KOMPLET K-JC 503 User manual

Use and Maintenance Manual
K-JC 503
Serial number: 321790
Date: 03/02/2022
Use and Maintenance Manual Translated from the Original Language in Italian

Table of contents
1. Introduction................................................................................................................................................. 7
1.1 Instructions......................................................................................................................................... 7
1.1.1 Structure and concept.................................................................................................................... 9
1.1.2 Symbols used .............................................................................................................................. 11
1.1.3 Definitions used ........................................................................................................................... 11
1.1.4 Additional documents .................................................................................................................. 12
1.2 The machine.................................................................................................................................... 13
1.3 Work................................................................................................................................................. 16
1.3.1 Qualified personnel...................................................................................................................... 16
1.3.2 Due diligence............................................................................................................................... 17
1.3.3 Behaviour in the event of faults ................................................................................................... 19
1.3.4 Maintenance and service work.................................................................................................... 20
2. Safety ....................................................................................................................................................... 21
2.1 Introduction...................................................................................................................................... 21
2.1.1 Personal protective clothing......................................................................................................... 21
2.1.2 Danger zones............................................................................................................................... 22
2.1.3 Warnings, safety signs and marking............................................................................................ 25
2.2 Basic principle, intended use........................................................................................................... 30
2.3 Organisational measures................................................................................................................. 31
2.4 Selection and qualification of personnel; basic obligations ............................................................. 32
2.5 Safety warnings for certain operational phases............................................................................... 33
2.6 Warnings for specific types of danger ............................................................................................. 36
3. Description................................................................................................................................................ 38
3.1 Machine concept.............................................................................................................................. 38
3.2 Material............................................................................................................................................ 39
3.2.1 Permissible material .................................................................................................................... 39
3.2.2 Prohibited material....................................................................................................................... 39
3.3 Orientation ....................................................................................................................................... 40
3.4 Construction units............................................................................................................................ 41
3.5 Protective devices............................................................................................................................ 42
3.5.1 EMERGENCY STOP button on the control panel....................................................................... 42
3.5.2 EMERGENCY STOP button on the radio remote control ........................................................... 43
3.5.3 Battery disconnector.................................................................................................................... 44
3.5.4 External covers............................................................................................................................ 45
3.6 Alarm devices .................................................................................................................................. 46
3.7 Signs................................................................................................................................................ 48
3.8 Description....................................................................................................................................... 49
3.8.1 Loading hopper............................................................................................................................ 49
3.8.2 Loading conveyor ........................................................................................................................ 49
3.8.3 Jaw crusher.................................................................................................................................. 51
3.8.4 Dust suppression system............................................................................................................. 52

3.8.5 Extracting conveyor ..................................................................................................................... 53
3.8.6 Undercarriage crawler ................................................................................................................. 54
3.8.7 Controls........................................................................................................................................ 55
3.8.8 Drive unit...................................................................................................................................... 63
3.8.1 Additional equipment and accessories........................................................................................ 66
3.9 Operating modes ............................................................................................................................. 67
3.9.1 Preparation .................................................................................................................................. 67
3.9.2 Machine operation ....................................................................................................................... 67
4. Transport .................................................................................................................................................. 68
4.1 Safety during transport .................................................................................................................... 68
4.2 Transport data ................................................................................................................................. 70
4.3 Loading/unloading with lifting hook.................................................................................................. 72
4.4 Loading/Unloading using crawler tracks.......................................................................................... 75
4.5 Container transport.......................................................................................................................... 79
4.6 Moving with crawler tracks............................................................................................................... 80
4.6.1 Moving on inclined planes and sloping paths.............................................................................. 80
4.6.2 Switching on the radio remote control ......................................................................................... 81
4.6.4 Switching off the radio remote control ......................................................................................... 82
5. Preparation for use................................................................................................................................... 83
5.1 Safety during installation.................................................................................................................. 83
5.2 Overall dimensions in working condition ......................................................................................... 87
5.3 Characteristics of the installation site .............................................................................................. 89
5.4 Secure the work area....................................................................................................................... 91
5.5 Measures to be taken after long stops ............................................................................................ 91
5.6 Checks before starting..................................................................................................................... 92
5.7 EMERGENCY STOP device check................................................................................................. 97
5.8 Machine start-up.............................................................................................................................. 98
5.9 EMERGENCY STOP....................................................................................................................... 99
5.10 Restart after an EMERGENCY STOP........................................................................................... 100
6. Use ......................................................................................................................................................... 101
6.1 Start-up.......................................................................................................................................... 101
6.2 Preparing for use ........................................................................................................................... 103
6.3 Material loading ............................................................................................................................. 106
6.4 Intended use.................................................................................................................................. 109
6.5 Improper use.................................................................................................................................. 111
7. Technical Information............................................................................................................................. 112
7.1 Machine ......................................................................................................................................... 112
7.2 Dimensions and weights................................................................................................................ 112
7.3 Performance data .......................................................................................................................... 113
7.1 Lubricant table ............................................................................................................................... 114
7.2 Noise data...................................................................................................................................... 115
8. Maintenance work .................................................................................................................................. 116
8.1 Safety during maintenance............................................................................................................ 116

8.2 Terminology................................................................................................................................... 118
8.3 Maintenance rules ......................................................................................................................... 119
8.4 Tank capacity and operating fluids................................................................................................ 120
8.5 Inspection and maintenance.......................................................................................................... 121
8.5.1 Lubrication points....................................................................................................................... 122
8.5.2 Loading/discharge conveyor check ........................................................................................... 125
8.5.3 Crusher check............................................................................................................................ 129
8.5.4 Base chassis and crawler tracks ............................................................................................... 133
8.5.5 Diesel engine............................................................................................................................. 135
8.5.6 Hydraulic system........................................................................................................................ 139
8.5.7 Radio remote control ................................................................................................................. 142
8.5.8 Dust suppression system........................................................................................................... 144
8.6 Maintenance plan .......................................................................................................................... 145
8.1 Faults............................................................................................................................................. 148
9. Decommissioning and disposal.............................................................................................................. 149

K-JC 503
Introduction
Instructions
321790
EN - 7
1. Introduction
1.1 Instructions
For whom
These instructions are intended for K-JC 503 managers,
transporters, installers, operators and technicians. The
instructions must be available to this group of people.
Objective
These instructions primarily help to ensure the safety of all
persons working with or on this machine. The main objective is
to avoid personal injury.
Read and learn the instructions before working with or on this
machine.
If any doubts or questions arise, contact your supervisors,
dealers or the manufacturer.
The instructions will help you to correctly operate and maintain
the machine. You will also find instructions in this manual on how
to use the machine economically and in an environmentally
friendly manner.
Summary
The table of contents is structured as follows:
1. Introduction
2. Safety
3. Description
4. Transport
5. Preparation for use
6. Use
7. Technical Information
8. Maintenance work
9. Decommissioning and Disposal

Introduction
Instructions
K-JC 503
EN - 8
321790
Identification
For clear identification of the instructions, the following are indicated
on each page:
Machine type in the header
Edition number in the footer
1
2

K-JC 503
Introduction
Instructions
321790
EN - 9
1.1.1 Structure and concept
Chapter
The table of contents of these instructions is structured in several
chapters.
The division takes into account the legislation in force as well as
the different operational steps and the groups of persons
envisaged for this purpose.
The operational steps and groups of persons are clearly defined
and named in these instructions.
The groups of persons are differentiated according to their
training and authorisation.
Safety Chapter
The Safety chapter is very important.
The Safety chapter takes into account the legislation in force as
well as the different chapters and possible situations that may
arise.
Likewise, the Safety chapter is expanded by the results of the
risk analysis and their subsequent assessment and the
remaining residual risks.
The Safety chapter must have been read and understood by all
persons and groups of persons working with or on the machine
and the information and orders must be observed.
Description Chapter
The Description chapter is very important.
The Description chapter explains the machine in detail.
All other chapters are based on the information in the Description
chapter.
The Description chapter is subdivided according to the
construction units of the machine.
The study or knowledge of the information provided is a
prerequisite for safe and economical operation.
Activity chapters
Transport, Installation, Use and Dismantling are so-called
"Activity Chapters".
The structure of all activity chapters is identical:
Safety
Safety is the first section of each activity chapter.
First, a warning is given of the remaining residual risks,
according to the results of the risk analysis and the subsequent
assessment.
Specific texts from the Safety chapter are mentioned.
Authorised persons, persons to be instructed, personal
protective clothing as well as the predominant danger zones are
named.

Introduction
Instructions
K-JC 503
EN - 10
321790
Activity
Activity is carried out according to a traffic light pattern:
Requirements
Designates conditions, status and preparatory work that must
be carried out or performed in order to achieve the objective.
Objective
Names the objective to be achieved by the
procedure.
Procedure
Names the procedure that is to be carried out to achieve the
stated objective.
Annex chapter
The Annex chapter contains further information.
Additional information may be: Manufacturer's documentation,
drawings, circuit diagrams, sheets etc.
Chapter Without content
“Chapter without content” means that the documentation present
sets this chapter aside, depending on which group of people you
belong to.
The operator's task is only to operate the machine. It is not
his/her task to transport, install/uninstall, perform maintenance,
etc. He/she normally does not have the required experience,
professional training or authorisation.
There are instructions for all named activities and for authorised
groups of persons:
Transport instructions
Assembly instructions
Maintenance instructions
Repair instructions