ALLU D Series User manual

ALLU Finland Oy
Jokimäentie 1, 16320 Pennala, Finland
Tel:[phone], Fax:[phone], E-mail:[email protected]
ALLU Screener Crusher
INSTRUCTION MANUAL
D SERIES
Type
Serial number
www.allu.net
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ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6-M-DENG0615 1
Table of contents
1General information.......................................................................................................4
1.1The purpose of the instructions..............................................................................4
1.2Identification..........................................................................................................5
1.3Manufacturer..........................................................................................................5
1.4CE marking and conformity declaration................................................................5
1.5The content of the EC-conformity declaration ......................................................6
1.6The scope of the manual ........................................................................................6
1.6.1The screener crusher models covered by this manual .......................................7
1.7Copying..................................................................................................................7
2Safety and the environment ...........................................................................................8
2.1Safety notations......................................................................................................8
2.1.1Explanations for symbols...................................................................................9
2.1.2Safety markings on the Screener crusher.........................................................10
2.2Danger zones and exposure to dangers during work ...........................................11
2.2.1Danger zone I (5 m) .........................................................................................11
2.2.2Danger zone II (20 m)......................................................................................12
2.3Exposure to dangers in connection with transport and maintenance...................13
2.3.1The Screener crusher tipping over or falling ...................................................13
2.3.2High-pressure spray .........................................................................................13
2.3.3Unintentional start-up ......................................................................................14
2.3.4Environmental damage ....................................................................................14
2.4User responsibilities and general safety instructions...........................................15
2.5Intended use and operating environment .............................................................16
2.5.1Intended use .....................................................................................................16
2.5.2Operation range................................................................................................16
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ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6-M-DENG0615 2
2.5.3Unanticipated and incorrect use.......................................................................17
2.5.4Repairs and changes.........................................................................................17
3Entry into service and use............................................................................................18
3.1Transport, lifting, and storage..............................................................................18
3.1.1Transport..........................................................................................................18
3.1.2Lifting and transfer ..........................................................................................18
3.1.3Long-term storage............................................................................................20
3.2Attachment to the base machine ..........................................................................20
3.2.1Mechanical attachment and adapters ...............................................................20
3.2.2Diagrams of adapters .......................................................................................23
3.2.3Attachment to the base machine ......................................................................24
3.2.4Connection of the hydraulic system and requirements for the system ............24
3.3New users and procedures before use..................................................................30
3.3.1Inspection upon receipt....................................................................................30
3.4Use and operation ................................................................................................31
3.4.1The principle of operation of the Screener crusher..........................................31
3.4.2The first start-up and commissioning ..............................................................31
3.4.3Correct use .......................................................................................................32
3.4.4Forbidden work methods: ................................................................................34
4Maintenance.................................................................................................................36
4.1Maintenance work in connection with use ..........................................................37
4.1.1Daily inspection (8 hrs)....................................................................................38
4.1.2Weekly inspection (40 hrs) ..............................................................................38
4.2Extensive maintenance ........................................................................................40
4.3Replacement of wear parts...................................................................................42
4.3.1Replacement of blades (DN, DS, and DH models with XHD drums).............42
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ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6-M-DENG0615 3
4.3.2Replacement of counter blades (DN, DS, and DH models with XHD and X
drums) ………………………………………………………………………………..44
4.3.3Replacement of fine screening blades (DNS, DSB, and DHB models) ..........46
4.3.4Replacement of wear parts in TS models and changing of the end-product
size……………………………………………………………………………………49
4.3.5Replacement of TS blades ...............................................................................52
4.3.6Replacement of the bearing-protection fender.................................................60
4.3.7Replacement of drums .....................................................................................62
4.3.8Removal and installation of bearings and chain wheels ..................................68
4.3.9Maintenance of the bearing unit ......................................................................71
4.4Troubleshooting ...................................................................................................75
4.5Disposal ...............................................................................................................78
5Technical description...................................................................................................79
5.1Mounting dimensions ..........................................................................................79
5.2Technical specifications.......................................................................................81
5.3Hydraulic schematics...........................................................................................84
5.3.1Connecting the Screener crusher with the base machine’s hydraulic system..84
5.3.2Single-motor buckets .......................................................................................85
5.3.3Two-motor buckets ..........................................................................................86
5.4Noise level ...........................................................................................................88
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ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6-M-DENG0615 4
1GENERAL INFORMATION
Important information is found in this manual, labels affixed to the product, transport
guidelines, and other country- or project-site-specific guidelines for the safe use of the
product. The manuals constitute an integral and important part of the product and must
always be made available to the user. This manual must always be stored in the cabin of the
base machine in a location where it is readily accessible when necessary. Ensure that the
manual remains clean and intact. When it is necessary, ask for assistance in interpreting the
instructions.
1.1 The purpose of the instructions
The instructions are intended to promote safety and the appropriate, correct, and cost-
efficient use of the machine. This manual will help the user to identify, avoid, and prevent
dangerous situations and their consequences.
Operations must comply with these instructions; obey all locally applicable laws, decrees,
and regulations; and employ all locally dictated protective measures (such as practices for
safe work methods).
Read this manual carefully, and follow the instructions meticulously. If something seems
unclear, ask your employer or your nearest ALLU representative for clarification. Each part
of this manual contains information that is important for your safety.
These instructions are also used in user training. Compliance with these instructions helps
to keep maintenance costs and downtime to a minimum and the machine’s reliability and
durability optimal.
WARNING
COMPLIANCE WITH INSTRUCTIONS
Read the manual before use or maintenance work, and
always comply with the instructions provided. Incorrect
handling of the machine creates a risk of death or serious
injury.
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ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6-M-DENG0615 5
1.2 Identification
The Screener crusher’s model and serial number can be found on the machine plate. Check
that the model matches the model list in this manual. It is important to indicate the serial
number in any discussion about the machine – for example, when ordering spare parts.
1.3 Manufacturer
This Screener crusher was manufactured by:
ALLU Finland Oy
Jokimäentie 1
16320 Pennala
FINLAND
Telephone:[phone]
[phone]
Web: www.allu.net
E-mail: [email protected]
1.4 CE marking and conformity declaration
The CE marking can be found on the machine plate. As it leaves the factory, this Screener
crusher meets all the health and safety requirements set forth in the Machinery Directive.
Store the EC-conformity declaration appropriately, and ensure that it is also passed on to any
new owner of the machine.
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ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6-M-DENG0615 6
1.5 The content of the EC-conformity declaration
EC-conformity declaration
(2006/42/EC, Appendix II A, Directive 2000/14/EC)
The manufacturer: ALLU Finland Oy
Of the address: Jokimäentie 1, 16320 Pennala, FINLAND
Declares that Screener crusher model AAA, serial number ZZZ
conforms with the terms of the Machinery Directive (2006/42/EC)
and conforms with the terms of the Noise Emission Directive (2000/14/EC).
This conformity declaration is valid if the machine has not undergone any changes not
approved by the manufacturer in writing.
N.N., authorised to compile the technical specifications for this machine
N.N.,authorised to prepare this conformity declaration
Date: dd.mm.yy
Place: Jokimäentie 1, 16320 Pennala, FINLAND
1.6 The scope of the manual
This manual contains instructions for safety and on the use, transport, lubrication, and
maintenance of this machine in the state it was in when released from the factory.
This manual and the safety instructions, in particular, along with the EC-conformity
declaration, are valid only if changes not approved by the manufacturer have not been made
to the machine.
A different machine model may have been used for some of the manual’s illustrations, or
some covers or similar parts may have been removed to allow for clearer depiction of the
situation.
Because the product undergoes continuous improvement and development work, some
changes might have been made to it that are not reflected in this manual.
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ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6-M-DENG0615 7
If you have any questions on the product or this manual, please contact your local ALLU
representative.
1.6.1 The screener crusher models covered by this manual
DN 2-09 DNS 2-09 DS 3-12 DSB 2-12 DH 3-12 DHB 2-12
DN 2-12 DNS 2-12 DS 3-17 DSB 2-17 DH 3-17 DHB 2-17
DN 2-17 DNS 2-17 DS 3-23 DSB 2-23 DH 3-23 DHB 2-23
DN 3-09 DNS 3-09 DS 4-12 DSB 3-12 DH 4-12 DHB 3-12
DN 3-12 DNS 3-12 DS 4-17 DSB 3-17 DH 4-17 DHB 3-17
DN 3-17 DNS 3-17 DS 4-23 DSB 3-23 DH 4-23 DHB 3-23
DN 3-12 TS DSH 3-23 TS DH 4-27
DN 3-17 TS DSH 4-23 TS DH 3-12 TS
DH 3-17 TS
DH 4-17 TS
1.7 Copying
The copyrights for this manual belong to ALLU Finland Oy, Jokimäentie 1, 16320 Pennala,
FINLAND.
It is forbidden to copy or reproduce the manual or parts of it or to otherwise redistribute the
manual to third parties without the manufacturer’s written permission.
All rights are reserved.
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ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6-M-DENG0615 8
2SAFETY AND THE ENVIRONMENT
2.1 Safety notations
The following safety notations are used in this manual:
DANGER
The danger sign refers to an imminent dangerous situation that
causes a risk of death or serious injury unless steps are taken to
avert it.
WARNING
The warning sign refers to a potentially dangerous situation that
causes a risk of death or serious injury unless steps are taken to
avert it.
CAUTION
The caution sign refers to a potentially dangerous situation that
causes a risk of slight or moderate injury or damage unless steps
are taken to avert it.
NOTE
A note contains instructions or describes pertinent regulations.
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ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6-M-DENG0615 9
2.1.1 Explanations for symbols
Warning signs:
General
danger
Danger
from
flying
objects
Danger
related to
working
load
Danger of
crushing
Danger of
ignition
Danger
related to
high-
pressure
oil spray
Danger
related to
crushing
of the
hands or
other body
parts
DO NOT signs:
Do not remain in the danger
zone
Do not put a hand or fingers
between moving parts
DO signs:
Read and observe
the instructions
for use
Maintain a safe
distance
Use safety
goggles
Use a respirator
Wear a safety
helmet
Use hearing
protection
Wear protective
clothing
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ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6-M-DENG0615 10
2.1.2 Safety markings on the Screener crusher
The following warning markings must be displayed on the ALLU screener crusher. Any
damaged or loose warning labels must be replaced.
DANGE
R
RISK OF BEING CRUSHED OR
THROWN
Anyone under five metres from
the machine is at risk of being
crushed or thrown by a moving or
falling machine or by material
falling from the Screener crusher!
W
ARNING
COMPLIANCE WITH
INSTRUCTIONS
Read the manual before use or
maintenance work, and always
comply with the regulations and
instructions indicated.
W
ARNING
FLYING OBJECTS
Anyone less than 20 metres from
the Screener crusher is at risk
from flying objects, noise, and
dust.
W
ARNING
RISK OF HANDS GETTING
CAUGHT BETWEEN MOVING
PARTS
Do not put hands or fingers
between moving parts!
W
ARNING
HIGH-PRESSURE SPRAY
Turn off the base machine and
depressurise the hydraulic
system before connecting or
servicing the system.
W
ARNING
USE PERSONAL
PROTECTIVE
EQUIPMENT
Exposure to noise, dust, or
flying objects may cause a
risk of death or serious
injury.
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ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6-M-DENG0615 11
2.2 Danger zones and exposure to dangers during work
2.2.1 Danger zone I (5 m)
Danger zone I covers an area five metres in every
direction from the Screener crusher and the base
machine. No-one is allowed in danger zone I while the
Screener crusher is in operation. Anyone within five
metres of the machine is at risk from dangers related to
material falling from the machine, high-pressure oil
spray, and machines moving or falling over. The user
must observe the surroundings continuously and stop
working immediately if another person enters the area
within five metres from the Screener crusher or base
machine.
A protective structure must be installed for open-top base machines to protect the user
from falling and flying objects.
DANGER
Stop working immediately if you observe another person
in danger zone I.
Material falling from the Screener crusher or a work
machine falling creates a risk of death or serious injury
within this zone. Under no circumstances go under the
Screener crusher!
WARNING
Exposure to high-pressure oil spray within danger zone I
causes a risk of death or serious injury.
5 m
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ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6-M-DENG0615 12
2.2.2 Danger zone II (20 m)
Danger zone II covers an area 20 metres in
every direction from the Screener crusher.
No-one is allowed in danger zone while the
Screener crusher is in operation. Anyone
within 20 metres of the Screener crusher is
at risk from dangers related to material
thrown by the machine, noise, and dust.
The user must observe the surroundings
continuously and stop working
immediately if another person enters the
area within 20 metres of the Screener
crusher.
If, under exceptional circumstances, another person has to enter the danger zones, the
user must be made aware of this, so that he or she can take extra care when operating
the Screener crusher.
WARNING
Stop working immediately if you observe another person
in danger zone II
Exposure to material thrown by the Screener crusher in
danger zone II causes a risk of death or serious injury.
20m
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2.3 Exposure to dangers in connection with transport and
maintenance
2.3.1 The Screener crusher tipping over or falling
2.3.2 High-pressure spray
Seek medical assistance immediately if any hydraulic oil enters your eyes or high-pressure
spray penetrates your skin.
DANGER
Comply with the instructions for lifting and transport, and
use suitable and approved equipment when lifting the
Screener crusher. No-one is allowed closer than five
metres from a Screener crusher that is being lifted or
transferred.
A Screener crusher falling or toppling over causes a risk of
death or serious injury!
WARNING
Before any maintenance work performed in connection
with use (see Section 4) and before connecting or
disconnecting the hydraulic system (see Section 3), turn
off the base machine and depressurise the hydraulic system
by moving the control lever of the auxiliary hydraulic
system with only the starter motor turned on.
Exposure to high-pressure oil spray causes a risk of death
or serious injury.
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ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6-M-DENG0615 14
2.3.3 Unintentional start-up
2.3.4 Environmental damage
Minimise the environmental damage by using solid material such as sand or peat to absorb
the leaking lubricant. Dispose of the contaminated sand or other material in an appropriate
manner.
WARNING
Detach the Screener crusher from the base machine and
disconnect the hydraulic system before changing any wear
parts or performing extensive maintenance work (see
Section 4), to prevent unintentional start-up. Under no
circumstances place your hands between rotating parts
while the Screen crusher is attached to the base machine.
Falling under a moving Screener crusher or getting caught
between rotating parts causes a risk of death or serious
injury!
CAUTION
Stop working immediately if you observe leakage of oil or
another lubricant. Turn off the base machine and
depressurise the hydraulic system by moving the control
lever of the auxiliary hydraulic system with only the starter
motor turned on.
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ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6-M-DENG0615 15
2.4 User responsibilities and general safety instructions
The user must find out in advance any country- or project-site-specific safety regulations on
the use of protective personal equipment, safety of the machines, and work methods when
one is using a Screener crusher and must comply with said regulations. This owner’s manual
must be kept in the cabin of the base machine, so that the instructions are readily available.
The following are general regulations, prohibitions, and instructions to which the user must
adhere:
The Screener crusher must never be used by someone under the influence of alcohol
or illegal substances.
The Screener crusher must never be used for lifting or transporting people.
The Screener crusher must never be serviced, inspected, repaired, or checked while
the engine of the base machine is running.
The Screener crusher is to be operated only from the cabin of the base machine.
WARNING
The Screener crusher is to be installed, used, and serviced
by only a person who has read and understood this manual
and has the knowledge, skills, and experience required for
safe and appropriate work methods. Always adhere to all
general and specific safety regulations and take the
measures applicable.
Incorrect installation, inappropriate use, or incorrectly
performed maintenance of the machine creates a risk of
death or serious injury!
WARNING
Use the protective personal equipment required
by the working conditions and project-site
specific regulations.
Being exposed to noise, dust, or flying objects
causes a risk of death or serious injury.
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The user must learn about the features of the base machine, including
depressurisation of the hydraulic system.
The user must always use the personal protective equipment required by the
operating environment, conditions, and regulations.
The user must always stop working when another person enters the danger zones.
The user must inform other persons on the project site when, for instance, the
Screener crusher is being moved to a different location or is being transferred, to
prevent people from unintentionally entering the danger zones.
2.5 Intended use and operating environment
2.5.1 Intended use
The Screener crusher is a hydraulic attachment to be used with hydraulic excavators, wheel
loaders, and similar base machines for the screening, crushing, pulverising, mixing, and
feeding of a variety of materials.
The Screener crusher is not designed for digging of soil, crushing of hard stones, or
transferring of large and heavy objects.
2.5.2 Operation range
The Screener crusher is to be operated only outdoors and in indoor spaces suitable
for work with such machines.
The Screener crusher’s intended operating temperature range is -25 °C to 60 °C.
DANGER
Do not use the Screener crusher in an environment with an ignition or
combustion risk!
A fire or explosion resulting from a spark causes a risk of death or serious
injury!
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ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6-M-DENG0615 17
Use of the Screener crusher underwater is forbidden without project-site specific
risk assessment and safety measures, because of the risk of an oil leak.
In work with hazardous or toxic materials, the appropriate safety measures and
personal protective equipment must be in use.
2.5.3 Unanticipated and incorrect use
The Screener crusher is intended for the processing of various materials, as described in this
manual. ‘Unanticipated and incorrect use’ refers to all use that is not in line with this manual.
Unanticipated or incorrect use may create a risk of casualties or damage to the
Screener crusher, the base machine, or the environment.
2.5.4 Repairs and changes
ALLU Screener crushers are to be repaired and equipped with only genuine ALLU spare
parts and accessories. It is forbidden to make any changes to the Screener crusher without
written permission from the manufacturer.
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3ENTRY INTO SERVICE AND USE
3.1 Transport, lifting, and storage
3.1.1 Transport
When transporting a Screener crusher,
secure it separately to the transport
equipment, with its bottom facing
downward.
3.1.2 Lifting and transfer
For lifting and transfer, connect hoist belts
or chains to the hoist rings fixed to the
threaded holes further back in the adapter.
If an adapter has been installed for the
Screener crusher, secure the hoist belts or
chains around parts from which they
cannot come loose.
The weight of the Screener crusher
(without accessories and an adapter) is
stated on the machine plate and in the table
of technical data in this manual.
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When using a forklift, always lift the
Screener crusher from the side of the
drums.
Never lift the Screener crusher from the
side of the lip shroud. Hoisting the
Screener crusher from the lip shroud side
may cause it to topple over, because its
centre of gravity is high and toward the
back.
Never disconnect the Screener crusher
from the base machine or a hoisting device
on a sloping or soft surface, to prevent it
from falling over. Note the risk of falling
when loosening the straps used to secure
the Screener crusher for transport.
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