock nuts etc.. Check all fluid levels before starting work.

III. SAFETY

Side e 25

CONTENT:
I Preface I. P f II. Intended use III Safety Safety hazard symbols p g instructions Operating Maintenance work IV.Technical data Overview Building groups V. Start up V Operation devices Transport System set up Gap adjustment VI. Operation VI O ti Special operating information Procedure crusher operation VII. Maintenance Hydraulic system Di Diesel l motor t Vibration feeder Caterpillar crawler Crawler gear Conveyor belts V belts V-belts Jaw crusher Welding preparations Oil level monitor Service plan Recommended oil qualities VIII. Standard forms Rockster warranty registration CAT warranty registration Warranty claim Terms and conditions Sid 2 Side Side 4 Side 6 Side 7 Side 13 Side 24 Side 26 Side 27 Side 28 Side 33 Side 34 Side 40 Side 42 Side 45 Sid 46 Side Side 47 Side 49 Side 51 Side 52 Sid 53 Side Side 53 Side 54 Side 54 Side 55 Side 55 Side 56 Side 57 Side 60 Side 62 Side 64 Side 65 Side 66 Side 67 Side 68 Side 69

IV TECHNICAL DATA IV.

R800 JAW CRUSHER
IV. TECHNICAL DATA
Side e 26

1. Crawler gear 2. Drive motor 3. Drive system 4. Feeding hopper 5. Vibration feeder 6. Pre-screening with reversible chute 7. Crusher cover 8. Jaw crusher 9. Main discharge belt 10 Sid 10. Side di discharge h b belt l 11. Magnetic belt 12. V-belt protector 13. Flywheel 14. Panelling 15. Diesel tank 16 Hydraulic tank 16. 17. Catwalk 18. Hydraulic switchbox 19 El 19. Electric t i switchbox it hb 20. Remote control

17 9 8

13

18 11 1

19 10

7 12 6 5 14 3 16 20 1 15 2 4

IV. TECHNICAL DATA

Side e 27

BUILDING GROUPS: CRAWLER GEAR: The crusher system is mounted on a caterpilla ar crawler. The caterpillar crawlers are driven via a 2-stage gear which enables the system to move at two different speeds. peeds The maximum hill climbing ability is 34 34 . The chain tread consists of 49 x 3-rib plates with 400 mm width. DRIVE MOTOR: Motor: see Original - CAT 7.0/187 kW || JOHN N DEERE 6068/181kW - Manual The motor is housed in noise-insulated housing. All filter and fluid displays are easily accessible. COMBI-COOLER The blower wheel is mounted directly on the engine. The water cooler has an additional equalizing tank with a pressure control valve. OIL-COOLER The blower wheel is driven hydraulically and lim mited to 230bar. DRIVE SYSTEM: Both the hydrostat for the crusher as well as the t hydraulic pump for the operating hydraulics are driven via a distributor gear unit which is flange-mounted on the drive e motor. FEEDING HOPPER: Th f The feeding di h hopper i is made d f from hi highly hl rear re esistant i t t Hardox H d 400 steel. t l Th The capacity it of f th the f feeding di h hopper i is 4 m. VIBRATION FEEDER: The vibration feeder guarantees even material feeding into the hopper. It is lined with highly wear resistant Hardox 400 steel p plates. The p preliminary y screening g is integ g grated in the vibration feeder. The vibration feeder is driven via the vibration drive, which is driven hydraulically. Th he vibration feeder can be activated or deactivated using the hand lever or by remote control. The speed of the vibration feeder f is controlled infinitely via a hydraulic valve.

IV. TECHNICAL DATA

Side e 28

PRE-SCREENING WITH REVERSIBLE CHUT TE: The screening area of the preliminary screenin ng is 1200 mm x 900 mm. The standard gap width of the zigzag grid is 35 5 mm. The pre-screened material can be directed ont to the side belt via a reversible chute, chute or is directly routed onto the main conveyor at the crusher.
Picture IV.1: Reversible chute

CRUSHER COVER:

Picture IV.2: Reversible chute control lever

The crusher cover covers the crusher feed from m above. The crusher cover serves for maintenance purposes only and may be opened only if the rotor is switched off and protected against rotation. It can be opened and closed hydraulically (by wireless remote control or manually) and serves s as protection against falling/flying stones when closed with a chain screen and rubber skirt. An irrigation strip is int tegrated in the crusher cover. JAW CRUSHER R800: The jaw crusher R800 is a single toggle jaw crusher equipped with one moveable and one fixed crushing jaw. The gap width idth of the ja jaws s can be h hydraulically dra licall adjusted adj sted from 30 - 120 mm mm. The crusher speed can be infinitely adjusted. The T direction of rotation can be changed e.g. in case of blockage. The jaws are made of high wear resistent Man ngan steel. CRUSHER SPEED: The granulation of the final product as well as the wear behavior can be individually affected with the help of the crusher speed. The crusher speed is adjusted by the switch s Crusher Speed (see page 35, picture V.2: Electrical switchboard No 2).

IV. TECHNICAL DATA

Side e 29

MAIN DISCHARGE BELT: The main discharge g conveyor y is a solid steel construction c with the dimensions: Length (centre line distance) 7900 mm Width (belt width) 1000 mm Height (discharge height) 3170 mm The conveyor belt of the main discharge conve eyor is located under the crusher where it is protected from impacts by SANPRO plates. The absorbing impact plates are fixed on rubber buffers (rubber mountings), which are additionally absorbing the impact effects. The conveyor belt is manufactured in RIP-STO OP quality. The drive is hydraulic. The operating pressure is limited with 220 bar. The entire construction can be folded up hydra aulically for transport purposes. Attention: Before folding release main belt (open tensioning spindle of driving drum). Retighten belt before operation! Attention: when changing the belt, make sure to use an original RIP-STOP-belt from the manufacturer. If using another belt with different qualities s than the original, a smooth operation can not be guaranteed. Damages resulting from this will no ot be issues of warranty or guarantee. SIDE DISCHARGE BELT BELT: The side discharge conveyor is a solid steel co onstruction with the dimensions: 4100 mm Length (centre line distance) Width (belt width) 500 mm 2300 mm Height g ( (discharge g height) g ) The drive is hydraulic. The operating pressure is limited with 210 bar. The entire construction can be folded up hydra aulically for transport purposes. Attention: Before folding release main belt (open tensioning spindle of driving drum). drum) Before operation, tighten safety screws, retighten belt and check that belt runs centrally and, if necessary, Reset!

IV. TECHNICAL DATA

Side e 30

Side-conveyor: Safety screw

Side-conveyor: Safety screw

MAGNETIC BELT: The magnetic conveyor belt is mounted over th he main conveyor belt. It separates all loose iron fragments from the crushed material and discharges the metallic im mpurities beside the main conveyor belt. The gap between the magnetic surface and ma aterial to be conveyed must be at least 200 mm. The magnetic conveyor belt should have aroun nd 25 mm of slack. Overtensioning can damage the bearings. The drive is hydraulic. The operating pressure is limited with 80 bar. V-BELT PROTECTOR: The V-belt protector is a metal housing. The sy ystem must be shut down before checking or tensioning the V-belt. The V-belt protector an the side door must alw ways be closed and secured after working on the V-belt. PANELLING: The panelling on the crusher serves to provide e operational safety and noise protection. It may only be opened and/or removed for maintenance and repair work. Cru usher operation with dismounted panelling must be avoided at all times. DIESEL TANK: The diesel tank is equipped with an electrical refuelling r pump and is provided with a ventilation opening. This opening is covered with a filter cover. A diesel drain cock is located on the bottom of the diesel tank. The capacity is 330 litres.

IV. TECHNICAL DATA

Side e 31

HYDRAULIC TANK: The hydraulic tank is fitted with an inspection glass,a g level sensor and a temperature sensor. The level sensor switches off the vibration chute immediately if the level falls f below the adjusted limit, the temperature sensor does the same, if the oil temperature is too high. Time-delayed (c ca. 30 sec.) also the operating hydraulics switches off. The capacity is 420 liters. liters Upon filling the hydraulic tank tank, 10 cm m must be left from the upper edge (hydraulic tank) to the liquid level level. On the underside of the tank a drain cock is loc cated.

CATWALK: Catwalks serve for maintenance, revision and monitoring of the system. The catwalks are firmly attached to the system and do not have to be removed for transport.

HYDRAULIC SWITCHBOARD: The most important manual valves for controlli ing the system are located in the hydraulic cabinet.

ELECTRICAL SWITCHBOARD: All the operating elements relevant to the user r are located in the electrical cabinet.

REMOTE CONTROLS: The wireless remote control can be used to mo ove the machine, open/close the crusher cover, activate the hydraulic and activate/deactivate the vibration feeder feeder. The sy ystem can also be operated with the cable remote control but only to move the machine. On both remote controls there ar re EMERGENCY-OFF switch.

IV. TECHNICAL DATA

Side e 32

CONTENT:
I Preface I. P f II. Intended use III Safety Safety hazard symbols p g instructions Operating Maintenance work IV.Technical data Overview Building groups V. Start up V Operation devices Transport System set up Gap adjustment VI. Operation VI O ti Special operating information Procedure crusher operation VII. Maintenance Hydraulic system Di Diesel l motor t Vibration feeder Caterpillar crawler Crawler gear Conveyor belts V belts V-belts Jaw crusher Welding preparations Oil level monitor Service plan Recommended oil qualities VIII. Standard forms Rockster warranty registration CAT warranty registration Warranty claim Terms and conditions Sid 2 Side Side 4 Side 6 Side 7 Side 13 Side 24 Side 26 Side 27 Side 28 Side 33 Side 34 Side 40 Side 42 Side 45 Sid 46 Side Side 47 Side 49 Side 51 Side 52 Sid 53 Side Side 53 Side 54 Side 54 Side 55 Side 55 Side 56 Side 57 Side 60 Side 62 Side 64 Side 65 Side 66 Side 67 Side 68 Side 69

V START U V. UP
R800 JAW CRUSHER
V. START UP
Side e 33

OPERATION DEVICES:

OPERATOR CONTROLS: The operator controls required for operation ar re individually described in the following: HYDRAULIC SWITCHBOARD: 1. Vibration feeder and side discharge belt 2. Main discharge belt 3. Side discharge belt - folding cylinder 4. Main discharge belt - folding cylinders 5. Gap-adjustment-beam - adjustment cylinder rs (main valve) 6. Without function
1 2 3 4 5 6

Picture V.1: Hydraulic switchboard

V. START UP

Side e 34

ELECTRICAL SWITCHBOARD:
1. Hydrostat left/right rotation (only valid, if Duplex System) S 2. Set rotor speed 3 A 3. Activate ti t hydraulics h d li
1 3 5 17

4. Deactivate hydraulics 5. Warning lamp 6. Diagnostic lamp (drive engine) 7. Switchboard lock 8 St 8. Starting ti aid id 9. Adjustment of engine speed 10. Switch for emergency mode (transport) 11. Screen box ON/OFF (option) 12. Water pump ON/OFF (option) 13 Vibration ch 13. chute te ON/OFF (man (manual/remote al/remote control l) 14. Engine preheat lamp 15. Starter key 16. Tank display 17. Monitoring system (motor and crusher unit) 18 Headlight ON/OFF 18.
18 12 14 15 16 7 13 11 8 9 10 2 4 6

Picture V.2: switch board

V. START UP

Side e 35

MOTOR MONITORING SYSTEM:

1 2 3+4 5+6 7 8 ESC-Button ConfirmationButton Scroll Button + / - Buttons Enter Button Indication of engine speed Indication of second parameter of engine Indication of crusher speed Operating-informationdisplay

1 This button enables to return to a previous or higher le evel in the display. 2 With this button error messages can be confirmed. 3+4 Used for navigation between the various menu items in the display. 5+6 Allow to select a value or to change the indication-parameter in the display (see point 9 ). 7 This Thi b button tt effects ff t th the confirmation fi ti of f a selected l t d adjus dj stment t t as well ll as the changing of indication of display to a selected mod de. 8 Indicates the current engine speed. 9 After selecting g this indication item by y using g the scroll buttons b (3+4) ( ) this item is going to be marked in grey colour. By pressing the + or button (5+ 6) the requested indication parameter (hours of op peration, coolant temperature, etc) now can be chosen. By pressing the e enter button (7) this selected parameter then remains active in the display and indicates the condition of this parameter during operation of eng gine. 10 After activating the crusher and running up the crushe er with the crusherspeed-adjusting-buttons, the current crusher speed appears a in this indication. 11 If the block menu is marked in grey and the enter-button (7) ( will then be pressed, you will get into a further submenu (inputs, outputs, alarm protocol and
language). g g ) Within this menu field y you can navigate g with the e scroll buttons ( (3+4). ) After selecting g a menu field this one can be called by y pressing g the enter button (7). After e.g. selecting the menu field language the requested language can be adjusted by pressing the +/- buttons. This one has to be confirmed then with the enter-button (7). In the menu field alarms th he last 100 error messages can be called by pressing the scroll-buttons (3+4). With the ESCbutton (1) you can return from this level in the display to the main menu (=standard indication).

8 9 12 10 13 12a 11

4 3

5 6 7

1 2

10

Picture V.3: motor monitoring system

11

12 12a

Indication of arising problems of diesel motor Indication as per code number of engine manual Indication of arising problems of crusher control

12 The current problem (indicated as plaintext) appears in the display until the error is corrected or due to a change of the operating status of the engine the error is cleared. In case of critical operatio on conditions (e.g. excess temperature of the cooling water) the diesel engine will stop
automatically. An automatic cut-off due to lack of cooling water w is not provided (a regular control of the coolant level is necessary). 12a Errors, which are not indicated as plaintext here appear with w the appropriate code number. The meaning of this code can be read in the engine manual.

13

13 These notices / errors are also indicated as plaintext. If there are no notices, the display is empty.

V. START UP

Side e 36

ERROR MESSAGES OF ENGINE CONTR ROL SYSTEM:

The pressure in the hydraulic circuit of crusher drive has exceeded the adjusted limit value or the crusher speed went below the crusher limit value. The feeder stops immediately as long as this overload of crusher is active. When there is no more overload (hydraulic pressure again at a lower level) the feeder starts again automatically. Indication, that the level of hydraulic oil in the oil tank has reached a level below the limit value. The feeder stops immediately. After a short period of time (30 sec conds) also the complete hydraulics stops. To start again the hydraulics, the oil level must reach a higher level (oil must be filled up in the tank or the function of level senor has to be checked). Indicates, that the temperature of the hydraulic oil has exceeded the adjusted limit value. The feeder stops immediately. After a short period of time (30 seconds) also th he complete hydraulics stops. A new activation is only possible, if the oil has cooled down and reached a lower tempera ature range (under the adjusted limit value). Is indicated indicated, when the load at the main conveyo or (pressure in the hydraulic circuit) is too high high. The feeder will stop automatically. For a further activation the hydra aulic on button has to be pressed on the electrical switchboard or on the remote control (see page 35, picture V.2: electrical switchboard, item 3 or page 38, picture V.4 switch 9). This message g is indicated, , if the safety y switch of o side conveyor y has been activated. The complete p hydraulic y stops p immediately. For new start of hydraulics, this sa afety switch has to be readjusted. Is indicated, when the limit switch at the crushe er cover or the switch board is not adjusted in the right position (distance between surface of switch and surface at crush her cover: 2 3 mm). If this happens during operating the crusher, the feeder will stop immediately and after some sho ort time delay (5 seconds) also the crusher switches off. If the error disappears (problem caused by bad contact or shaking of the plant) during this time, then the feeder will restart again automatically. Indicates, , that the electric motor of water pump p p of sprinkling p g unit has switched of because of lack of water in the suction line (only if an optionally sprinkling pump was in nstalled). The last 100 error messages can be seen in the e error diagnostics (see page 36, point 11, operating-information-display).

Crusher overload:

Hy. oil level too low:

Oil temp. too high:

Overload of main con.: S it h side Switch id conveyor:

Limit switch:

Level of water:

V. START UP

Side e 37

WIRELESS REMOTE CONTROL:

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

Right caterpillar crawler moves forwards

3 4

Left caterpillar crawler moves backwards

5 6

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

Right caterpillar crawler moves backwards

7 8

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

V. START UP

Side e 38

CABLE REMOTE CONTROL:

1 5

1. Forwards left 2 F 2. Forwards d right i ht

Left caterpillar crawler moves forwards Right caterpillar crawler moves forwards

Picture V.5: Cable remote control

For straight-ahead movement press both butto ons (1,2) at the same time 3. Backwards left 4. Backwards right Left caterpillar crawler moves backwards Right caterpillar crawler moves backwards For straight backwards movement press both buttons (3,4) at the same time 5. Emergency OFF Switch Pull to activate the remote control. Press in order to stop the machine in an emer rgency.
Picture V.6: Connecting point

CRUSH HAZARD: Particular caution must be exercised in respect to operating chains when using the cable remote control. Connecting the cable remote control to the cru usher at the industry connecting point, see picture V.6/7. ATTENTION: Machine function is only guaran nteed, if the circuit is closed via cable remote control or the indu ustry connecting point.

Picture V.7: Connecting g cable remote control

V. START UP

Side e 39

TRANSPORT: UNLOADING THE SYSTEM: Check machine on loose parts or material accum mulations. Activate remote control (see page 39) or plug in n cable remote control (see page 40). Start the motor (see Caterpillar Manual) Manual). Press the hydraulic button on electrical switchbo oard (see page 36, point 3). Set ascent angle of the low-loader ramps to not t more than 15 (or ratio 1:4). Carefully drive away from low-loader at low engine speed (below 1000 rpm). LOADING THE SYSTEM: Check machine on loose parts or material accum mulations. Fold and secure side conveyor and catwalk ladd ders. Carefully drive onto the low-loader at low engine e speed (below 1000 rpm) Observe angel of ascent Fasten system with appropriate chains at the an nchoring points points. After the loading reverse battery switch and pull l off ignition key. ATTENTION: Observe transport dimensions. Set ascent angle of the low-loade er ramps to not more than 15 (or ratio 1:4). Use adequate low low-loader loader ramps (for steel chain crawlers) crawlers). Make sure to have a stable groun nd during the loading and unloading process. Remove snow, ice and material from f ramps and caterpillar crawlers. Use outriggers of the trailer Machine tilts when it passes the ramp angle.

V. START UP

Side e 40

TRANSPORT SAFETY: Observe the statutory transport dimensions currently applicable. Secure the system against slipping at the eight anchoring points envisaged for this. .

Picture V.8: lateral lashing ring

Picture V.9: backmost lashing ring

Picture V.10: V 10: front lashing ring

V. START UP

Side e 41

SYSTEM SET UP: Ensure an even ground space, if necessary co ompact. Bring the crusher into position. Move the syste em as close as possible to the material to be crushed. A suitable ramp must be tipped for loading with h a wheeled loader. A clear view onto the hopper and crusher feed must be provided for excavator loading. The material to be crushed must be located in the rear part of the hopper for excavator loading.

Bring the main conveyor belt and side conveyo or belt into the working position (see picture V.8; position 1+2) Attention: Fix saftey screws and tightening g screws! Check that belt runs centrally and, if necessary y, reset (see chapter VII. maintenance). Check belt tension.

Picture V.8: Hydraulic switchboard

NOTE: The material cone under the main and side conveyor belt must not rise above the driving drums. RISK OF DAMAGE TO THE DRIVE UNIT AND THE CO ONVEYOR BELTS.

V. START UP

Side e 42

MATERIAL PREPARATION: The crushing material must be pre-crushed, de epending on the machine type. The process material (recycling material) must t not exceed a max. length of 500 mm. Objects that cannot be crushed must not enter r the crusher. Remove impurities such as iron, wood and sim milar from the material to be crushed. Metal objects larger than the gap width set must not enter the crusher crusher.

CAUTION: Risk of damage to the conveyor belts cut iron pieces that are too long, max. length 500 mm, max. diameter 15 mm REMOVING BLOCKAGES: Start engine. Turn crusher speed to zero (switch 2, side 35 picture p V.2) Change direction of rotation (switch 1, side 35 picture V.2) Softly increase crusher speed to release blockage. Stop crusher. Change direction of rotation back back. Start up again. If blockage could not been removed. Switch h off the main-conveyer-belt, side-conveyor-belt, the vibro and also the crusher. Open p the inlet-cover. Switch off the machine, pull off ignition key y and battery switch. (Protect machine against re-start by externa al persons). The machine must always be switched off. The gap adjustment beam must be brought t to a standstill before removing any blockages and must be secured Remove the blockage with extrem secured. me caution caution. Never step into the crusher Remove the blockage with extreme caution n.

V. START UP

Side e 43

1. A clear view onto the hopper and a crusher feed must be provided for excavator loading.

Point 1

Point 2

Point 3

2. Material preparation: As far as possible, remove all impurities from the process material. Crush parts that are too small into the processing size.

3. The material cone under the main and side conveyor belt must not rise above the driving drums Risk of damage to the drive unit and the conveyor belts.

V. START UP

Side e 44

GAP ADJUSTMENT: The size of the final material is determined by the gap adjustment.

Gap reduction: o Release spring (see picture V.9). o Reduce gap with adjustment cylinder (see picture p V.9.1) to the requested size. o Open cover for the distance-plates. 2) o Take of the safety screws, (see picture V.9.2 o Mount additional distance-plates acc. requested gap size o Move-in the adjustment cylinder till the cylinder is on block with distance plates. o Secure the plates with the safety screws. o Readjust the tension of the spring and contr rol tension during operation (the Toggle-Plate Toggle Plate must have a tight position during operation; the pressed spring has a length about 250m mm)

Picture V.9: spring

Gap enlargement: o Release spring (see pict picture re V V.9). 9) o Reduce gap with adjustment cylinder (see picture p V.9.1) to the requested size. o Open cover for the input plates o Take of the safety screws, (see picture V.9.2) o Remove distance-plates p and move-in the ad djustment j cylinder y to the requested gap width (cylinder is on block thr rough distance-plates). o Secure the plates with the safety screws. o Enlarge gap with adjustment cylinder rol tension during operation o Readjust the tension of the spring and contr (the Toggle Toggle-Plate Plate must have a tight position during operation; the pressed spring has a length about 250m mm)

Picture V.9.1: spring

Picture V.9.2: spring

V. START UP

Side e 45

CONTENT:
I Preface I. P f II. Intended use III Safety Safety hazard symbols p g instructions Operating Maintenance work IV.Technical data Overview Building groups V. Start up V Operation devices Transport System set up Gap adjustment VI. Operation VI O ti Special operating information Procedure crusher operation VII. Maintenance Hydraulic system Di Diesel l motor t Vibration feeder Caterpillar crawler Crawler gear Conveyor belts V belts V-belts Jaw crusher Welding preparations Oil level monitor Service plan Recommended oil qualities VIII. Standard forms Rockster warranty registration CAT warranty registration Warranty claim Terms and conditions Sid 2 Side Side 4 Side 6 Side 7 Side 13 Side 24 Side 26 Side 27 Side 28 Side 33 Side 34 Side 40 Side 42 Side 45 Sid 46 Side Side 47 Side 49 Side 51 Side 52 Sid 53 Side Side 53 Side 54 Side 54 Side 55 Side 55 Side 56 Side 57 Side 60 Side 62 Side 64 Side 65 Side 66 Side 67 Side 68 Side 69

VI OPERATIO VI. ON
R800 JAW CRUSHER
VI. OPERATION
Side e 46

SPECIAL OPERATING INFORMATION: VIBRATION FEEDER: FEEDER Switch on the vibration feeder:
The vibration feeder is manually activated in th he Manual position (see page 35, picture V.2. Nr. 13, vibration feed der) The ball valve (see picture VI.1) in the control panel is closed (closed=vertical) The vibration feeder can be switched on and off o via the ball valve (see picture VI.1) The rate governor (see picture VI.1) on the con ntrol station is used to control the required conveyor speed for the material on the vibration feeder feeder. If the vibration chute does not work, the green Hydraulic-ON - switch must again be pressed. c Switch on the vibration feeder via remote control: The vibration feeder can be activated via the re emote control (see page 38) provided that the Radio" position is switched on (see page 35, picture V.2, Nr. 13) and provided that the ball valve in the control panel is closed. The vibration feeder can be activated and deac ctivated via wireless remote control. The ball valve must be closed in order to us se the remote function of the vibration chute chute. THE CRUSHER CAN BECOME BLOCKED IF F THE VIBRATION FEEDER TRANSPORT SPEED IS TOO HIGH. THIS CAN REDUCE PERFORMANCE, INCRE EASE WEAR AND LEAD TO INFERIOR QUALITY OF THE CRUSHED MATERIAL.
Picture VI.1: Rate governor

CRUSHER COVER:
The crusher cover can be opened and closed again a by hand or by remote control, if required. This procedure is necessary if process materia al has become blocked in the infeed area of the impact crusher (observe process size) size). Opening the crusher c cover increases the infeed and the material is able to enter the crusher space. The crusher cover serves for maintenance m purposes only and may be opened only if the rotor is switched off and protected against rotation. EVER OPEN THE CRUSHER COVER. MATERIAL IS HURLED DURING OPERATION OF THE MACHINE NE OUT BACKWARDS FROM THE CRUSHER!

VI. OPERATION

Side e 47

SPECIAL OPERATING INFORMATION: CRUSHER: Always check the crusher for free running befo ore starting operation. The quality of the final product can be controlle ed by fine adjustment of the crusher speed: a higher rotational speed increases the degree of fines fines, a lower ro otational speed makes the final product coarser coarser. REVERSIBLE CHUTE: The reversible chute guides the pre-screened material into the main discharge belt or the side discharge belt, depending on requirements. Only operate the reversible chute if the materia al flow for pre-screening pre screening is interrupted and the hopper has become empty, otherwise the reverse mechanism may become jammed. MAIN DISCHARGE BELT: The main discharge belt is protected from over rloads by a pressure switch. This pressure balance deactivates the vibration feeder in the event of an overload. Fo or a further activation the Hydraulic-ON button has to be pressed on the electrical switchboard or on the remote control. The most frequent causes of overloading for the main discharge belt are: a) Blockages of concrete iron between belt and d crusher discharge b) Accumulation of material due to slow belt sp peed It is important to check the conveyor belt for iro on pieces and other impurities that may have become caught several times during crushing. This minimizes downtimes of the belt (gaps). Th main The i di discharge h b belt lt can also l b be operated t d in i th the reverse di direction ti f for a short h t period, i d if required. i d MAGNETIC BELT: The ball valve (see page 50 picture VI.4) enab bles the magnetic belt to be activated and deactivated independently p y of the manual valve ( (see page p g 35 5, , picture p V.1, , position p 2). ) The magnetic g belt can be reversed for a short period by operating the manual valve in the t opposite direction (spring offset). Short forwards and backwards movements can help release material blockages. The exchange of the hydraulic quick couplings on o the direction of the magnetic belt. the magentic belt engine enables the change of

VI. OPERATION

Side e 48

PROCEDURE FOR CRUSHER OPERATION: IMPORTANT FIRST CAREFULLY READ THR IMPORTANT: ROUGH THE SECTION "SPECIAL OPERATING INFORMATION".
1 3 4 5 6 17

Step 1: Start motor

See Caterpillar Manual. The starter key y is located in the switchboard ( (se ee p picture VI.2 item 14). ) In case of difficulties during the starting procedu ure, the button Starting Aid (item 7) must be pressed during starting.
7

13

11

8 7

9 8

10

Step p 2: Start hydraulic

Press the hydraulic button in the switchboard (s see picture VI VI.2 2 item 3) 3). The operating hydraulics are activated in the idle mode.
16 18 12 14 15 14

Step 3: St t hydrostat Start h d t t

1 into the Jaw crusher" Put the hydrostat switch (see picture VI.2 item 1) position. iti

Picture VI.2: switch board

Step 4: Start up p crusher

Increase the crusher speed with the rotary knob b (see picture VI.2. item 2) to appr. pp 50-100 rpm. p The current rotor speed p ca an be controlled at the display. p y

Step 5: Start conveyor belts

Switch on the conveyor belts at the hydraulic sw witchboard (see picture VI.3) by pressing the hydraulic valves.

Step 6: Increase motor speed

Increase the motor speed with the switch (see picture p VI.2 item 8). The crusher rotor goes to the pre-selected rotor r speed.

MOTOR SPEED DURING CRUSHING OPERA ATION MAX. 2000 RPM!

Picture VI.3: Hydraulic switchboard

VI. OPERATION

Side e 49

PROCEDURE FOR CRUSHER OPERATION (continued): (

Step 7: Adjust crusher speed

Set the required crusher speed, depending on the required crushing material, with the rotary knob (see picture VI.2. item 2).

Step 8: Start magnet

Close the ball valve on the crusher frame (closed=lever is vertical to the direction of flow, see picture VI.4).

Step 9: Start vibration feeder

Turn the switch Vibro chute (see page 49, pic cture VI.2, item 13) to radio or manual operation. Adjust the spe eed with the rate governor at the operator console (see page 49 49, picture V VI 1) VI.1).
Picture VI.4: Ball valve

Step 10: Feeding

When choosing radio operation, the ball valve e (see page 49, picture VI.1) has to be closed (closed=lever vertically to the e direction flow). The crusher Th h is i ready d for f operation. ti You can now start feeding the material.

The sequence described ensures that no material blockage forms in the system to interrupt the workflow. Proceed in the reverse order when stopping the e system.

VI. OPERATION

Side e 50

CONTENT:
I Preface I. P f II. Intended use III Safety Safety hazard symbols p g instructions Operating Maintenance work IV.Technical data Overview Building groups V. Start up V Operation devices Transport System set up Gap adjustment VI. Operation VI O ti Special operating information Procedure crusher operation VII. Maintenance Hydraulic system Di Diesel l motor t Vibration feeder Caterpillar crawler Crawler gear Conveyor belts V belts V-belts Jaw crusher Welding preparations Oil level monitor Service plan Recommended oil qualities VIII. Standard forms Rockster warranty registration CAT warranty registration Warranty claim Terms and conditions Sid 2 Side Side 4 Side 6 Side 7 Side 13 Side 24 Side 26 Side 27 Side 28 Side 33 Side 34 Side 40 Side 42 Side 45 Sid 46 Side Side 47 Side 49 Side 51 Side 52 Sid 53 Side Side 53 Side 54 Side 54 Side 55 Side 55 Side 56 Side 57 Side 60 Side 62 Side 64 Side 65 Side 66 Side 67 Side 68 Side 69

VII MAINTENA VII. ANCE

R800 JAW CRUSHER
VII. MAINTAINANCE
Side e 51

HYDRAULIC SYSTEM: Replacing the return flow filter and over rflow oil filter: First filter change 100 hours after first comm missioning, further filter changes every 1000 hours or according a to clogging indicator. Turn off diesel motor. Clean filter housing (outer). (outer) Remove filter cover. Pull out filter element (with disa assembly handles). Insert new filter element.
Picture VII VII.4: 4: Return filter

Picture VII.1: Main cocks

Replacing R l i the th filter filt of f the th hydrostat: h d t t First filter change 100 hours after first comm missioning, further filter changes every 1000 hours (see e picture VII.2). Changing the hydraulic oil: Change of hydraulic oil all 1000 hours or o annually. Bring hydraulic oil to operating temperature e. Turn off motor. Close main cocks (see picture VII.1). Open drain cock (see picture VII.3). Drain oil. Close drain cock. Open main cocks. Clean filling cap open. (see picture VII.2.1) Pour in new oil until upper edge of inspectio on glass. V t pump: open (2-3 Vent (2 3 t turns) ) ventilation til ti scr rew (see picture VII.5). As soon as oil leaks from the ventilation screw, close it again. Start system. Activate load ( (ventilation). ) Check oil level. (see picture VII.2.1) Shut down system. Fill up further with oil below level.

Picture VII.3: Drain cock

Picture VII.2: Hydrostat filter

ass

Picture VII.5: Ventilation Screw

Picture VII.2.1: filling gap and oil level indicator oil-level

VII. MAINTENANCE

Side e 52

Manometer 1 (picture VII.3: green arrow) : 60 bar, shows the charge pressure of the hydr rostatic pump During operation the manometer has to show between 28-34 bar. Manometer 2 (picture VII.3: red arrow) : h pump 600 bar, shows the operating pressure of the hydrostatic During operation the pressure in this manome eter ranges from 90 to 420 bar. Hydraulic oil cooler: In principle, the hydraulic oil cooler does not re equire maintenance. If required, blow out with compressed air from inside to outside e. Pay attention to a clean cooler mesh! Attention: Danger of overheating if cooler is contaminated! c Charge Air-, Watercooler: Water level = the distance from filler to water has h to be 8 cm (Page 61, Picture VII.21) For further maintenance instructions see Cate erpillar manual. Coolant temperature p resistance has to be -35 C After refilling coolant check temperature resist tance Attention: Danger of overheating when Coole er is polluted DIESEL MOTOR: see Caterpillar Manuels VIBRATION FEEDER: Checking the oil: Correct oil level = Lower edge oil-level plug (se ee picture VII.7.1). Open oil-level plug if no oil emerges, refill wi ith oil (around 3,5 l). Oil change: Open oil-level plug. Open oil drain plug. Drain oil. Cl Close d drain i plug. l Fill with new oil up to lower edge of oil-level plug. Close oil-level plug. Check fastening bolts of vibration gear for firm m mounting once a week.
Picture VII.6: Manometers

Picture VII.7.1: Oil level plugs

VII. MAINTENANCE

Side e 53

TRANSFER GEAR BOX: Open oil drain plug and bleeder screw. Drain oil. Close drain plug and bleeder screw. Fill with new oil (ca. 1 liter) - between mark (min n and max) at the dip stick (see picture VII.7). CATERPILLAR CRAWLER: The crawler gear chain and 3-rib base plates are e maintenance-free. Weekly inspection for potentially loose bolts. The track rollers are maintenance-free. A weekly visual inspection must be carried out fo or possible leakages in the area of f the th duocone d seals. l Th The d drive i wheel h l unit it i is ma aintenance-free. i t f It consists i t of f the drive wheel with the sliding elements, the cro oss member with mounted spring assembly and integrated grease tension cylinder.

Bild VII.7: Messstab

A weekly inspection must be carried out for poss sible leakages in the sliding elements of the drive wheel wheel. The grease tension cylinder h has the function of bringing the crawler gear chain into the operating position. Feeding is achieved by means of grease filling (via ( hand lever press). The chain is correctly tensioned if there is slack of approx. 25 mm on both sides of the chain support. pp It must be noted that only y the driv ve wheel feeding g or chain tensioning g is initiated with the grease tension cylinder; the spring travel of the spring assembly is not shortened. Picture VII.8: Chain tension The grease tension cylinder must be relieved by y carefully unscrewing the filling valve. The pressurised grease then escapes via a groo ove in the filling valve in order to loosen the chain. The main ring gear is maintenance-free. A regular visual inspection must be carried out out, as incorrect chain tensioning can lead to premature wear wear. Accumulating material can become trapped betw ween the track and carrying rollers as well as the lead and drive wheels. This mater rial then obstructs the crawler gear parts from working together effectively, whi ich can lead to increased wear and chain breakage. breakage For this reason reason, it must be ensured that all crawler gear components are regularly cleaned and that t foreign bodies and accumulated material are removed. Crawler gear unit Correct oil level with correct oil plug arrangemen nt (see side VII.10).

Pi t Picture VII.10: VII 10 Crawler C l gear unit it

VII. MAINTENANCE

Side e 54

CONVEYOR BELTS: Check the conveyor belts for cracks, cuts etc as a part of the daily visual inspection. Damage can be caused by foreign bodies (e.g. iron pieces) which become caught in the belt frame or between the track rollers. Crushing material may also have accumulated d in the frame edges edges, which can have a considerable adverse effect on the belt running. Freezing temperatures in particular can lead to o faults in and damage to the conveyor unit. All carrying rollers, track rollers, lower chord ro ollers and side guide rollers must run freely. The tail pulleys of the main conveyor must be checked c for free running. Accumulated materials can cause the conveyo or belt to stop and consequently lead to blockage in the crusher. This also applies for the driving drums of the main m and side conveyor belts. Check the belt scrapers for correct mounting. Replace worn belt scrapers. Ensure correct belt tensioning.

MAGNETIC BELT: The belt must m st be checked regularly reg larl to ascertain whether hether it is running r nning straight and and, if necessar necessary corrected corrected. The bearings must be lubricated accordingly. Dedusting belts must be checked for damage and, a if necessary, replaced.

V-BELTS: Check V-belts for correct tensioning (see picture VII.10). D = 0,016 . x D....[mm] x .... [m] F = FORCE = 50-65 N To tension the V V-belts, belts open the door for the m motor housing housing. The V-belts are tensioned by moving the hydra aulic motor backwards using slide rails Ensure correct belt tensioning!
Picture VII.10: V-belt tension

VII. MAINTENANCE

Side e 55

JAW CRUSHER: Moveable jaw: - Stop diesel motor, remove starter key and ba attery key. Ignition key and battery switch have to be pu ulled off, the machine has to be protected against start-up by external persons. - Open eccentric eccentric-bolts bolts (see picture VII.11.1) VII 11 1) - Open bolts on back side of fixing wedge. (se ee picture VII.12) - Remove fixing wedge. - Pull jaw out (see picture VII.11.3). - Clean the g guide liners and contact surfaces. - Visual inspection of side-wear-plates. - Replace jaw. - Put in fixing wedge and safe the wedge with hexagon-nuts. - Adjust and fix and the jaw-position with the eccentric-bolts. e - Check gap between jaw and side-wear-plate es es. - Tighten bolts of fixing wedges. Fixed jaw: - Stop diesel motor, remove starter key and ba attery key. Ignition key and battery switch have to be pu ulled off, off the machine has to be protected against start-up by exter rnal persons. - Dismount pre-screen and access cover of by ypass chute (see picture VII.11.2). - Open bolts on back side of fixing wedge. - Remove fixing wedge. - Pull jaw out (see picture VII.11.3). - Clean the guide liners and contact surfaces. - Visual inspection of side-wear-plates. - Replace jaw. - Put in fixing wedge. - Check gap between jaw and side liners. - Tighten bolts of fixing wedges. - Close cover of bypass chute. - Install pre-screen.

Picture VII.11.2: bypass chute plate

Picture VII.11.1: eccentric-bolts

Picture VII.11: fixing wedges

Picture VII.11.3: fixation point

Picture VII VII.12: 12: bolts - fixing wedges

VII. MAINTENANCE

Side e 56

Preparation before Welding

Step 1: (A till C)
(A) Take care that all electrical connection-points to the diesel-engine an nd control-unit are disconnected Turn off the circuit breaker Nr.19 and 24 till 29 Disconnect both connector of the PLC (position 23)

(B) (C)

A A

C
57

Side e 57

Preparation before Welding continuation Step 2: (D till E)

(D) (E) Take off the main-fuse (pos. 31 and 34) Turn off the main-battery-switch (pos. 32)

D D

E D
58

Side e 58

Preparation before Welding continuation Step 3: (F)

(F) Pull out the connector for the remote-control

Side e 59

59

LSTANDSKONTROLLE: Diesel Motor Hydrauliktank

Bild VII.16: Messstab Diesel Motor Bild VII.17: lstand Hydrauliktank

Vibrogetriebe

Laufwerksgetriebe

Bild VII.18: VII 18: lstand Vibrogetriebe

Bild VII.19: lstand Laufwerksgetriebe

VII. MAINTENANCE

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LSTANDSKONTROLLE: Verteilergetriebe

KHLWASSERSTANDKONTROLLE: Ausgleichsgef

Bild VII.20: lstand Verteilergetriebe

Bild VII.21: Khlwasser-Ausgleichsgef

VII. MAINTENANCE

Side e 61

1000h or annually ll

200 h

100 h

50 h

daily

SERVICE AND REPAIR PLAN: Jaw crusher: Check jaw wear status Check crusher gap Check wedge for firm mounting ed plating wear status Check crusher housing reinforce ed plating for firm mounting Check crusher housing reinforce p lifts with grease press per each greasing point and lubrication interval) Lubricate shaft bearing (10 pump Vibration feeder and gear, pre-screening: Check bolts and connections for firm mounting Check wear Oil change (first after 100h, then annually or after 1000h) Chutes and hoppers: Check material clearance Check wear Main discharge belt: e Check conveyor belt for damage Check conveyor route Lubricate bearings of the tail pull ley and the driving drum (1-2 pump lifts with grease press) Check setting and belt tension Check safety guard Side discharge belt: e Check conveyor belt for damage Check conveyor route Lubricate bearings of the tail pull ley and the driving drum (1 (1-2 2 pump lifts with grease press) Check setting and belt tension Check safety guard Magnetic separator: Check belt for damage Check conveyor route ley and the driving drum (1/2 or every 2nd day 1 pump lift with grease press) Lubricate bearings of the tail pull Check setting and belt tension Check safety guard

x x x x x x x x x x x x x x x x x x x x x x x x x x x

VII. MAINTENANCE

Side e 62

1000h or annually

200 h

100 h

50h

daily

SERVICE AND REPAIR PLAN P (continued): Caterpillar crawler gear: ng to instructions in Maintenance/Crawler track Chapter Visual inspection, accordin m sag) Check chain tension (25mm er 500h, then annually or after 1000h Gear oil change, first afte Structures and platforms s: orms for firm mounting Check structures and platfo Drive unit: ork, see Caterpillar 7.0 Manual! Maintenance and repair wo Check V-belt tension Check firm mounting of components C Clean/Replace / the air filter f r insert y cartridge Replace the air filter safety Combi-Cooler: Clean cooling element Check water level Ch k the Check th coolant/antifreez l t/ tif ze (see ( CAT M CAT-Manual) l) Oil-cooler: Clean cooling element Hydrostat: 0 h, then every 1000 hours or annually (concerining filter display) Replace filter first after 100 L bi t h Lubricate hydrostat d t tb bearing i gs (3 pump lift lifts with ith grease press per lubrication l b i ti interval) i t l) Hydraulics: r first after 100 h, then every 1000 hours or annually Change of return flow filter er first after 100 h, then every 1000 hours or annually Change of overflow oil filte Funnel-air-filter Check system for leakages s Pump transfer gear: Check oil-level Oil change first after 100 h, then annually or after 1000h V-belt drive: Check V-belt and V-belt tension m mounting (one-time after 100h) Check V-belt pulley for firm Complete electrical syste em: ng plugs for firm mounting 8one-time after 100h) Check cable and connectin m mounting Check components for firm Check emergency OFF sw witch for correct functioning

x x x x

x x x x x x

x x x x x x x x x x x x x x x x x x

VII. MAINTENANCE

Side e 63

RECOMMENDED OIL QUALITIES:

Gear oil
Blasia 220 Degol BG 220 Energol GR-XP 220 Alphamax 220 Engranajes HP 220 Falcon CLP 220 Epona Z 220 Spartan EP 220 Renep Compound 106 Gearmaster CLP 220 Kluberoil GEM 1 1-220 220 Mobilgear XMP 220 Ripress EP 220 Gear HST 220 Optigear BM 220 Rembrandt EP 2 S Super Tauro T 220 Omala 220 Meropa 220 Carter EP 220 1100-220

Hydraulic oil
Energol HLP 46 Tellus HLP 46 Renolin B15 VG 46 OSO 46

Grease
Ara alup HLP 2 BP Energrease LS-EP2 Bea acon EP2 Centoplex 2 Mo obilux EP2 She ell Alvania EP Fet tt 2 Trib bol 3030

Motor oil
Vanellus-Multigrad 15 W 40 Vanellus C3 Rimula Super 15 W 40 Titan Universal HD 15 W 40 Blitum T 15 W 40 ECL Cat-anti-freeze

Antifreeze
Use only antifreeze who is suitable for all kind of metal (aluminium, steel) and complying with the standard ASTM D4985 or ASTM D6210. D6210

protection
Rowe Hightec Antifreeze Arteco Havoline AFC Arteco Havoline XLC

VII. MAINTAINANCE

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CONTENT: INHALTSVERZEICHNIS:
I Preface I. P f II. Intended use

Sid 2 Side Side 4

I. Vorwort III Safety

Safety hazard symbols

Seite 2 Side 6
Side 7

II. Verwendungszweck p g instructions Operating III. Sicherheit IV.Technical data Sicherheits/Gefahrensymbole Overview Betriebsanleitung Building groups Wartungsarbeiten
V Start up V. Operation devices IV. Technische Daten Transport berblick Baugruppen System set up Gap adjustment Maintenance work

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

Side 33 Side 34 Seite 26 Side 40 Seite 27 Seite 28 Side 42 Side 45 Side 24

V. Inbetriebnahme VI Operation VI. O ti Bedienelemente Special operating information Transport Procedure crusher operation Aufstellen der Anlage VII. Maintenance Spaltverstellung
Hydraulic system

Seite 34 Sid 46 Side Seite 35 Side 47 Seite 41 Side 49 Seite 43 Side 51 Seite 46
Side 52

VI. VI B lt motor i b Seite S it 53 48 Di Betrieb Diesel t Sid Side Besondere Betriebshinweise Seite 49 Vibration feeder Side 53 Vorgangsweise Brecherbetrieb Seite 51 Caterpillar crawler Side 54
Crawler gear Side 54

VIII.STANDARD FO ORMS
R800 JAW CRUSHER
VIII. STANDARD FORMS
Side e 65

VII. Wartung Conveyor belts Hydraulikanlage V belts V-belts Diesel Motor Jaw crusher Vibrationsrinne Welding preparations Laufwerk Oil level monitor Laufwerksgetriebe Service plan Frdergurte Recommended oil qualities Keilriemen VIII. Standard forms Prallbrecher Rockster warranty registration lstandskontrolle CAT warranty registration Wartungsplan Warranty claim Schmiermittelbersicht
Terms and conditions

Seite 53 Side 55 Seite 54 Side 55 Seite 56 Side 56 Seite 55 Side 57 Seite 56 Side 60 Seite 56 Side 62 Seite 58 Side 64 Seite 59 Side 65 Seite 59 Side 66 Seite 60 Side 67 Seite 62 Side 68 Seite 64
Side 69

Side e 66

VII. WARTUNG

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VII. WARTUNG

Side e 68

Side e 69

Side e 70