Extec C-12 CRUSHER User manual

Rev4.Iss1 C-12 CRUSHER
OPERATORS MANUAL
(Machine with Transport Bogie & Folding Hopper)
EXTEC SCREENS & CRUSHERS LTD
HEARTHCOTE ROAD,
SWADLINCOTE, DERBYSHIRE.
DE11 9DU. ENGLAND.
Tel:- [phone]
Fax:- [phone]
0

C-12 CRUSHER
This is to certify that the machine indicated below conforms to all as parts to:
Nous certfions que la machine definie ci-dessous est conforme dans sa totalite:
Hiermit wird erklärt, daß untengenannte Maschine in allen Einzelheiten übereinstimmt:
Si dichiara che la macchina sottoindicata e conforme in tutte le sue parti:
Este documento certifica que la máquina indicada más abajo se ajusta a
The directives issued by the council of European Communities. The machine conforms with all essential
health and safety requirements. As laid out in the supply of machinery (safety) Regulations 1992, also the
provision and the use of work equipment 1992.
All guarding on machine is in accordance with BS7300 1990.
- Aux Directives du Conseil des Communatee Europeennes:
- Nach den Richlinien des Europäischen Gemeinschaftsrates:
- Alle Direttive de Consigliodelle Comunita Europee:
- Las directivas emitidas por el Consejo de Comunidades Europeas:
89/392. CEE (91/368/CEE-93/44/CEE-93/68/CEE)
89/622. CEE (98/37/EC.CEE) (92/58/EEC)
E.M.C. 89/336/EEC(91/263/EEC 92/31/EEC.)
-European harmonised standards
- Aux Normes Europeennes Harmonisees
- Und den in Einklang stehenden Europäischen Normen
- Alle Norme europee armonizzate
- Estándares armonizados europeos
EN 292-2
EN 474-1 (EN 474-5)
Manufacturer EXTEC SCREENS & CRUSHERS TYPE C-12 CRUSHER
Constructeur Hearthcote Road, Swadlincote Modele
Hersteller Derbyshire, England Modell
Costruttore DE11 9DU Tipo
Fabricante Tipo
Serial No:- __________
Numero de chassis
Fahrzeug-Ident-Nr
Matricola
Número de serie
Category MOBILE CRUSHING PLANT ENGINE DEUTZ
Categorie Moteur
Erzeugnis Moto
Categoria Motore
Categoría Motor
PRODUCTION MANAGER: ____________________
DATE: ___________________
DECLARATION OF CONFORMITY
DECLARATION DE CONFORMITE
ÜBEREINSTIMMUNGSERKLÄRUNG
DICHIARAZIONE DI CONFORMITA
DECLARACIÓN DE CONFORMIDAD
1

C-12 CRUSHER
INTRODUCTION
Congratulations on the purchase of your Extec C-12 Crusher. This machine has
been designed and constructed using first class materials and it will reach you in
optimum condition.
Operation of the plant contrary to the instructions contained in this manual, or
modifications to the machine without the agreement of the manufacturer, will
invalidate any undertakings given by the manufacturer attaching to the machine.
The manufacturer will in no way accept any liability should the machine be
misused, abused or operated outside the working parameters specified by the
manufacturers.
Every effort has been taken to ensure the accuracy of this manual, nevertheless,
as operating conditions vary considerably, all performance data contained herein is
indicative only for plant operated in accordance with the conditions set out in this
manual.
It is ESSENTIAL that the operator reads and observes the safety instructions in
this manual. Failure to do so will invalidate any liability the manufacturer may
have.
This manual should be kept at a specific location near the machines site of
operation and be available at all times.
I acknowledge receipt of this operation/safety manual, and fully understand its
content and implications.
Signed ....................
Signed ................... (Extec representative)
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C-12 CRUSHER
OPERATORS MANUAL - CONTENTS
SAFETY INSTRUCTIONS Page:- 4
TRANSPORTATION DIMENSIONS Page:- 5
NOISE EMISSIONS Page:- 6
PRESTART INSTRUCTIONS Page:- 7
STARTING THE MACHINE Page:- 8
STOPPING THE MACHINE Page:- 9
REMOVING TRACTOR UNIT & BOGIE Page- 10 - 12
TRACKING/MOVING MACHINE Page:- 13 & 14
SETTING UP MACHINE Page:- 15 - 18
ADJUSTING OUTPUT SIZE Page:- 19 - 21
OPERATING MACHINE - (CRUSHING) Page:- 22 & 23
FEEDING MATERIAL INTO MACHINE Page:- 22
ADJUSTING FEEDER SPEED Page:- 23
REVERSE JAW OPERATION Page:- 24
JAW BRAKE PRESSURE ADJUSTMENT Page:- 25
MAINTENANCE Page:- 26 - 36
MAINTENANCE - (DAILY) Page:- 26 & 27
MAINTENANCE - (WEEKLY) Page:- 28 - 34
MAINTENANCE - (EVERY 250hrs) Page:- 35
MAINTENANCE - (EVERY 1000hrs) Page:- 36
COLLAPSIBLE TOGGLE Page:- 37 & 38
TROUBLE SHOOTING GUIDE Page:- 39 - 41
3

C-12 CRUSHER
SAFETY INSTRUCTIONS
For safe operation of this machine, the following instructions MUST
be followed at ALL times:-
i) Machine must ONLY be operated by trained personnel.
ii) Different countries and states often have specific legislation relating to the operation of
different types of machinery and their effects on safety and the environment. Therefore, it is
the users responsibility to find out those that apply to their particular circumstances and ensure
that they are complied with.
iii) Always pay attention and concentrate on the job at hand.
iv) Read and follow warnings and labels.
v) Read and understand this manual and all machine aspects.
vi) Familiarise yourself with the surrounding work area.
vii) ONLY operate this machine if guards and safety devices are in position and operative.
viii) ALL personnel in the vicinity of the machine MUST wear suitable safety equipment,
i.e Safety boots, ear protection, eye protection, protective clothing, hard hat, etc.
NEVER:-
i) Run machine without guards in place.
ii) Make adjustments or clean moving parts whilst machine is running.
iii) Reach into the machine to clean, lubricate or adjust without first shutting off power to engine &
removing ignition key.
iv) Operate the machine while under the influence of drink or drugs. (NOTE:- medicines
prescribed by your medical advisor may make you unfit to operate machinery. Always check
before attempting to operate machinery)
v) Allow grease or oil to remain on platforms or the area surrounding the machine.
vi) Wear clothing or jewellery that could become entangled in the moving parts of the machine.
vii) Try to clear any blockage whilst any part of the machine is running.
viii) Permit any flame, cigarette, spark or other heat source near fuel tank.
ix) Fill fuel tank while machine is running.
x) Operate this machine on 'sloping' ground.
xi) Operate machine while it is lifted off ground by jacking legs.
xii) Climb onto crusher or touch any moving part when the machine is running
xiii) Attempt to lift crusher using lifting points on jawstock.
NOTE:- The above list is not exhaustive, if you are unsure whether anything is unsafe,
stop the machine IMMEDIATELY and contact your supervisor.
4

C-12 CRUSHER
13966 [45'-101
4"]
3385 [11'-11
4"]
2495 [8'-21
4"] 4625 [15'-21
4"] 4475 [14'-81
4"]
MACHINE TRANSPORTATION DIMENSIONS
TRANSPORTATION
WIDTH = 2743 (9')
*
*
* ENSURE HOPPER DOORS, INLET CHUTE COVER,
EXHAUST STACK & SPRAY BAR ARE FOLDED DOWN
FOR TRANSPORTATION*
BEFORE TRANSPORTING THIS MACHINERY ALL MEASUREMENTS OF THE MACHINE SHOULD BE CHECKED TO ENSURE THEY ARE WITHIN THE LEGAL TRANSPORT DIMENSIONS.
*
*
5

C-12 CRUSHER
NOISE EMISSIONS
To comply with the supply of machine (safety) regulations 1992, amended 1994, EXTEC
provides the following information.
The diagram below shows decibel readings taken by Castle GA 101/701 meter - calibrated on
the 13.9.94 with all systems running, sited on factory assembly line.
As stated in the Safety Instructions section of this manual, ear protection is compulsory within 10
meters of the machine when the engine and other moving parts of the machine are in operation.
7m - 77 dB
10m - 77 dB
7m - 85 dB
7m - 81 dB
7m - 77 dB
10m - 77 dB
7m - 81 dB 7m - 85 dB
6

C-12 CRUSHER
PRESTART INSTRUCTIONS
BEFORE starting this machine it is IMPERATIVE that the instructions below are followed:-
i) Ensure that this manual is read & understood by the operator. DO NOT attempt to start the machine until
you are aware of ALL aspects of its operation. Any questions should be referred to your supervisor.
ii) Remove any temporary sealing.
iii) Check that the machine is in good mechanical condition and that there is no component damage or loss.
Ensure all bolts and fixings are tight and that all guards are in place with all safety devices operating
correctly. NEVER start machine without guards and safety devices operating correctly.
iv) Ensure that crusher chamber, feeder and conveyor belts are free of material.
v) Remove all tools and equipment from the operational area. Make sure that ALL personnel are well clear of
the machine, its drives, tracks and auxiliary equipment.
vi) Ensure that the checks and prestart procedures outlined in the engine manufacturers instruction manual are
complied with.
vii) Check oil levels in engine and vibrating feeder.
viii) Check that all drums and rollers turn freely. This should be done by hand. (NEVER attempt to touch drums
or rollers whilst machine is running.)
ix) Make sure that skirting rubbers and scrapers are in good condition and working properly.
x) Refit exhaust stack in vertical position.
xi) Close inlet chute top cover.
xii) Raise oil cooler to working position. (If Fitted)
xi) Rotate cover into position & attach
chains.
chain
clamp
xii) IF FITTED - Machine is transported with oil cooler in the down position. Release
transportation bolt & rotate oil cooler into position. Remove transport bracket then
attach cover plate to deck & retain oil cooler with stay bar.
bolt
Cover
Stay Bar
x) Machine is transported with exhaust stack in a lowered position. Release exhaust
clamp & rotate stack to a vertical position. Re-tighten clamp. xi) Machine is transported with inlet
chute cover in the open position.
7

C-12 CRUSHER
STARTING SEQUENCE
COLD START:- When starting the machine in temperatures of 0°C or below, run all systems at engine
speed No.1 for 15 minutes to allow hydraulic oil to reach working temperature. DO NOT feed material into
machine during this time. When this is done stop all systems, turn engine speed switch to No.2 & restart all
systems. DO NOT turn engine speed switch from position 1 to 2 while any systems are running. See page 22
for proper sequence to start systems running - DO NOT operate systems contrary to these instructions.
NOTE:- The machine MUST be level in both longitudinal and traverse planes and set up on firm level
ground before being operated. Failure to comply with this or any other instructions in this manual may cause
damage to the machine and may invalidate any warranty.
i) Set speed control to No.1 position
ii) Turn key clockwise to 'on' position. All lights will flash for
several seconds.
iii) Turn key to 'start' position and hold until engine starts.
iv) Release key. (Key will return to 'on' position)
v) Engine is now running at idling speed.
2:- Speed control
1:- OPEN ELECTRICAL CONTROL BOX 1Emergency Stop
2Ignition Key (ON/OFF)
3Warning Lights
4Engine Speed Control
5Engine R.P.M Meter
6Interlock (ON/OFF)
7Main Conveyor (ON/OFF)
8Side Conveyor (ON/OFF)
9Magnet (ON/OFF)
10 Crusher (ON/OFF)
11 Feeder (ON/OFF)
12 Crusher Reverse (ON/OFF)
13 Tracks (ON/OFF)
14 Main Conveyor (UP/DOWN)
14
13
7
8
9
10
11
4
12
16
2
35
Ignition Key
8

C-12 CRUSHER
STOPPING THE MACHINE
To stop the machine, it is ESSENTIAL that the following steps be followed - in order to prevent
damage to the machine:-
i) Stop feeding material into hopper.
ii) Wait for all material to fully discharge from feeder, crusher chamber and conveyor belts.
iii) Shut down systems in following order using "stop" buttons in electrical control box:-
a) Feeder
b) Crusher
c) Main conveyor
d) Magnet
e) Side conveyor
iv) Wait for each system to come to a complete stop.
v) Turn engine speed switch to position No.1 and allow engine to idle briefly.
vi) Stop engine by turning ignition key to 'off' position
STOPPING MACHINE IN AN EMERGENCY
THE MACHINE CAN BE STOPPED IN AN EMERGENCY BY PRESSING THE EMERGENCY
STOP BUTTONS LOCATED ON THE ELECTRICAL CONTROL PANEL AND ALONG EACH
SIDE OF THE MACHINE OR BY TURNING THE IGNITION KEY DIRECTLY TO 'OFF'
POSITION.
ENSURE THAT ALL PERSONNEL IN THE VICINITY OF THE MACHINE ARE FULLY AWARE OF
THE LOCATIONS OF THE EMERGENCY STOPS.
1:- Emergency stop & ignition
switch in control box. 2:- Emergency stop on L/H walkway ladder. 3:- Emergency stop on L/H side of crusher box.
4:- Emergency stop on R/H side
walkway ladder. 5:- Emergency stop on R/H side of crusher box.
Note:-
i) Emergency stop switches should only
be used in an emergency as frequent
use will cause damage to hydraulic
components.
ii) Switches must be reset before the
machine can be restarted.
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C-12 CRUSHER
REMOVING TRACTOR UNIT AND BOGIE
3:- Remove tractor unit air brakes & lighting
connections then unhitch from machine.
1:- Front Jacking Legs lever. 2:- Lower front Jacking Legs to raise fifth wheel
neck by approximately 100 mm.
4:- Unlock bogie from machine (4 positions).
5:- Rear Jacking Legs lever. 6:- Lower rear Jacking Legs to raise machine clear
of the bogie locking mechanism .
NOTE:- Before attempting to lower the
jacking legs ALL of the leg transportation
retaining screws MUST be removed.
Jack retention screw
10

C-12 CRUSHER
REMOVING TRACTOR UNIT AND BOGIE
7:- Remove Bogie air brakes & lighting
connections then tow away from machine. 8:- Retract both front and rear jacking legs so
that weight of machine is taken on tracks .
10:- Raise R/H hopper side9:- Raise L/H hopper side
Hopper back door being raised11:- Raise hopper back door
Hopper side fully raisedHopper side being raised
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C-12 CRUSHER
REMOVING TRACTOR UNIT AND BOGIE
12:- Remove rear door ram hose. 13:- Attach hose to fifth wheel lifting ram.
14:- Remove struts from 5th wheel neck, then
remove connection panel & umbilical cord
completely from machine.
Rear hopper door / 5th wheel neck lever .
15:- Remove struts and lift 5th wheel neck up into a vertical position to avoid damage when
loading material into hopper .
16:- Reattach hose to rear door ram.
Fitting the bogie and attaching the tractor for transportation is a reversed procedure to that describe above.
IMPORTANT:- Before transporting with the bogie fitted ensure that the jacking legs are fully
retracted and the leg transportation retaining screw have been refitted and tightened to prevent
the legs from dropping.
Struts
Connection panel
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C-12 CRUSHER
TRACKING (MOVING) PROCEDURE
When engine is running at speed No.1, the machine can be moved to desired position on site by
following the instructions below:-
Main conveyor in raised position
2:- Press button "Interlock On"
3:- Press button "Main conveyor lift"
4a:- Activate levers to raise front jacking legs 4b:- Activate levers to raise rear jacking legs
1:- Press button "Clamp On".
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C-12 CRUSHER
5:- Press button "Tracks On"Jacking legs fully raised
After following instructions on the previous page, use either the Remote handset or Hard Wire Drive to move
machine to desired position.
NOTE:- The Remote Handset will be supplied as either yellow or white (Not Both) and must be fully
recharged at regular intervals. PLEASE use the correct instructions for your type of controller.
Plug in Umbilical socket for
Hard wire drive.
Yellow Remote Handset.
WARNING:- Under NO circumstances try to move the machine when engine speed is set at position No.2 or
when ANY personnel are standing on the machine.
For safety reasons, it is essential to check all around machine for obstacles or personnel which may be endangered by
moving the machine.
When moving machine, ensure that it is only moved over firm ground suitable for carrying the weight of the machine.
Prior to operating the machine, it is ESSENTIAL that both tracks are in contact with firm level ground to avoid
excessive vibration or rocking of the machine. DO NOT MOVE THE MACHINE ACROSS EXCESSIVELY
SLOPING GROUND.
NOTE:- i) When operating the Yellow Remote Handset, the directional arrows relate to the machines forward
& reverse movement.
ii) When operating the White Remote Handset, the yellow buttons are for forward movement and the
blue ones for reverse. (These correspond to direction indicator stickers on machine)
iii) When operating the Hard Wire Handset, the yellow buttons are for forward movement and the blue
ones for reverse. (These correspond to direction indicator stickers on machine)
When the machine is moved to its desired operating position, prepare the crusher for operation by following the
procedures laid out in the following pages.
White Remote Handset.
OR
Hard Wire Handset.
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C-12 CRUSHER
PREPARING THE CRUSHER FOR OPERATION
Main conveyor in working position
5:- Raise R/H hopper side
2:- Press button "Interlock On"
4:- Raise L/H hopper side
3:- Press button "main conveyor lower"
1:- Press button "Clamp On"
15

C-12 CRUSHER
PREPARING THE CRUSHER FOR OPERATION Cont.
Hopper back door being raised
8:- Fit hopper cross-tie box & secure with pins &
R-clip
6:- Raise hopper back door
7:- Fit locking pins to hopper sides/rear
Hopper side fully raisedHopper side being raised
16

C-12 CRUSHER
PREPARING THE CRUSHER FOR OPERATION Cont.
10:- Remove side conveyor locking pin
11:- Activate lever marked "Side Con Fold" to lower
side conveyor. Side conveyor in working position
12b:- Fix main conv. spray bar in working position.12a:- Raise main conv. spray bar to working
position.
Locking Pin
9:- Fit & tighten bolts at hopper leg/chassis. (Both
sides)
17

C-12 CRUSHER
PREPARING THE CRUSHER FOR OPERATION Cont.
13a:- Locate safety gate in holes in RH side walkway.
15:- Fit pins & R-clips to jack legs (8 off)
WARNING:- a) Ensure the machine is on a level surface before operating the jack leg levers.
b) Lift the machine uniformly.
13b:- Push safety gate firmly down into holes.
13c:- Raise up rotating gate section. (NOTE:- while
operator is using the platforms the safety gates
MUST be closed).
13d:- Rotate & lower gate into position. Repeat
procedure on other side of machine.
14:- Lower jack legs by operating levers.
18

C-12 CRUSHER
SETTING MATERIAL OUTPUT SIZE:
The C-12 crusher has an adjustable discharge setting capacity. To set the size of the output material, carry
out the following procedure :
WARNING:- The machine MUST be stationary and the crusher turned off
whilst this procedure is carried out.
2:- Restart machine as described on page 8 and
leave speed switch at position No.1.
1:- Stop the machine as described on page 9.
NOTE :- MACHINE MUST BE SHUT DOWN AND RESTARTED
(SEE STEPS 1 & 2) BEFORE JAW CAN BE OPENED / CLOSED.
Ignition Key
19