Powerscreen XA750S User manual

XA750S JAW CRUSHER
SUBJECT TO CHANGE WITHOUT PRIOR NOTICE
Original Instructions
Issue Date: 14.02.2012
Language: English (en)
Revision No.: 1.0
Reference No: XA750S-01
Operations Manual

160412
USER MANUAL
OPERATION
SET-UP
TRANSPORT
nSAFETY
This manual contains safety information which the operator should read and follow.
Failure to do this will increase the risk of injury or may result in death. This user manual is
part of the plant and must always be available wherever the plant is in use and kept with it
at all times.
EN - English
SERVICING
LUBRICATION
WEAR PARTS
XA750S
XA750S Rev 1.0

i
Powerscreen® XA750S
EN
01
EN
Introduction
Introduction to User Manual ----------------------------------------01-2
Safety Warnings and Symbols --------------------------------------01-3
Designated Use of Machine ----------------------------------------01-4
Additional Information and Features ----------------------------------01-5
AM0009 Fuel Transfer Pumps [EN] -------------------------------------- AM0009-1
AM0010 M.C.S. Belt Weigher BW100 [EN] ------------------------- AM0010-1
AM0011 Water Pump [EN] ------------------------------------ AM0011-1
02
EN
Safety Notices and Hazards
Safety Notices -------------------------------------------------02-2
Safety Information -----------------------------------------------02-6
Organisation Measures -------------------------------------------02-7
Selection and Quali󰘰cation of Personnel - Basic Responsibilities --------------02-8
Safety Instructions Governing Speci󰘰c Operational Phases------------------02-9
Warning of Special Dangers---------------------------------------02-12
Safety Signs --------------------------------------------------02-16
03
EN
General Information
General ------------------------------------------------------03-2
EC Conformity -------------------------------------------------03-2
Units of Measure------------------------------------------------03-3
Copyright -----------------------------------------------------03-3
Operating Temperature -------------------------------------------03-4
Information and Advice -------------------------------------------03-4
04
EN
Plant Speci󰘰cation and Information
Dimensions ---------------------------------------------------04-2
Plant Description------------------------------------------------04-3
Weights ------------------------------------------------------04-3
Plant Components-----------------------------------------------04-4
Jaw Crusher ---------------------------------------------------04-8
06
EN
General Screen Icons
Plant Icons ----------------------------------------------------06-2
10
EN
Preparing to Move the Plant
Initial Preparation -----------------------------------------------10-2
Preparing for Loading [Engine stopped]----------------------------------10-3
Product Conveyor -----------------------------------------------10-5
Dirt Conveyor [If 󰘰tted] ---------------------------------------------10-8
Hopper------------------------------------------------------10-10
Safety Grid ---------------------------------------------------10-11
Maintenance Platforms ------------------------------------------10-12
Secure Loose Items --------------------------------------------10-13
Set Plant to Track Mode -----------------------------------------10-14

ii
Manual Contents
11
EN
Unloading and Loading - Transport Trailer
Unloading from Trailer --------------------------------------------11-2
Loading on to Trailer ---------------------------------------------11-3
12
EN
Moving the Machine [‘860’ control]
Moving the machine on the tracks------------------------------------12-2
Initial Preparation -----------------------------------------------12-2
Preparing Umbilical Control ----------------------------------------12-3
Preparing Radio Control [if 󰘰tted] -------------------------------------12-4
Manoeuvring the Machine -----------------------------------------12-6
Finish Manoeuvring the Machine -----------------------------------12-10
14
EN
‘860’ Radio Remote Control
Operation [if 󰘰tted] ----------------------------------------------------------14-2
Battery Recharging ----------------------------------------------14-3
Battery Replacement ---------------------------------------------14-4
15
EN
Engine Stop
Switching o󰘯 engine ---------------------------------------------15-2
16
EN
Emergency Stop
Emergency Stopping the Machine -----------------------------------16-2
Re-Setting Emergency Stops ---------------------------------------16-3
Testing Emergency Stops -----------------------------------------16-4
17
EN
Preparing to Crush
Plant Location Considerations --------------------------------------17-2
Initial Preparation -----------------------------------------------17-3
Hopper-------------------------------------------------------17-5
Secure Hopper -------------------------------------------------17-6
Dirt Conveyor [if 󰘰tted] ---------------------------------------------17-7
Crusher Safety Grid----------------------------------------------17-8
Product Conveyor -----------------------------------------------17-9
Access Platforms and Ladders -------------------------------------17-11
18
EN
Loading the Vibrating Feeder Hopper
Correct Loading of Hopper -----------------------------------------18-2
20
EN
Crusher Operation
Starting to Crush Material -----------------------------------------20-2
Starting the Plant -----------------------------------------------20-3
Product Conveyor -----------------------------------------------20-6

iii
Powerscreen® XA750S
EN
Crusher ------------------------------------------------------20-8
Dirt Conveyor [if 󰘰tted] --------------------------------------------20-10
Vibrating Feeder -----------------------------------------------20-12
Setting the Speed of the Vibrating Feeder -----------------------------20-14
Finishing Plant Start Up ------------------------------------------20-16
21
EN
Operation - Adjusting and Setting
Measuring Discharge Opening --------------------------------------21-2
Adjustment System ----------------------------------------------21-3
Adjusting Discharge Opening ---------------------------------------21-4
22
EN
Operation - Clearing Blockages
Clearing Blocked Crusher -----------------------------------------22-2
23
EN
Plant Alarms
Active Plant Alarms ----------------------------------------------23-2
24
EN
Daily Plant Checks
Checks Prior to Daily Start -----------------------------------------24-2
25
EN
Dust Suppression System
Dust Suppression Water Spray System [if 󰘰tted] --------------------------------25-2
26
EN
Re-fuelling
Check Fuel Level and Fill Up ---------------------------------------26-2
27
EN
Feeder Stop and Start [‘860’ Radio Remote]
Radio Remote Control - Feeder Stop & Start, [if 󰘰tted] ----------------------27-2
31
EN
Preparing to Finish Crushing
Normal Closing Down the Plant -------------------------------------31-2
32
EN
Clearing a Stalled Jaw Crusher
Stalled Jaw Crusher ---------------------------------------------32-2
33
EN
Initial Checks - Running In
Initial Start-Up--------------------------------------------------33-2
Actions During Running-In Period ------------------------------------33-3
34
EN
Jaw Crusher Checks
Jaw Crushers --------------------------------------------------34-2
Wear Checks --------------------------------------------------34-2
Routine Inspection Checks-----------------------------------------34-4

iv
Manual Contents
40
EN
Servicing Safety and Precautions
Servicing Safety Information----------------------------------------40-2
41
EN
Servicing - Lubrication
Lubrication Requirements -----------------------------------------41-2
Lubrication and Hydraulic System Schedule ----------------------------41-4
Ambient Temperature Variations -----------------------------------41-10
42
EN
Lubricant and Fluid Speci󰘰cations
Lubricant Oil Speci󰘰cations ----------------------------------------42-2
Grease Speci󰘰cations --------------------------------------------42-4
Hydraulic Fluid Speci󰘰cations---------------------------------------42-6
43
EN
Servicing Vibrating Hopper Feeder
Vibrating Hopper Feeder - Servicing ----------------------------------43-2
44
EN
Servicing Jaw Crusher
Jaw Crusher Lubrication ------------------------------------------44-2
45
EN
Servicing Vee Belts
General ------------------------------------------------------45-2
Alignment -----------------------------------------------------45-3
Adjustment ----------------------------------------------------45-4
Replacement --------------------------------------------------45-7
Drive Belt Tension-----------------------------------------------45-8
Fault Finding--------------------------------------------------45-10
46
EN
Servicing Conveyors
Magnetic Separator [if 󰘰tted] -------------------------------------------------46-2
Training of Belts ------------------------------------------------46-3
Conveyor Belt Tensioning -----------------------------------------46-4
Inspection of Conveyors ------------------------------------------46-6
Lubrication ----------------------------------------------------46-8
Cleaning Conveyor Belts ------------------------------------------46-9
47
EN
Servicing of Tracks
Plant Tracks ---------------------------------------------------47-2
Adjusting Track Tension ------------------------------------------47-4
Drive Oil Draining & Filling -----------------------------------------47-6

v
Powerscreen® XA750S
EN
48
EN
Servicing Clutch type ‘G’
Engine Power Transmission----------------------------------------48-2
49
EN
Servicing Magnetic Separator
Magnetic Separator - General [if 󰘰tted] ----------------------------------------49-2
Inspection-----------------------------------------------------49-2
Servicing -----------------------------------------------------49-3
50
EN
Servicing Electrical System
General ------------------------------------------------------50-2
Battery Replacement ---------------------------------------------50-3
51
EN
Servicing Hydraulic System
General ------------------------------------------------------51-2
Hydraulic Fluid Level ---------------------------------------------51-3
Suction Filter --------------------------------------------------51-4
Return Filter ---------------------------------------------------51-6
Tank Breather--------------------------------------------------51-7
Pressure Filters [if 󰘰tted]-----------------------------------------------------51-8
60
EN
Replacing Worn Jaws
Jaw Replacement -----------------------------------------------60-2

vi
Manual Contents

01-1
Introduction to the Machine
EN
01
EN
Introduction

01-2
Introduction to the Machine
Introduction to User Manual
1. This instruction manual contains important
information on how to operate the machine
safely, properly and most e󰘲ciently.
2. To be assured of faultless operation we would
ask you to carefully read the manual and give
the required time and attention to essential
maintenance, cleaning and inspection.
3. Observing these instructions and exercising
common sense helps to avoid danger, to
reduce repair costs and down time and to
increase the reliability and life of the machine.
Failure to do so may invalidate any warranties
in force.
4. This manual is part of the machine and must
always be available wherever the machine is in
use and kept with it at all times.
5. These operating instructions must be read and
applied by any person in charge of and/or
working on the machine such as:-
Operation
6. Includes manoeuvring, setting up, operation
during the course of work, evacuation of
production material and waste, care and
disposal of fuels and consumable items, etc.
Servicing
7. Servicing, lubrication, inspection and
adjustments.
Transport
8. Follow all applicable laws and safety regulations
for accident prevention and environmental
protection.

01-3
02
Introduction to the Machine
EN
Safety Warnings and Symbols
9. The following signs and designations are used
in the manual to designate instructions of
particular importance.
n
This is the safety alert symbol. When
you see this symbol on the machine or
in this manual be alert to the potential for
personal injury or equipment damage.
Follow the recommended precautions and
safe operating practices.
nDANGER
Indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
nWARNING
Indicates a potentially hazardous situation
which, if not avoided, could result in death
or serious injury.
nCAUTION
Indicates a potentially hazardous situation
which, if not avoided, may result in minor
or moderate injury. It may also be used to
alert against unsafe working practices.
NOTICE
Indicates a statement of company
policy as the message relates directly or
indirectly to the safety of personnel and
protection of property.

01-4
03
Introduction to the Machine
Designated Use of Machine
10. Tracked crusher machines are designed
exclusively as a self-contained mobile unit for
crushing materials in a wide range of quarry
applications, within the parameters set out and
described within this manual. It is also possible
for some models to be used in demolition and
recycling applications.
11. The machine is intended to be used only in
above ground open air environments. Use of
the machine in any other way is contrary to its
intended use.
nWARNING
This machine is designed for stone
crushing applications. It is vitally important
that large pieces of steel or similar
uncrushable objects are not allowed to
enter the crushing chamber as severe
damage and injury may occur. The
machine is not designed to accept large
pieces of steel or other uncrushable
objects such as bucket teeth from a
loading shovel.
12. Operating the machine outside it’s
recommended range of applications and
operating parameters shown will result in a loss
of guarantee and the manufacturer/supplier
cannot be held liable for any damage resulting
from such use. The risk of such misuse lies
entirely with the user.
NOTICE
If you have any doubts about any aspect
of the machine’s capability or servicing
procedures, you must consult your local
Powerscreen® dealer or Powerscreen®
technical support.

01-5
Introduction to the Machine
EN
Additional Information and Features
THESE CHANGES MAY AFFECT THE INFORMATION GIVEN IN THIS MANUAL.
CHECK FOR ANY ADDENDUM OR BULLETIN WHICH IS INCLUDED IN THIS
SECTION TO SUPPORT THESE VARIATIONS.
TAKE NOTE OF ANY VARIATIONS AS THEY MAY AFFECT PROCEDURES.
MACHINES CAN VARY IN SPECIFICATION.
The machine may have several changes such as:
OPTIONAL EQUIPMENT
SPECIAL FEATURES
ADDITIONAL FEATURES OR INFORMATION
MODIFICATIONS

01-6
Introduction to the Machine

AM0009-1
Fuel Transfer Pump [if 󰘰tted]
EN
Addendum to User Manual
Operating Instructions
Introduction and Speci󰘰cation
1. This is available as originally 󰘰tted equipment
installed at the time of machine manufacture.
2. The pump is for the purpose of transferring
diesel fuel from a fuel container positioned at
ground level alongside the machine fuel tank.
3. The pump is permanently mounted in a suitable
position on the machine in the vicinity of the
engine and is electrically driven from a 24v DC
supply. The unit is 󰘰tted with an integral on/o󰘯
switch.
4. Also supplied as part of the kit are lengths of
plain hose 25mm (1in) bore for suction [with
strainer] and delivery.
5. The 2573-7002 pump is suitable for equipment
with diesel fuel tanks between 200 and 500
litres (53 and 132 US gallons). Flow is 50 l/min
(13.2 US gal/min)
6. The 2573-7014 pump is suitable for equipment
with diesel fuel tanks between 500 and 1000
litres (132 and 264 US gallons). Flow is 100 l/
min (26.4 US gal/min)
7. Duty is continuous up to 40°C (104°F) ambient,
self priming dry up to 3m (9.8 ft) head.
Maximum head 10m (32.8 ft).
nDANGER
Do not use the fuel transfer pump for any
other purpose than 󰘰lling the diesel fuel
tank.
Observe the safety instructions in these
instructions plus safety and information
given in the re-fuelling section of the
machine user manual.
AM0009 Fuel Transfer Pumps [EN]

AM0009-2
1
2
3
Fuel Transfer Pump [if 󰘰tted]
1. DO NOT USE A TRIGGER NOZZLE FOR
DELIVERY INTO THE FUEL TANK.
2. FLASHPOINT BELOW 37°C (99°F)
PETROL
GASOLINE
BENZINE
3. FLASHPOINT ABOVE 37°C (99°F)
DIESEL
GAS OIL
FUEL OIL
SAFETY

AM0009-3
4
5
6
7
Fuel Transfer Pump [if 󰘰tted]
EN
INSTALLATION & USE
4. CONTINUOUS DUTY AT 40°C (104°F)
5. TEMPERATURE RANGE
6. DO NOT ALLOW THE PUMP TO RUN DRY.
7. SWITCH OFF IMMEDIATELY DELIVERY OF
THE FUEL IS COMPLETED.

AM0009-4
Fuel Transfer Pump [if 󰘰tted]
Top Up With Fuel
NOTICE
Do Not 󰘰ll the tank to over󰘱ow or full
capacity.
Allow room for expansion and wipe up
spilt fuel immediately.
1. Check the fuel gauge on the machine.
2. Observe all safety warnings.
3. Follow the instructions to re-fuel in the machine
user manual
4. Connect both hoses to the pump and insert the
suction hose into the fuel supply.
5. Remove the 󰘰ller cap and insert the delivery
hose into the machine fuel tank.
6. Operate the switch on the pump to top up the
fuel tank. Use only in accordance with the
introduction and speci󰘰cation.
7. When re-fuelling is complete, switch o󰘯 the
pump and stow the hoses.
8. Replace the 󰘰ller cap.
9. If the machine is to be operated, refer to engine
starting in the user manual to start up.
10. If the machine is not being used, set the
isolation switch to the ‘0’ position.
nDANGER
Diesel fuel is highly 󰘱ammable and is an
explosion/burns hazard. NEVER remove
the 󰘰ller cap or re-fuel, with the engine
running.
NEVER add petrol, gasoline or any other
fuel mixes to diesel because of increased
󰘰re or explosion risks.
DO NOT smoke while re󰘰lling or carrying
out maintenance on the fuel system. DO
NOT carry out maintenance on the fuel
system near naked lights or sources of
sparks, such as welding equipment.