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
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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
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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
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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.

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Instructions
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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

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Instructions
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1.1.2 Symbols used
Information
Indicates information regarding the use of this machine.
The information should make it easier to use this machine.
Press button
This symbol is used when you need to press a button or click a
key.
Visual check
Visual checks are used to determine visible damage and help to
protect people and the environment from hazards and prevent
other material damage.
Acoustic check
Acoustic checks are used to determine abnormal noises and
help to detect damage over time.
Visual leakage check
Visual leakage checks help to detect leaks over time and prevent
downtimes due to machine faults.
These help safeguard resources and avoid environmental
damage.
1.1.3 Definitions used
Hazard
A potential source of injury or damage to health.
Danger zone
Any zone within and/or around machinery in which a person is
subject to a risk to his health or safety.
Risk
A combination of the probability and the degree of an injury or
damage to health that can arise in a hazardous situation.
Intended use
The use of machinery in accordance with the information
provided in the instructions for use.
Reasonably foreseeable misuse
The use of machinery in a way not intended in the instructions
for use, but which may result from readily predictable human
behaviour.

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Instructions
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1.1.4 Additional documents
Manufacturer documentation
- CE Declaration of Conformity
- Spare parts manual
- Electrical system diagram
- Hydraulic system diagram
Supplier documentation
- Propulsion engine

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Introduction
The machine
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1.2 The machine
Conformity
With K-JC 503, you have purchased a product that has achieved
a level of safety and technological development that is among
the most advanced.
With our CE Declaration of Conformity, included in the “Annex”
chapter, we confirm that the K-JC 503 meets the essential health
and safety requirements of the relevant EC Machinery Directive.
Intended use
This machine is designed to crush various types of material. The
maximum size indicated must not be exceeded. The permissible
material and the maximum size are specified.
The machine must be placed on flat, solid subsoil with sufficient
grip and bearing capacity.
If you need to process materials that are not listed below, please
contact your dealer or the manufacturer's technical department.
Only reliable, authorised, trained and instructed persons may
work on or with this machine.
Only use the machine if it is in perfect working order and in
accordance with its intended use, observing the safety
instructions and the manual! Immediately rectify any faults which
could impair safety!
Intended use also includes observing the safety procedures and
instructions described in this manual.
Incorrect use is prohibited!
Reasonably foreseeable misuse
The following are considered to be misuse:
Loading and processing of material that is not
permissible.
Loading and processing of material that is permissible but
exceeds the maximum size.
Working with or on the machine without permission or
training.
Working with or on the machine when not all
EMERGENCY STOP devices are complete and fully
operational.
Working with or on the machine when not all protective
devices are fully operational.
Working with or on the machine when not all the alarm
devices are complete and fully operational.

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The machine
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Permissible material
Only the following materials can be loaded and processed with this
machine.
Aggregates from demolition and renovation work in
construction
Waste from marble processing
Waste from cement processing
Maximum size
The maximum size allowed
Modifications or changes
Modifications or changes to the machine are prohibited and entail
the exclusion of the manufacturer's liability if personal injury or
damage to property occurs as a result.
The validity of the CE Declaration of Conformity according to the
Machinery Directive 2006/42/EC shall also cease.
Use of a modified machine within the scope of the aforementioned
directive is inadmissible and prohibited. The manager is responsible
for this.
Signs
The K-JC 503 must be marked for different purposes according to
the requirements of the machinery directive.
It must be ensured that the machine signs are complete and in
legible conditions.
A list with the machine signs and their positions can be found in
chapter 3 “Description” in the "Signs" section.

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Introduction
The machine
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Rating plate
The rating plate is riveted to the machine frame on the front right-
hand side.
Use the rating plate to check whether you have valid documentation
for the machine.

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Work
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1.3 Work
1.3.1 Qualified personnel
Select personnel
All work with and on the machine must be carried out by reliable,
authorised, trained and instructed personnel.
Minimum legal age
Age limits must be complied with as per regulations.
Groups of people
Different groups of people work on the machine, taking into
account the operating phases of the machine.
With regard to K-JC 503, these groups are divided into:
Transporters
Installers
Operators
Technicians
Clarifying competences
Explain the limits of their competence and authorisation to the
different groups of people.
Transporters
Installers
Operators
Technicians
Transport
X
Preparation and loading works
X
Inspection
X
X
X
Use
X
Troubleshooting
X
(X)
X
Maintenance
X
X
Repairs
X
Dismantling and Disposal
X
Instruct personnel
In particular, personnel must be instructed in the risks and

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Introduction
Work
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possible dangers involved in using this machine.
1.3.2 Due diligence
Employ qualified
personnel
Persons working on this machine must be qualified according to
their activities and must be trained (see previous section). The
manager is responsible for ensuring that appropriate personnel
are employed, applying the relevant instructions and checks.
Wear
protective clothing
In particular, personnel working with this machine must wear
protective and properly fitted clothing (EN/ANSI approved) at all
times. The manager is responsible for ensuring that protective
clothing is worn, applying the relevant instructions and checks.
Take the site into account
All local regulations, all possible safety rules for accident
prevention and environmental protection must be added to these
instructions. Behave according to the existing conditions on site
and according to the instructions.
Maintain order
Keep the workplace in order. The manager is responsible for
ensuring that the workplace is clean and tidy, applying the
relevant instructions and checks.
Read the instructions
Read and understand all instructions before working with or on
this machine.
Read, understand and follow the indications in the instructions or
manuals delivered with the machine.
The manager is responsible for ensuring understanding of the
contents of this manual and for applying the relevant instructions
and checks.
Only use the machine if it is in
perfect working order
Only use the machine if it is in perfect working order in
accordance with its intended use, in compliance with the safety
instructions and after carrying out the described work steps. The
manager is responsible for ensuring that the machine is in
perfect working order, following the relevant instructions and
checks.
Check the danger zone
Talk a walk around the machine before starting the engine. Make
sure that nobody and nothing is in the danger zone. Do not start
the machine as long as people, objects or obstacles are in the
danger zone.
There are different danger zones depending on the various
activities carried out on the machine.
An overview of the danger zones can be found in the “Safety”
chapter. The existing danger zones according to the operating
phase or activity can be found at the beginning of each specific
chapter.
Report defects and damage
The operator is responsible for reporting changes or damage to
the machine to the manager. The same applies to changes in
the operating behaviour of the machine as well as any unsafe

Introduction
Work
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working conditions.
The machine must be stopped immediately if any safety-related
operating faults or faults in the machine's behaviour are noted.

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Introduction
Work
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Report defects and damage
The manager is responsible for rectifying defects and damage
immediately.
Worn, damaged or broken parts, leaking hoses, damaged cables
or connectors must be replaced or repaired immediately.
Repair components only after approval.
Check the protective and safety
devices
Only use the machine when all protective and safety devices
(cladding, EMERGENCY STOP buttons, limit switches,
soundproofing devices, exhaust system) have been installed
correctly and are fully operational.
If preparation, maintenance or repair work requires the
dismantling of protective or safety devices, these must be
reinstalled and checked immediately after work has been
completed.
Never modify a protective or safety device or create a bridge.
Follow the disengagement
procedure
There must be no material in the machine before you switch it
off.
In an emergency, switch off the machine using one of the
EMERGENCY STOP buttons.
Do not use the EMERGENCY STOP buttons or lines for a
regular machine stop.
1.3.3 Behaviour in the event of faults
Malfunction
In the event of a malfunction, stop and secure the machine
immediately.
Eliminate any malfunction immediately!
EMERGENCY STOP
If the malfunction cannot be eliminated from the control station,
press the EMERGENCY STOP button.
Lock and mark
If there is no malfunction that can be cleared quickly, disengage
the machine with the main switch. Lock the main switch and
remove the key. Mark the machine with a warning sign.

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Work
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1.3.4 Maintenance and service work
Use original parts
Original parts and accessories are specially designed for the
machine.
Parts and accessories that are not supplied by the manufacturer
have not been tested and approved by the manufacturer. The
assembly and use of these products may alter the characteristics
of the machine as defined by the construction and may also
compromise safety.
It must be considered that the manufacturer or supplier parts are
often subjected to particular production and supply standards.
We only offer replacement parts that are equipped with the latest
technology and comply with the applicable standards.
Our warranty applies exclusively to original spare parts supplied
by us.
We explicitly warn that we accept no liability for spare parts and
accessories not supplied by us.
Employ
specialised personnel
The manager of the machine is responsible for ensuring that the
specific skills of the person/s hired are in accordance with the
current state of the art and professional training.
Environmental protection
We take environmental protection seriously. Even during
machine design and production, we as a manufacturer have paid
particular attention to the economical use of resources and the
elimination of pollutants. We comply with legal guidelines.
Exemption from liability
Damage caused by using non-original parts and accessories or
by incorrect assembly or replacement of original parts and
accessories; in this case the manufacturer accepts no liability.