Extec E-7 Operating instructions

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Extec Screens & Crushers Ltd
E-7
Operating and Maintenance Manual
Manufactured by Extec Screens and Crushers Ltd
Hearthcote Road
Swadlingcote
Derbyshire
DE11 9DU
England
Telephone [phone]
Fax [phone]
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Introduction
This document has been prepared to ensure the equipment constructed by Extec Ltd is
installed put into use and operated efficiently and safely.
Read the manual carefully to learn how to operate and service your machine correctly.
Failure to do so could result in personal injury or equipment damage.
It is recommended that this manual is thoroughly understood before the equipment is
operated.
Operation of the plant contrary to the to the instructions contained in this manual or
modification to the machine without prior agreement with Extec Ltd will invalidate any
undertakings given by the manufacturer in regard to this machine
Whilst every effort has been made to ensure the accuracy of information contained
within this manual. Extec Ltd can assume no responsibility for any errors, omissions, or
their consequences. As Operating conditions vary considerably, all performance data is
indicative only for plant operated in accordance with the conditions set out in this
manual.
Please contact Extec Ltd if any part of this manual is unclear.
A copy of this manual must be kept at the operational site for easy reference.
Extec Ltd reserves the right to change the content of this manual without prior notice.
The information contained within this manual should be considered to be commercially
confidential and should not be released to any third party without prior consent from
Extec Ltd.

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Contents
Section 1 Safety Instructions
Description Page Number
1.1 Notes 2
1.2 Alarms and Warnings 2
1.2.3 Warnings Marked on the machine 2
1.2.4 Personnel Safety Warnings 3
1.2.5 Machine Safety Warnings 4
1.2.6 Machine Legend Plate 4
1.3 Component Safety Features 5
1.4 Features for Operator safety 5
1.5 Environmental safety 5
1.6 Personal Protective Equipment (PPE) 6
1.7 Measured Noise levels 7
1.8 Vibration Levels 7
1.9 Organisational Safety Measures 8
1.10 Personnel Qualification, Requirements and
Responsibilities 8
1.11 Safety Advice Regarding Specific Operational
Phases 9
1.11.1 Standard Operation 9
1.11.2 Blockage or Malfunction 9
1.11.3 Unguarded Areas 9
1.12 Special Work. Such as Plant Maintenance and
Repairs during Operation; Disposal of Parts and
Consumables 9
1.12.1 Isolation 10
1.12.2 Maintenance Site Conditions 10
1.12.3 Replacement & Removal of Component 10
1.12.4 Climbing and falling 10
1.12.5 Safety Consideration during advanced
maintenance. 11
1.12.6 Safety considerations during cleaning 11
1.12.7 Removal of safety devices and guards 11
1.12.8 Surrounding Structures 11
1.12.9 Safety when refuelling 12
1.13 Specific Hazards 13
1.13.1 Electrical Energy 13
1.13.2 Gas, dust, steam, smoke and noise 14
1.13.3 Hydraulic Equipment 15
1.13.4 Hazardous Substances 15
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Section 2 Description and Technical Information
Description Page Number
2.1 Application & Limitations 2
2.2 Description 2
2.3 Operation Description 2
2.4 Key Features 3
2.5 Common Applications 3
2.6 Machine Layout Indicating Main Components 4
2.7 Machine Layout Indicating Emergency Stop
Positions 5
2.8 Data 6
2.9 E-7 Transport Dimensions 7
Section 3 Transport Commissioning and Operation
Description Page Number
3.1 Transport 2-3
3.2 Pre Start Instructions 4
3.3 Machine Starting Sequence 5
3.4 Stopping the Machine 6
3.5 Tracking (Moving Procedures 7-8
3.6 Preparing the Machine for Operation 9-16
3.7 Operating the Machine 17-18
Section 4 Maintenance
Description Page Number
4.1 Introduction 2
4.2 Daily Maintenance Schedule 3-4
4.3 Weekly Maintenance Schedule 5-9
4.4 Maintenance Schedule Every 250 Hrs 10
4.5 Maintenance Schedule Every 1000 Hrs 11-12
4.6 Tensioning and Tracking Belts 13-16
4.7 Screen Mesh Replacement 17-18
4.8 Trouble Shooting Guide 19
Section 5 Appendix
Contents Description
Appendix 1 Documentation
Appendix 2 Parts manual
Appendix 3 Drawing Pack
Appendix 4 OEM Manuals Supplied with this Machine
Appendix 5 Hazardous Substances Listing and details

Section 1 Page 1
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Section 1 Safety Instructions
Contents Description Page Number
1.1 Notes 2
1.2 Alarms and Warnings 2
1.2.3 Warnings Marked on the machine 2
1.2.4 Personnel Safety Warnings 3
1.2.5 Machine Safety Warnings 4
1.2.6 Machine Legend Plate 4
1.3 Component Safety Features 5
1.4 Features for Operator safety 5
1.5 Environmental safety 5
1.6 Personal Protective Equipment (PPE) 6
1.7 Measured Noise levels 7
1.8 Vibration Levels 7
1.9 Organisational Safety Measures 8
1.10 Personnel Qualification, Requirements and
Responsibilities 8
1.11 Safety Advice Regarding Specific Operational
Phases 9
1.11.1 Standard Operation 9
1.11.2 Blockage or Malfunction 9
1.11.3 Unguarded Areas 9
1.12 Special Work. Such as Plant Maintenance and
Repairs during Operation; Disposal of Parts and
Consumables
9
1.12.1 Isolation 10
1.12.2 Maintenance Site Conditions 10
1.12.3 Replacement & Removal of Component 10
1.12.4 Climbing and falling 10
1.12.5 Safety Consideration during advanced
maintenance. 11
1.12.6 Safety considerations during cleaning 11
1.12.7 Removal of safety devices and guards 11
1.12.8 Surrounding Structures 11
1.12.9 Safety when refuelling 12
1.13 Specific Hazards 13
1.13.1 Electrical Energy 13
1.13.2 Gas, dust, steam, smoke and noise 14
1.13.3 Hydraulic Equipment 15
1.13.4 Hazardous Substances 15
Section 1 Page 2
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SAFETY INSTRUCTIONS
1.1 Notes
1.1.1 Read this manual and familiarise yourself with any associated documentation.
1.1.2 Ensure that a copy of this manual is available for any persons installing, using,
maintaining or repairing this equipment.
Training should be provided to ensure safe working practices.
Initial commissioning and starting must only be undertaken by a competent
person who has read and fully understands the information provided in the
manual pack.
1.1.3 To avoid the risk of electric shock always isolate this equipment from the supply
prior to carrying out any maintenance adjustment or removing any guards or
covers.
1.1.4 Always follow the procedures outlined in the operating and maintenance
instruction.
1.1.5 If in doubt ask, do not take personal risk.
1.1.6 This equipment is manufactured in accordance with the Supply of Machinery
Safety Regulations 98/37EC. The customer should ensure that this equipment
is in conformance with local and national legislation if used outside of the EU.
1.1.7 Only trained personal should be allowed to install, set, operate, maintain, and
decommission this equipment.
1.2 Alarms and warnings
1.2.1 All electrical control boxes are labelled.
1.2.2 Any residual risks are identified within this manual with the equipment marked
where appropriate.
1.2.3 Warnings marked on the machine
The following labels are posted on the machine for your safety Observe all
warnings
xYou can be injured if you do not obey the safety
instructions as indicated on warning stickers.
xObserve all safety instructions and warnings attached
to the plant.
xEnsure that safety instructions and warnings attached
to the plant are always complete and perfectly legible.
xKeep warnings and instruction labels clean.
xReplace unreadable or missing labels with new ones
before operating the plant. Make sure replacement
parts include warning or instruction labels where
necessary.

Section 1 Page 3
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1.2.4 Personnel Safety Warnings
Section 1 Page 4
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1.2.5 Machine Safety Warnings

Section 1 Page 5
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1.3 Component safety features
1.3.1 Do not use this equipment with guards removed or incorrectly fastened.
1.3.2 Do not use this equipment with safety devices maladjusted or removed.
1.4 Features for operator safety
1.4.1 Safety features associated with this equipment have been assessed in
accordance with BS EN 954 to Category 3.
1.4.2 The E Stop circuit is a 12V dc series circuit and hard wired to remove power
from the ECU Engine management system and stop the engine. Following an
activation of the Safety Circuit this will take approximately five seconds to de-
energize.
1.4.3 Safety Components - E stop Buttons, All Guards are bolted down. The detailed
Safety circuit diagram can be found within the drawing pack as an appendix to
this manual.
1.4.4 Steps handrails Tread plate and fixed guards are provided where personnel are
required to climb on the machine. If for any reason other areas need to be
accessed the risk associated with the activity must be assessed and
appropriate control measures implemented.
1.5 Environmental safety
1.5.1 It is essential that the service intervals detailed in the maintenance procedures
are followed to ensure that engine emissions are kept to a minimum.
1.5.2 Consumable Materials
xDiesel spillages must be dealt with immediately.
xOnly use the Lubricating Oils recommended in the maintenance schedule.
xObserve the Coshh Information contained in the appendix to this manual.
xLocal & National regulations must be observed when disposing of waste
xImproperly disposing of waste can threaten the environment and ecology.
xPotentially harmful waste used on this equipment includes such items as oil,
fuel, coolant, filters and batteries, etc. details can be found in the appendix to
this manual
xUse leak proof containers when draining fluids. Do not use food or beverage
containers that may mislead someone into drinking from them.
xDo not pour waste onto the ground, down a drain or into any water source.
xEnsure that all consumables and replaced parts are disposed of safely and with
minimum environmental impact.
1.5.3 Machine disposal. This machine must only be disposed of at a specialist
machine breaker.
Section 1 Page 6
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1.6 Personal Protective Equipment (PPE)
Loose or baggy clothing can get caught in running machinery.
Where possible when working close to engines or machinery, only do so when
they are stopped. If this is not practical, remember to keep tools, test equipment
and all other parts of your body well away from the moving parts.
For reasons of safety, long hair must be tied back or otherwise secured,
garments must be close fitting and no jewellery such as rings may be worn.
Injury may result from being caught up in the machinery or from rings catching
on moving parts.
Always wear correctly fitting (CE approved) personal protective equipment.
Recommended Personal Protective Equipment includes:-
xHard Hat,
xSafety Glasses
xHearing Protection
xDust Mask
xClose fitting Overalls
xSafety Boots
xIndustrial Gloves
xHigh Visibility Vest or jacket.

Section 1 Page 7
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1.7 Measured Noise Level
The above diagram indicates the measured noise levels at a measured distance.
i.e. 7M – 85dB indicates at 7 Meters the sound recorded was 85 decibels. The
readings were measured using a Castle GA101/701 meter with a calibration date of
13/9/94. with all systems running situated on the factory assembly line.
The product and local conditions will affect the noise levels
Ear Protection is compulsory within 10 Meters of the machine when the engine and all
other parts of the machine are running.
1.8 Vibration Levels
There are no circumstances where an operator needs to be on or touching this
equipment when it is running.
Section 1 Page 8
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1.9 Organisational Safety Measures
xUnderstand the service procedure before doing work. Keep area clean and dry.
xNever lubricate, clean, service or adjust machinery while it is moving. Keep
hands, feet and clothing clear of power driven parts and in running nip-points.
Disengage all power and operate controls to relieve pressure. Stop the engine.
Implement lockout procedure. Allow the machinery to cool.
xKeep all parts in good condition. Ensure that all parts are properly installed. Fix
damage immediately. Replace worn and broken parts. Remove any build up of
grease, oil and debris.
xDisconnect battery ground cable before making adjustments on electrical
systems or welding on plant.
xDuring Maintenance only use the correct tool for the job.
xNever make any modifications, additions or conversions which might affect
safety without the manufacturers’ approval.
xIn the event of safety relevant modifications or changes in the behaviour of the
plant during operation, stop the plant and lock out immediately and report the
malfunction to the competent authority/person.
1.10 Personnel Qualification, Requirements and Responsibilities
1.10.1 Any work on and/or with the plant must be executed by trained, reliable and
authorised personnel only. Statutory minimum age limits must be observed.
1.10.2 Work on electrical system and equipment of the plant must be carried out only
by a skilled electrician or by instructed persons under the supervision and
guidance of a skilled electrician and in accordance with electrical engineering
rules and regulations.
1.10.3 Work on the hydraulic system must be carried out only by personnel with
special knowledge and experience of hydraulic equipment.

Section 1 Page 9
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1.11 Safety Advice Regarding Specific Operational Phases
1.11.1 Standard Operation
xTake the necessary precautions to ensure that the plant is used only when in a
safe and reliable state.
xOperate the plant only for it's designed purpose and only if all guarding,
protective and safety orientated devices, emergency shut-off equipment, sound
proofing elements and exhausts, are in all place and fully functional.
xEnsure that any local barriers erected to stop unauthorized entry to this
equipment are in place
xBefore starting the engine ensures it is safe to do so.
1.11.2 Blockage or Malfunction
xIn the event of material blockage, any malfunction or operational difficulty, stop
the plant immediately and lockout. Have any defects rectified immediately.
1.11.3 Unguarded areas
xIn-running nip points on moving machinery can cause serious injury or even
death.
xDo not reach into unguarded machinery. Your arm could be pulled in and
amputated.
xSwitch off and lockout the plant before removing any safety devices or
guarding.
xLimit access to the machine and its surrounds by erecting barrier guards to
reduce the risk of residual mechanical hazards, falling lifted loads and ejected
materials.
1.12 Special Work. Such as Plant Maintenance and Repairs during Operation;
Disposal of Parts and Consumables
Observe the adjusting, maintenance and intervals set out in these operating
instructions, except where:
xWarning, horn/light/gauge or indicator calls for immediate action.
xAdverse conditions necessitate more frequent servicing.
xAlways read instructions supplied with replacement of parts and equipment.
Ensure only properly trained personnel undertake these tasks.
Section 1 Page 10
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1.12.1 Isolation
When undertaking maintenance and repair work, the plant must be first made
safe
xSwitching off the engine, Switch off at Isolation point and remove the ignition
switch/key.
xImplementing the lockout procedure.
xAttaching a warning sign(s) to the plant in appropriate positions.
1.12.2 Maintenance site conditions
Prior to starting any maintenance work ensure the machine is positioned on
stable and level ground and has been secured against inadvertent movement
and buckling.
1.12.3 Replacement & Removal of Components
xAlways observe handling instructions itemised in this manual, The Original
Equipment Manufacturers manuals or the Spare parts suppliers’ instructions.
xNever allow untrained staff to attempt to remove or replace any part of the
plant.
xThe removal of large or heavy components without adequate lifting equipment
is prohibited.
xTo avoid the risk of accidents, individual parts and large assemblies being
moved for replacement purposes should be carefully attached to lifting tackle
and secured. Use only suitable and technically adequate lifting gear supplied or
approved by Extec Ltd.
xNever work or stand under suspended loads.
xKeep away from the feed hopper and product conveyor discharge, where there
is risk of serious injury or death due to the loading and removal of material.
xLimit access to the machine and its surrounds by erecting barrier guards to
reduce the risk of residual mechanical hazards, falling lifted loads and ejected
materials.
1.12.4 Climbing, Falling
xFalling from and/or onto this plant could cause injury or even death.
xNever climb on the plant whilst it is in operation.
xNever use plant parts as a climbing aid.
xAlways keep the area around the plant clear of debris and trip hazards
xBeware of moving haulage and loading equipment in the vicinity of the plant
xFor carrying out overhead assembly work always use specially designed or
otherwise safety-oriented ladders and working platforms.
xOnly use any walkway/platforms provided on the machine or on an approved
safe and secure platform.
xOnly use CE certified safety harness when reaching any points 2M or more
above the ground level.
xKeep all handles, steps, handrails, platforms, landing and ladders free from dirt,
oil, snow and ice.

Section 1 Page 11
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1.12.5 Safety Consideration during advanced maintenance.
Prior to undertaking all but normal planned maintenance activities it is essential
that a method statement regarding safe working practices for the job in hand is
produced.
xRestrict access to the maintenance to essential staff only. Where appropriate
erect barrier guards and post warnings
xThe fastening of loads and instructing of crane operators should be entrusted to
qualified persons only.
xThe marshal providing instructions must be within sight or sound of the operator
with an all round view of the operation.
xAlways ensure that any safety fitment such as locking wedges, securing chains,
bars or struts are utilised as indicated in these operating instructions.
xParticularly make sure that any part of the plant raised for any reason is
prevented from falling by securing in a safe reliable manner.
xNever work under unsupported equipment.
xNever work alone.
1.12.6 Safety considerations during cleaning
xThis equipment must be isolated prior to cleaning.
xDo not direct power washers near or into control boxes and devices.
xAfter cleaning, examine all fuel, lubricant, and hydraulic fluid lines for leaks,
loose connections, chafe marks and damage. Any defects found must be
rectified without delay.
1.12.7 Removal of safety devices and guards
xAll safety devices (Control devices or Guard) temporarily removed for set-up,
maintenance or repair purposes must be refitted and checked immediately upon
completion of the maintenance and repair work prior to operation.
xNever operate the machine with Safety devices or Guards removed or
unsecured
xAlways report any defects regarding Guards, Safety devices or Control devices.
1.12.8 Surrounding structures
xThis equipment must only be operated in a position away from buildings,
permanent structures or high ground to eliminate the risk of persons falling onto
the equipment or its surrounds.
xAny temporary structures erected around the machine must be removed prior to
operating this equipment
Section 1 Page 12
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1.12.9 Safety when refuelling
xOnly refuel with diesel from approved storage and supply equipment
xDiesel fuel is highly flammable.
xNever remove the filler cap, or refuel, with the engine running.
xNever add gasoline or any other fuels mixed to diesel because of increased fire
or explosion risks and damage to the engine.
xDo not carry out maintenance on the fuel system near naked lights or sources
of sparks, such as welding equipment or whilst smoking.
xTo avoid spillages use drip trays.
xImmediately clear up spilt fuel and dispose of correctly to minimise any
environmental impact.

Section 1 Page 13
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1.13 Specific Hazards
1.13.1 Electrical Energy
External Considerations and hazards
When working with the plant, maintain a safe distance from overhead electric lines.
If work is to be carried out close to overhead lines, the working equipment must be
kept well away from them. Check out the prescribed safety distances.
If in Doubt Ask.
If your plant comes into contact with a live wire
xVacate the area
xWarn others against approaching and touching the plant
xReport the incident and have the live wire de-energized.
Machine - Electrical
Work on the electrical system or equipment may only be carried out by a skilled and
qualified electrician or by specially instructed personnel under the control and
supervision of such an electrician and in accordance with applicable electrical
engineering rules.
The power supply to the plants, on which inspection, maintenance and repair work is
to be carried out must be isolated before starting any work, check the de-energised
parts for presence of power and ground or short circuit them in addition to insulating
adjacent live parts and elements.
The electrical equipment of the plant is to be inspected and checked at regular
intervals. Defects such as loose connections or scorched or otherwise damaged
cables must be rectified immediately.
If working on live parts and elements cannot be avoided this must only be carried
out in the presence of a second person, who can cut off the power supply in the
case of danger by actuating the emergency shut off or main power switch. Secure
the working area with a red and white safety chain and a warning sign. Use
insulated tools only.
Use only original fuses with the specified current rating. Switch off the plant
immediately if trouble occurs in the electrical system.
This plant is wired on a negative earth. Always observe correct polarity.
Battery
xAlways disconnect battery leads before carrying out any maintenance to the
electrical system.
xRecharge the battery in a well ventilated area
xThe battery contains sulphuric acid, an electrolyte which can cause severe
burns and produce explosive gases.
xAvoid contact with the skin, eyes or clothing.
xNo Smoking when maintaining Battery.
Section 1 Page 14
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1.13.2 Gas, Dust, Steam, Smoke and Noise
Always operate internal combustion engines out of doors or in a well ventilated area.
If plant is operated for maintenance purposes in an enclosed area, ensure that there
is sufficient ventilation or provide forced ventilation.
Observe the regulations in force at the respective site.
Dust found on the plant or produced during work on the plant should be removed by
extraction, not blowing.
Dust waste should be dampened, placed in a sealed container and marked, to
ensure safe disposal.
Welding or naked flames
Never carry out welding, flame cutting and grinding work on the plant only if this has
been expressly authorised, as there may be a risk of explosion and fire.
Before carrying out welding, flame cutting and grinding operations, clean the plant
and its surroundings from dust and other inflammable substances and make sure
the premises are adequately ventilated (as there may be a risk of explosion).
Avoid all naked flames in the vicinity of this equipment
Personal Protection
Ensure that the operators are provided with hearing protection of approved pattern
and that these are worn at all times when the plant is operating.
Ensure operators wear a suitable face mask where exposed to possible harmful
effects of air pollution of any kind.