SMA 110J Manual

SMA 110J
Twin Feeders (Mog) with C13 Engine
OPERATION & MAINTENANCE
MANUAL
Subject to change without notice.
O & M 04/2019 Issue –Original. (English)

SMA 110J (C13) O&M 04-2019
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FOREWORD/RESERVATION OF RIGHTS:
The SMA 110J Mobile Crushing Plant is a robust, skilfully engineered piece of equipment incorporating diesel,
hydraulic and mechanical components of the highest quality.
In the interest of continuous plant reliability, it is essential that the machine is maintained with meticulous care and
attention. This operation and maintenance manual has been produced to assist the user to obtain the maximum
output from the machine and to trace and remedy faults, should they arise. Failure to do so could result in personal
injury or equipment damage.
We strongly insist that the owners, operators, health & safety staff and all personnel associated with this machine,
must read and understand all aspects of this manual and pay particular attention to the safety and maintenance
sections.
Keep a copy of this manual at the operational site at all times.
While all the information, illustrations and specifications in this manual are based on the latest information available
at the time of publication, some variations do exist between machine specifications. Therefore, some of the
information may be slightly inaccurate.
Future updated issues of this manual or manuals belonging to other SMA equipment, will not be specific to all
machines. SMA reserve the right to change the specification of their equipment and therefore reserve the right to
alter any information contained in this manual without prior notice.
MACHINE DESIGNATED USE:
This machine is a portable, self-contained, material crushing plant. Typical materials include rock, ore, gravel, coal
and recycled materials. If you need to crush any other material not listed please contact SMA.

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CONTENTS.
SECTION 1.0: FAMILIARISATION.
1.1 MAIN ASSEMBLY DESCRIPTIONS & ORIENTATION.
1.2 TECHNICAL SPECIFICATION.
1.3 MAIN CONTROL PANEL FAMILIARISATION.
1.4 CRUSHER UNIT FAMILIATISATION.
1.5 IMPORTANT FEATURES OF THIS MACHINE.
1.6 FAMILIARISATION OF OPERATION LABELS DISPLAYED ON THE MACHINE.
SECTION 2.0: SAFETY.
2.1 SAFETY INTRODUCTION.
2.2 SAFETY WARNING LABELS.
2.3 SAFETY HAZARDS.
2.3.1 WORKING AT HEIGHTS.
2.3.2 NIP/CRUSH POINTS.
2.3.3 MATERIAL FALLING FROM HEIGHTS.
2.3.4 MOVING THE MACHINE.
2.3.5 SLIPPERY SURFACES.
2.3.6 DIESEL FUMES.
2.3.7 ELECTRICAL SAFETY.
2.3.8 NOISE.
2.4 HAZARD ZONE.
2.5 LOCKOUT PROCEDURE.
2.6 EMERGENCY STOPS LOCATIONS.
2.7 EMERGENCY SHUT DOWN.
2.7.1 RE-START PROCEDURE AFTER EMERGENCY SHUT DOWN.
2.8 SAFETY BEFORE AND DURING TRACKING.
2.9 SAFETY BEFORE AND DURING SET-UP.
2.10 SAFETY BEFORE AND DURING OPERATION.
2.11 SAFETY BEFORE AND DURING MAINTENANCE.
2.11.1 SAFETY WHEN WORKING WITH HYDRAULICS.
2.11.2 SAFETY WHEN WORKING WITH BATTERIES.
2.11.3 SAFE DISPOSAL OF WASTE PRODUCTS.
SECTION 3.0: ENGINE START-UP INSTRUCTIONS.
3.1 IMPORTANT CHECKS PRIOR TO STARTING THE ENIGNE.
3.2 ENGINE START UP PROCEDURES.
SECTION 4.0: TRACKING INSTRUCTIONS.
4.1 SAFETY BEFORE AND DURING TRACKING.
4.1.1 TRACKING THE MACHINE USING THE DOGLEAD.
4.1.2 TRACKING THE MACHINE USING THE REMOTE CONTROL.
SECTION 5.0: INSTALLATION.
5.1 INSTALLATION OVERVIEW.
5.2 INSTALLATION PROCEDURES.
5.3 STEP 1: UNLOAD THE MACHINE.
5.4 STEP 2: POSITION THE MACHINE INTO THE DESIRED LOCATION.
5.5 STEP 3: ACTIVATE THE HYDRAULIC RAMS.
5.6STEP 4: LOWER THE JACKING LEGS.
5.7STEP 5: FIT THE PRE-CLEANER.
5.8STEP 6: REMOVE ALL TRANSPORT BRACKETS, TIE STRAPS AND SPARE PARTS.
5.9STEP 7: FOLD UP THE CRIBS.
5.10 STEP 8: FIT THE FEED IN CHUTE GRID FRAME.
5.11 STEP 9: FOLD OUT THE DIRT CONVEYOR.
5.12 STEP 10: FIT THE WORKING LIGHTS.
5.13 STEP 11: CONNECT THE DUST SUPPRESSION.
5.14 STEP 12: FOLD UP THE PRODUCT CONVEYOR HEAD SECTION.
5.15 STEP 13: LOWER THE PRODUCT CONVEYOR BOTTOM END.
5.16 STEP 14: SET THE TROUSER CHUTE POSITION.
5.17 STEP 15: SET THE CRUSHING SIZE.
5.17.1 RELEASING THE TOGGLE SPRING TENSION.
5.17.2 ADJUSTING THE CRUSHER SIZE.
5.17.3 ENGAGE THE TOGGLE SPRING TENSION.
5.18 STEP 16: ADJUST THE PRODUCT CONVEYOR AND DIRT CONVEYOR BELTS.
5.18.1 BELT TENSIONING.
5.18.2 BELT TRACKING (ALIGNMENT).
SECTION 6.0: OPERATION.
6.1 OPERATION OVERVIEW.
6.2 IMPORTANT CHECKS PRIOR TO OPERATING THIS MACHINE.
6.3 MACHINE START-UP SEQUENCE.

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CONTENTS CONTINUED.
6.4 CONTROLLING THE SPEED OF THE FEEDER.
6.5 CONTROLLING THE SPEED OF THE MAGNET.
6.6 CONTROLLING THE SPEED OF THE DIRT CONVEYOR.
6.7 MACHINE SHUT-DOWN SEQUENCE.
SECTION 7.0: MAINTENANCE.
7.1 GENERAL MAINTENANCE INFORMATION.
7.2 DAILY MAINTENANCE.
7.3 VISUAL CHECKS DURING OPERATION.
7.4 WEEKLY MAINTENANCE.
7.5 LUBRICATION POINTS.
7.6 LUBRICATION SCHEDULE.
7.7 AUTOMATIC LUBRICATION
7.7.1 AUTOLUBE OVERVIEW.
7.7.2 AUTOLUBE MAINTENANCE.
7.7.3 CLEANING THE AUTOLUBE SYSTEM.
7.7.4 FILLING THE GREASE RESERVOIR.
7.7.5 TEST RUN / MANUAL LUBRICATION.
7.7.6 AUTOLUBE FAULT FINDING.
7.8 SERVICE SCHEDULE:
7.8.1 OIL & FLUID REPLACEMENT QUANTITIES:
7.8.2 RECOMMENDED LUBRICANTS
7.9 ENGINE MAINTENANCE.
7.9.1 ROUTINE DAILY ENGINE MAINTENANCE.
7.10 MANUAL CLUTCH MAINTENANCE.
7.10.1 MANUAL CLUTCH LUBRICATION.
7.11 HYDRAULIC CLUTCH MAINTENANCE.
7.12 TRACKS MAINTENANCE:
7.12.1 CHECKING THE TRACK TENSION:
7.12.2 INCREASING THE TRACK TENSION.
7.12.3 RELEASING THE TRACK TENSION.
7.12.4 TRACKS GEARBOX MAINTENANCE.
7.12.5 CHECKING AND FILLING THE GEARBOX OIL.
7.12.6 DRAINING THE GEARBOX OIL.
7.13 HYDRAULIC OIL SYSTEM MAINTENANCE.
7.13.1 CHECKING THE HYDRAULIC OIL LEVEL.
7.13.2 CHANGING THE HYDRAULIC OIL FILTERS.
7.13.3 HYDRAULIC OIL SERVICE.
7.13.4 GENERAL HYDRAULIC SYSTEM MAINTENANCE.
7.14 PRODUCT CONVEYOR GEARBOX MAINTENANCE.
7.14.1 CHANGING THE OIL IN THE GEARBOX.
7.15 CRUSHER DRIVE BELT MAINTENANCE.
7.15.1 DRIVE BELT TENSIONING.
7.16 CONVEYORS MAINTENANCE.
7.17 FEEDER MAINTENANCE (Mogenson).
7.17.1 FEEDER MAINTENANCE (McKenna).
7.17.11 CHECKING THE OIL BATH LUBRICANT LEVEL.
7.17.12 CHANGING THE OIL BATH LUBRICANT.
7.17.13 FITTING ADDITIONAL WEIGHTS TO THE PRIMARY FEEDER.
7.18 CRUSHER UNIT MAINTENANCE.
7.18.1 CHECK FOR SEPERATION OF THE TOGGLE.
7.18.2 CHECK FOR WEAR ON THE TOGGLE AND TOGGLE SEATS.
7.18.3 CHECKING THE WEAR LIMITS.
7.18.4 REPLACING THE FIXED JAW PLATE.
7.18.5 REPLACING THE SWING JAW PLATE.
7.18.6 REPLACING THE SIDE WEAR PLATES.
7.18.7 REPLACING THE TOGGLE.
7.18.8 ACCUMULATOR MAINTENANCE.
7.19 HYDRAULIC SYSTEM LAYOUT.
SECTION 8.0: TRANSPORTATION:
8.1 TRANSPORTATION OVERVIEW.
8.2 PREPARING FOR TRANSPORT SEQUENCE.
8.2.1 STEP 1: CLEAR THE MACHINE OF ALL MATERIAL.
8.2.2 STEP 2: RAISE THE PRODUCT CONVEYOR BOTTOM END.
8.2.3 STEP 3: FOLD UP THE DIRT CONVEYOR.
8.2.4 STEP 4: REMOVE THE FEED IN CHUTE GRID FRAME.
8.2.5 STEP 5: LOWER THE CRIBS.
8.2.6 STEP 6: REMOVE THE PRE-CLEANER AND WORKING LIGHTS.
8.2.7 STEP 7: RASIE THE JACKING LEGS.

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FRONT
LEFT HAND SIDE
REAR
SECTION 1.0
FAMILIARISATION
1.1 MAIN ASSEMBLY DESCRIPTIONS & ORIENTATION.
RIGHT HAND SIDE
Cribs
Scalping Feeder
Engine & Clutch Assembly
Hydraulic Tank
Magnet
Product (Discharge) Conveyor
Primary Feeder
Dirt Conveyor
Main Assembly Descriptions:
(A).
(B).
(C).
(D).
(E).
(F).
(G).
(H).
Trouser Chute
Crusher Unit
Tracks
Jacking Legs
Control Panel
(I).
(J).
(K).
(L).
(M).
Ensure that all personnel are completely
familiar with all aspects of this machine.
CAUTION
!
(A).
(B).
(D).
(C).
(E).
(F).
(H).
(J).
(I).
(K).
(M).
(L).
(G).

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1.2 TECHNICAL SPECIFICATION.
Transport Length: 16900mm
Transport Width: 3450mm
Transport Height: 3850mm
Machine Weight: 61,500kgs (135,584lbs)
NOTE: The weights and dimensions stated here are given for a standard
machine only. Optional extras fitted to the machine and/or transportation
laws in force in various countries, may alter the transportation weight and
dimensions of the machine.
OPERATING DIMENIONS (mm).
TRANSPORT DIMENIONS (mm).
Operating Length: 37610mm
Operating Width: 6190mm
Operating Height: 4480mm
3850
16,900
3850
3,450

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1.3 MAIN CONTROL PANEL FAMILIARISATION.
1) Clutch Start Switch. When this switch
is pressed the clutch will start. Note: This
switch is only present when a KPTO
clutch is fitted to the machine.
2) Feeder Switch. This switch is used to
select either manual or automatic feeder
operation.
Manual feeder operation
Automatic feeder operation
3) Clutch Stop Switch. When this switch
is pressed the clutch will stop. Note: This
switch is only present when a KPTO
clutch is fitted to the machine.
4) Fuel Gauge. This gauge indicates how
much fuel there is in the fuel tank.
5) Engine Display Module. This device
indicates various parameters of the
engine performance. See the engine
manufacturer’s operation & maintenance
manual for more information.
6) Engine Throttle Switch. This switch is
used to increase or decrease the engine
speed. Push the switch up to increase the
engine speed. Push the switch down to
decrease the engine speed. Note: If a
constant speed engine has been fitted to
your machine then there will only be two
engine speed settings: Idle (1000rpm)
and High (1800rpm). Push the throttle
switch up once to increase the engine
speed to ‘High’. Push the throttle switch
down once to decrease the engine speed
to ‘Idle’. With this option, if the engine
speed is reduced the engine must be re-
started before the engine speed can be
increased again.
7) Doglead / Remote Control Key Switch.
This switch is used to select either the
doglead or the remote control for tracking
and operation.
Doglead
Remote Control
8) Dust Suppression Switch. This switch
operates the automatic dust suppression
system. Note: This switch is only present
when a dust suppression system is fitted to
the machine.
9) Autolube Switch. This switch operates the
automatic greasing system. Note: This
switch is only present when an autolub
system is fitted to the machine.
10) Work Lamps ‘On/Off’ Switch. This switch
operates the work lamps. Note: This switch
is only present when working lamps are
fitted to the machine.
Continued on the next page........
(12)
(14)
(16)
(18)
(19)
(21)
(22)
(24)
(13)
(15)
(17)
(20)
(23)
(25)
(3)
(4)
(2)
(1)
(7)
(6)
(8)
(9)
(5)
(10)
(11)

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12) Engine Fault Lamp. When illuminated
‘red’ this indicates a potential engine fault.
See the engine manufacturer’s operation
& maintenance manual for more
information.
13) Diagnostic Lamp.
When flashing orange
this represents a ‘Fault Flash Code’ for the
engine. See the engine manufacturer’s
operation & maintenance manual for more
information.
14) Dust Suppression Lamp.
When
illuminated this indicates that the dust
suppression system is operating. Note:
This lamp is only active when a dust
suppression system is fitted to the
machine.
15) Hydraulic Clutch Engaged Lamp.
When
illuminated green, this indicates that the
hydraulic clutch is engaged. Note:
This
lamp is only active when a KPTO clutch is
fitted to the machine.
16) Maintenance Due Lamp.
When
illuminated this indicates that the engine
requires maintenance. See the engine
operation & maintenance manual for more
information.
17) Emergency Stop Lamp.
When
illuminated green this indicates that no
emergency stops are pressed. If not
illuminated this indicates that an
emergency stop has been pressed.
18) Work Lights Lamp.
When illuminated
this lamp indicates that the work lamps are
turned on. Note:
This lamp is only active
when working lamps are fitted to the
machine.
19) Feeder Run Lamp.
When illuminated this
lamp indicates that the feeders are being
operated manually.
20) Doglead Activated Lamp.
When
illuminated this lamp indicates that the
doglead function has been activated.
21)
1.3 MAIN CONTROL PANEL FAMILIARISATION CONTINUED….
11) Engine ‘Start/Stop’Switch. This switch
starts and stops the engine.
Ignition ‘Off’
Ignition ‘ON’
Engine ‘Start’
21) Hydraulic Oil Level Low Warning Lamp.
When illuminated this lamp indicates that the
level of hydraulic oil in the hydraulic tank has
dropped below a pre-set ‘warning’ limit.
22) Automatic Feeder Run Lamp. When
illuminated this lamp indicates that the
feeders are operating automatically.
23) Remote Control Activated Lamp. When
illuminated this lamp indicates that the
remote control function has been activated.
24) Low Hydraulic Oil ‘Stop’ Lamp. When
illuminated this lamp indicates that the
hydraulic oil level has reached a dangerously
low level. At this point the machine will shut
down.
25) Tracks Activated Lamp. When illuminated
this lamp indicates that the tracking function
has been activated.
!
26) Engine Maintenance Reset Switch (SB1). This
switch is used to reset the ‘engine maintenance due’
lamp after the engine has been serviced.
27) Crusher Sensors Bypass Switch (SB2). This
switch can be used to bypass the crusher speed and
height sensors. This may be required in the event of
damage or malfunction of the sensors. When the
machine is in operation SB2 must remain in the up
position.
28) Speed Relay Control Panel. This interface allows
the settings of the rotor speed relay system to be
changed or re-set.
29) CAT Engine Connection. This plug allows a
computer to be connected to the engine
management system for diagnostics and repair.
30) Control Panel Connection. This plug allows a
computer to be connected to the control panel
management system for diagnostics and repair.
(27)
(26)
(28)
(29)
(30)