Extec I-C13 Impactor Operating instructions

Ver: IC13-EN-10567 Operating and Maintenance Manual 19 June 2007
I-C13 Impactor
Operating and Maintenance Manual
Manufactured by: Extec Screens & Crushers Ltd
Address: Hearthcote Road
Swadlincote
Derbyshire
DE11 9DU
United Kingdom
Telephone: [phone]
Fax: [phone]
Parts and Service: [phone]
www: http://www.extecscreens.com

Page ii Introduction Ver: IC13-EN-10567
I-C13 Impactor
Introduction
This document has been prepared to ensure the equipment constructed by Extec Screens & Crushers
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 damage to the equipment.
It is recommended that this manual is thoroughly understood before operating the equipment.
Operation of the plant contrary to the instructions contained in this manual or modification to the
machine without prior agreement with Extec Screens & Crushers 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 Screens & Crushers 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 Screens & Crushers Ltd regarding any part of this manual that requires further
clarification.
A copy of this manual must be kept at the operational site for easy reference.
Extec Screens & Crushers Ltd reserve 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 Screens & Crushers Ltd.

Ver: IC13-EN-10567 Certificate of Conformity Page iii
I-C13 Impactor
Certificate of Conformity
Supply of Machinery Safety Regulations - Machinery Directive 98/37/EC
Serial No:
Engine Serial No:
Production Manager:
Date of build:
Issued Declaration of Conformity on next page.

Page iv Certificate of Conformity Ver: IC13-EN-10567
I-C13 Impactor
Name of manufacturer or supplier
Extec Screens & Crushers Ltd
Full postal address including country of origin
Hearthcote Road, Swadlincote, Derbyshire, England, DE11 9DU
Description of product
Impactor
Name, type or model, batch
Impactor Extec Screens & Crushers Ltd
In built diesel Swadlincote, Derbyshire, DE11 9DU
22278/D515
Standards used, including number, title, issue date and other relative documents
EN292-1, EN292-2, EN349, EN418, EN954-1, EN1050
Place of issue
Extec Screens & Crushers Ltd
Originating certification by
Laidler Associates, Belasis Business Centre, Coxwold way, Billingham, Teesside, TS23 4EA
Certificate number 22278/D515
Declaration
I declare that the above information in relation to the supply / manufacture of this product, is in
conformity with the stated standards and other related documents following the provisions of the
above Directives and their amendments.
Signature _____________________ Date
98/37/EC Machinery
89/336/EEC EMC

Ver: IC13-EN-10567 Contents Page v
I-C13 Impactor
Contents
Operating and Maintenance Manual
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Certificate of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Safety Instructions
1.1 Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Alarms and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Warnings marked on the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3.1 Personnel Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3.2 Machine Safety Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.3 Machine Legend Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Component Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Features for Operator Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.6 Environmental Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.6.1 Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.6.2 Machine Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.7 Personal Protective Equipment (PPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.8 Measured Noise Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.9 Vibration Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.10 Organisational Safety Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.11 Personnel Qualification, Requirements and Responsibilities . . . . . . . . . . . . . . 9
1.12 Safety Advice Regarding Specific Operational Phases. . . . . . . . . . . . . . . . . . 9
1.12.1 Standard Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.12.2 Blockage or Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.12.3 Unguarded Areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.13 Special Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.13.1 Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.13.2 Maintenance Site Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.13.3 Replacement & Removal of Components. . . . . . . . . . . . . . . . . . . . . . 10
1.13.4 Climbing, Falling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.13.5 Safety Consideration during Advanced Maintenance . . . . . . . . . . . 11
1.13.6 Safety Considerations during Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . 12
1.13.7 Removal of Safety Devices and Guards. . . . . . . . . . . . . . . . . . . . . . . . 12
1.13.8 Surrounding Structures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.13.9 Safety when Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Page vi Contents Ver: IC13-EN-10567
I-C13 Impactor
1.14 Specific Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.14.1 Electrical Energy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
External Considerations and Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Machine - Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.14.2 Gas, Dust, Steam, Smoke and Noise . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.14.3 Welding or Naked Flames. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.14.4 Hydraulic Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.14.5 Hazardous Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Transportation
2.1 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3 Machine Transportation Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Description and Technical Information
3.1 Application & Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3 Operation Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.4 Key Features of the I-C13 Impactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5 Common Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.6 Machine Layout Indicating Main Components . . . . . . . . . . . . . . . . . . . . . . . 21
3.7 Emergency Stop Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.8 Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fuel Consumption Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.9 Transport Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Commissioning and Operation
4.1 Pre-Start Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2 Main Control Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.3 Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.4 Stopping the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.5 Stopping Machine in an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.5.1 Emergency Stop Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.6 Removing Tractor Unit and Bogie - (Where fitted) . . . . . . . . . . . . . . . . . . . . . 30
4.7 Tracking Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.8 Preparing the I-C13 Impactor for Operation. . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.8.1 Installation of the Recirculation Unit (Where fitted). . . . . . . . . . . . . . . 37

Ver: IC13-EN-10567 Contents Page vii
I-C13 Impactor
4.8.2 Operation of the Recirculation Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.9 Operating The Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.9.1 Operating Starting Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.9.2 Loading Material Into Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.9.3 Feeder Cut-out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.10 Impactor Box Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.10.1 Start Up Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.10.2 Brake Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Machine Maintenance
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.2 Daily Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.2.1 Air Cleaner Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.3 Weekly Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.3.1 Checking Feeder Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.3.2 Checking/ Changing Hydraulic Tank Air Breather. . . . . . . . . . . . . . . . 55
5.3.3 Greasing Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.3.4 Inspecting/ Adjusting Belt Sealing Rubbers. . . . . . . . . . . . . . . . . . . . . . 56
5.3.5 Adjusting Belt Scraper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.3.6 Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.3.7 Changing Hydraulic Water Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.4 250 Hour Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.5 1000 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.5.1 Changing Oil in Tracks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.6 Track Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.6.1 Track Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.6.2 Track Adjustment Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.6.3 Increasing The Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.6.4 Releasing The Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.7 Magnetic Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.8 Oils And Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Trouble Shooting Guide
6.1 Checking Hydraulic Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.2 Checking 5 Station Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.3 Test Procedures for Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Appendix A Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Contact Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Parts Manual Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Loose Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Chassis, Walkways and Tracks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Page viii Contents Ver: IC13-EN-10567
I-C13 Impactor
Magnetic Conveyor and Supports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Power Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Control Boxes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Diesel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Feeder and Vibrator Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Transfer Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Crusher Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Torque Arm Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Main Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
.Extended Main Conveyor (Where fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Side Conveyor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Feeder Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Hydraulic Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Power Pack Hose Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Valve Plate Hose Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Side Conveyor Hose Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Main Conveyor Hose Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Chassis and Auxiliary Hose Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Control Box Hose Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Recirculation Hose Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Recirculation Layout (Where fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Recirculation Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Recirculation Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Recirculation Screen Sub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Recirculation Vibrating Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Recirculation Fines Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Recirculation Side Conveyor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Stickers - English. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Transport Bogie and Fifth Wheel - Optional. . . . . . . . . . . . . . . . . . . . . . . . . . 180
Water Pump - Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Appendix B Drawing Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
IMPACTOR CONTROL CONN. . . . . . . . . . . . . . . . . . . . . . TED6300sht9 26/04/04
IMPACTOR CONTROLLER CONN . . . . . . . . . . . . . . . . . . TED6300sht10 26/04/04
ENGINE SCHEMATIC IMPACTOR DEUTZ. . . . . . . . . . . . . TED6300sht11 26/04/04
IMPACTOR RECEIVER AND LOOM. . . . . . . . . . . . . . . . . TED6300sht12 26/04/04
IMPACTOR SOLENOID CONTROL PANEL. . . . . . . . . . . . TED6300sht13 26/04/04
IMPACTOR ENGINE PANEL ELECTRONIC. . . . . . . . . . . . TED6300sht14 26/04/04
IMPACTOR AUX LOOMS . . . . . . . . . . . . . . . . . . . . . . . . . TED6300sht15 26/04/04
CRUSHER JAW CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .REV1
LAMP DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REV 1
Appendix C OEM Manuals supplied with this machine . . . . . . . . . . . . . 199
CATERPILLAR C-13 Operation and Maintenance ManualSEBU7901 May 2004
C13 Industrial Engine Parts Manual CD . . . . . . . . . . . . .SERP4130-06 April 2005
ERIEZ MAGNET MODELS CP & OP INSTRUCTIONS. . . . . . . . . . . IM-108GB-(F.01)

Ver: IC13-EN-10567 Contents Page ix
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IMPACTOR BOX MANUAL
Appendix D Hazardous Substances associated with this machine . . . 209
Exxon Unirex N 3 Grease. . . . . . . . . . . . . . . . . . . . . . . . . . .570317-00 UNIREX N 3
Shell Albida Grease EP2 . . . . . . . . . . . . . . . . . . . . ACIYK GB/eng/C 19/03/2005
Shell Rimula Super 15W-40 . . . . . . . . . . . . . . . . . ACK9D GB/eng/C 26/11/2003
Shell Naturelle Fluid HF-M 46 . . . . . . . . . . . . . . . ACKXR GB/eng/C 09/06/2004
Shell Tellus Oil 46 . . . . . . . . . . . . . . . . . . . . . . . . .ACKQ6 GB/eng/C 29/04/2004
Shell Omala 220 Gear Oil. . . . . . . . . . . . . . . . . . ACH75 GB/eng/C 29/01/2003
Shell Safe Anti Freeze . . . . . . . . . . . . . . . . . . . . . . . . L84042 Revision 23 08 2004
Shell Agricultural Gas Oil . . . . . . . . . . . . . . . . . . . . . F32002 Revision 02 10 2002
Exol Ethena EP90 Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 2nd October 2002
Appendix E Heavy Component Weights . . . . . . . . . . . . . . . . . . . . . . . . 283
Return Conveyor (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1125 kg
Chassis Frame (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1125 kg
Screen Sub Assy (3,4,5,6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3668 kg
A15930000 Support Arm (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 kg

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Ver: IC13-EN-10567 Safety Instructions Page 1
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Section 1 Safety Instructions
1.1 Notes
a. Read this manual and familiarise yourself with any associated documentation.
b. Ensure that a copy of this manual is available for any persons installing, using,
maintaining or repairing this equipment.
c. 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.
d. 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.
e. Always follow the procedures outlined in the operating and maintenance instruction.
f. If in doubt ask. Do not take personal risk.
g. This equipment is manufactured in accordance with the Machinery Directive 98/37/EC1.
The customer should ensure that this equipment is in conformance with local and
national legislation if used outside of the EU.
h. Only trained personal should be allowed to install, set, operate, maintain, and
decommission this equipment.
1.2 Alarms and Warnings
a. All electrical control boxes are labelled. Ensure these labels remain in place.
b. Any residual risks are identified within this manual with the equipment marked where
appropriate. Ensure these warnings are maintained.
1. Directive 98/37/EC of 22.06.98 (OJ n° L 207 of 23.07.98, p.1)

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1.3 Warnings marked on the machine
The following labels are posted on the machine for your safety. Please observe all
warnings.
• You can be injured if you do not obey the safety instructions as indicated on warning
stickers.
• Observe all safety instructions and warnings attached to the plant.
• Ensure that safety instructions and warnings attached to the plant are always complete
and perfectly legible.
• Keep warning and instruction labels clean.
• Replace unreadable or missing labels with new ones before operating the plant. See
“Stickers - English” on page 174. for part numbers.
• Make sure replacement parts include warning or instruction labels where necessary.
1.3.1 Personnel Safety Warnings

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Ver: IC13-EN-10567 Safety Instructions Page 5
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1.3.2 Machine Safety Warnings
1.3.3 Machine Legend Plate
1.4 Component Safety Features
a. Do not use this equipment with guards removed or incorrectly fastened.
b. Do not use this equipment with safety devices maladjusted or removed.

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1.5 Features for Operator Safety
a. Safety features associated with this equipment have been assessed in accordance with
BS EN 954-1 to Category 3.
b. The Emergency Stop circuit is a 24 V DC series circuit and hard wired to remove power
from the ECU Engine management system and stop the engine. A residual hazard has
been identified in as much as the hydraulic circuit incorporates an accumulator fitted to
protect the system. When the Safety Circuit is activated this will takes approximately five
seconds to de-energize.
c. The detailed Safety Circuit diagram can be found within the drawing pack as an
appendix to this manual.
d. Safety Components - Emergency Stop Buttons, Ensure all Guards are bolted down.
e. Steps handrails, tread plates and fixed guards are provided where personnel are
required to climb on the machine.
f. If for any reason other areas need to be accessed the risk associated with the activity
must be assessed and appropriate control measures implemented.
1.6 Environmental Safety
It is essential that the service intervals detailed in the maintenance procedures are followed to
ensure that engine emissions are kept to a minimum.
1.6.1 Consumable Materials
• Diesel spillages must be dealt with immediately.
• Only use the lubricating oils recommended in the maintenance schedule.
• Observe the COSHH information contained in the appendix to this manual.
• Local & National regulations must be observed when disposing of waste.
• Improperly disposing of waste can threaten the environment and ecology and is illegal.
• Potentially 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.
• Use leak proof containers when draining fluids. Do not use food or beverage containers
that may mislead someone into drinking from them.
• Do not pour waste onto the ground, down a drain or into any water source.

Ver: IC13-EN-10567 Safety Instructions Page 7
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• Ensure that all consumables and replaced parts are disposed of safely and with
minimum environmental impact.
1.6.2 Machine Disposal
• This machine must only be disposed of at a specialist machine breaker.
1.7 Personal Protective Equipment (PPE)
a. Loose or baggy clothing can get caught in running machinery.
b. 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.
c. 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.
d. Always wear correctly fitting (CE approved) personal protective equipment.
Recommended Personal Protective Equipment includes:
•HardHat
• Safety Glasses/ Goggles
• Hearing Protection
•DustMask
• Close fitting Overalls
• Safety Boots
• Industrial Gloves
• High Visibility Vest or Jacket.

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1.8 Measured Noise Level
The above diagram indicates the measured noise levels at a measured distance. i.e. 7 m - 85
dB indicates that at 7 meters the sound measured was 85 decibels. The readings were
measured using a Castle GA101/701 meter with a calibration date of 05/06/04 and 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 theengine and all other parts
of the machine are running.
1.9 Vibration Levels
There are no circumstances where an operator needs to be on or touching this equipment when
it is running.
1.10 Organisational Safety Measures
• Understand the service procedure before doing work. Keep area clean and dry.
• Never 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
Figure 1-1: Measured Noise Level

Ver: IC13-EN-10567 Safety Instructions Page 9
I-C13 Impactor
and operate controls to relieve pressure. Stop the engine. Implement lockout procedures.
Allow the machinery to cool.
• Keep 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.
• Disconnect battery ground cable before making adjustments on electrical systems or
welding on plant.
• During maintenance only use the correct tool for the job.
• Never make any modifications, additions or conversions which might affect safety without
the manufacturer’s approval.
• In 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.
1.11 Personnel Qualification, Requirements and Responsibilities
a. 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.
b. 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.
c. Work on the hydraulic system must be carried out only by personnel with special
knowledge and experience of hydraulic equipment.
1.12 Safety Advice Regarding Specific Operational Phases
1.12.1 Standard Operation
• Take the necessary precautions to ensure that the plant is used only when in a safe and
reliable state.
• Operate 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.
• Ensure that any local barriers erected to stop unauthorized entry to this equipment are in
place.
• Before starting the engine ensure it is safe to do so.

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1.12.2 Blockage or Malfunction
In the event of material blockage, any malfunction or operational difficulty, stop the plant
immediately and lockout. Have any defects rectified immediately.
1.12.3 Unguarded Areas
• In-running nip points on moving machinery can cause serious injury or even death.
• Do not reach into unguarded machinery. Your arm could be pulled in and amputated.
• Switch off and lockout the plant before removing any safety devices or guarding.
• Limit 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.
1.13 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:
a. Warning, horn/ light/ gauge or indicator calls for immediate action.
b. Adverse conditions necessitate more frequent servicing.
c. Always read instructions supplied with replacement of parts and equipment. Ensure only
properly trained personnel undertake these tasks.
1.13.1 Isolation
When undertaking maintenance and repair work, the plant must be first made safe.
• Switch off the engine using the ignition key. Switch off at isolation point and remove the
ignition key.
• Implement lockout procedures.
• Attaching a warning sign(s) to the plant in appropriate positions.
1.13.2 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.
1.13.3 Replacement & Removal of Components
• Always observe handling instructions itemised in this manual, the Original Equipment
Manufacturer’s manuals or the spare parts suppliers' instructions.