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