manual r800 with mondial cat 7.0

Jaw Crusher R800 -MANSid

Serial number:

NUALe 0

CONTENTCONTENTR800 JAW CRUSHER

Sid

CONTENT:

I P f Sid 2I. Preface Side 2II. Intended use Side 4III Safety Side 6 Safety hazard symbols Side 7Operating instructions Side 13p gMaintenance work Side 24IV.Technical data Side 26Overview Side 27Building groups Side 28V Start up Side 33V. Start up Side 33Operation devices Side 34Transport Side 40 System set up Side 42Gap adjustment Side 45

VI O ti Sid 46VI. Operation Side 46Special operating information Side 47Procedure crusher operation Side 49VII. Maintenance Side 51Hydraulic system Side 52 Di l t Sid 53Diesel motor Side 53Vibration feeder Side 53Caterpillar crawler Side 54Crawler gear Side 54Conveyor belts Side 55V belts Side 55V-belts Side 55Jaw crusher Side 56Welding preparations Side 57Oil level monitor Side 60Service plan Side 62 Recommended oil qualities Side 64Recommended oil qualities Side 64VIII. Standard forms Side 65Rockster warranty registration Side 66CAT warranty registration Side 67Warranty claim Side 68Terms and conditions Side 69

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Terms and conditions Side 69

I PREFACEI. PREFACER800 JAW CRUSHER

SidI. PREFACE

CONTENT:


VI O ti Sid 46VI. Operation Side 46Special operating information Side 47Procedure crusher operation Side 49VII. Maintenance Side 51Hydraulic system Side 52 Di l t Sid 53Diesel motor Side 53Vibration feeder Side 53Caterpillar crawler Side 54Crawler gear Side 54Conveyor belts Side 55V belts Side 55

EV-belts Side 55Jaw crusher Side 56Welding preparations Side 57Oil level monitor Side 60Service plan Side 62 Recommended oil qualities Side 64E Recommended oil qualities Side 64VIII. Standard forms Side 65Rockster warranty registration Side 66CAT warranty registration Side 67Warranty claim Side 68Terms and conditions Side 69

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PREFACE:

This Operator's Manual applies for the track-mRecycler GmbH. The crushers are designed fo

The technical specifications drawings photosThe technical specifications, drawings, photosmay be changed, revised or updated due to fu

The machine owner/operator is responsible to applicable local guidelines and regulations for

This Operator's Manual must be available and

All persons who operate, maintain, repair or traOperator's Manual and must conscientiously oOperator s Manual and must conscientiously o

MMKWPe

SidI. PREFACE

mounted crushing plants R800 manufactured by Kormann Rockster or the processing of virgin stone and recycling material.

and other information contained in this manual are non-binding and, and other information contained in this manual are non-binding and rther technical developments at any time without obligation.

supplement the information contained in this manual with any and all safety prevention and environmental protection.

accessible at the operation site at all times.

ansport the crusher plant must first read and understand this observe and follow the guidelines and regulations.observe and follow the guidelines and regulations.

Manufacturer:Manufacturer:Kormann Rockster Recycler GmbHWirtschaftszeile West 2, A-4482 Ennsdorf / AustriaPhone: +43 (0) 7223 81000 Fax: +43 (0) 7223 81000-329e-Mail: [email protected] Homepage: www.rockster.at

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II INTENDED UII. INTENDED UR800 JAW CRUSHER

SidII. INTENDED USE

CONTENT:



USEV-belts Side 55Jaw crusher Side 56Welding preparations Side 57Oil level monitor Side 60Service plan Side 62 Recommended oil qualities Side 64USE Recommended oil qualities Side 64VIII. Standard forms Side 65Rockster warranty registration Side 66CAT warranty registration Side 67Warranty claim Side 68Terms and conditions Side 69

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INTENDED USE:

The machine is constructed in compliance withthe operation or use of the machine may be comaterial damage to the machine and/or other omaterial damage to the machine and/or other o

Operate the machine only in good order and coregulations and accident-prevention guidelinesCircumstances or technical defects which mayrepaired.

The machine is intended solely for the purposemachine for any other purpose is contrary to thliable for damages arising from such contrary uliable for damages arising from such contrary ucosts and damages which may result from suc

Use of the machine according to the manufactcompliance with all parts of the Operator's Man

SidII. INTENDED USE

h prevailing technical standards and safety regulations. Nonetheless, onnected with hazards which may endanger personal safety or lead to objectsobjects.

ondition and only in the intended manner of use. Observe all safety s according to this Operator's Manual and applicable local regulations. y pose a threat to operational safety must be immediately remedied or

e of crushing, screening, or sorting recycling material. Use of the he manufacturer's intended purpose. The manufacturer/dealer is not use. The customer/operator assumes sole risk and responsibility foruse. The customer/operator assumes sole risk and responsibility for ch contrary use.

turer's intended purpose explicitly includes the observation of and nual and the adherence to inspection and maintenance regulations.

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III SAFETYIII. SAFETYR800 JAW CRUSHER

SidIII. SAFETY

CONTENT:



YV-belts Side 55Jaw crusher Side 56Welding preparations Side 57Oil level monitor Side 60Service plan Side 62 Recommended oil qualities Side 64Y Recommended oil qualities Side 64VIII. Standard forms Side 65Rockster warranty registration Side 66CAT warranty registration Side 67Warranty claim Side 68Terms and conditions Side 69

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SAFETY HAZARD SYMBOLS:

Many of the following symbols appear frequenhazardous situations which may arise when op

Danger of entrapment. Do not reach into open

Entrapment may cause serious or fatal injuries

Body parts can be drawn in and crushed or tor

Be sure that all machinery has come to a comp

Keep in mind the necessary run-down time for V-belts, flywheel, vibro plate, grizzly, pre-scree

Danger of entrapment. Do not reach into open

Entrapment in rotating parts may cause seriou

Body parts can be drawn in and crushed or tor

Be sure that all machinery has come to a compBe sure that all machinery has come to a compIgnition key and battery switch have to be pullepersons.

SidIII. SAFETY

tly in these operating instructions; they call special attention to perating the machine.

machinery.

s.

rn.

plete standstill before opening or removing protective covers.

r rotating/sliding/reciprocating machinery (rotor, jaws, belt pulleys, ener, centrifugal weights, etc.).

machinery.

s or fatal injuries.

rn.

plete standstill before opening or removing protective coversplete standstill before opening or removing protective covers.ed off, the machine has to be protected against start-up by external

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SAFETY HAZARD SYMBOLS (continued):

Crush hazard. Caution is required at points wh

Never use feet, hands, fingers, or other body p

Always use the provided anchors and/or mech

Danger of falling/flying material.

Do not enter loading/discharging zones. Doing

A hard hat must be worn in the immediate vicinA hard hat must be worn in the immediate vicin

Personal hearing protection must be worn.

Never stay, work or go under suspended / han

Use only tested and certified lifting equipment

SidIII. SAFETY

here hands and/or feet can be crushed.

parts to support or hold machine parts.

hanical supports.

g so may cause serious or fatal injuries.

nity of the machine.nity of the machine.

ging load. Any stay is prohibited without exception.

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Wide or loose clothing may be drawn into or ca

Wear EN/ANSI tested correctly fitting protectivWear EN/ANSI tested, correctly fitting protectiv

Personal protective gear includes hard hat, goflourescent safety vest and protective gloves. D

The operator's manual must be read and unde

Read and observe the various warning symbol

Only specially schooled and trained personnel

Turn off the motor and remove the key from thyIgnition key and battery switch have to be pullepersons.

The key and battery switch must be kept on yo

We recommend, to never work alone.

SidIII. SAFETY

aught in moving machinery.

ve clothingve clothing.

ggles, hearing protection, close-fitting overalls, steel-toed boots, Do not wear jewellery.

erstood before operating the machine.

ls on the machine.

may operate or work with the machine.

e ignition before beginning maintenance or adjustment work.g g g jed off, the machine has to be protected against start-up by external

our person during maintenance or repair work.

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Danger of falling: do not climb onto or stand on

Only use the intended upward mobility “ladderOnly use the intended upward mobility ladder

An appropriate work platform must be used wh

Danger of burning or scalding: beware of hot m

Beware of escaping hydraulic oil.p g y

Pressurized hydraulic oil can penetrate the ski

The system must be depressurized before beg

If hydraulic oil has penetrated the skin it must b

SideIII. SAFETY

n the machine when it is moving or in operation.

on the catwalk”on the catwalk .

hen working at heights exceeding 2 m.

machinery or exhaust parts.

n and lead to poisoning.

ginning maintenance or adjustment work.

be surgically removed. Seek professional medical care immediately.

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Personal safety hazard: acids chemicals undPersonal safety hazard: acids, chemicals, und

Personal safety hazard: magnetic field.Personal safety hazard: magnetic field.

Do not allow persons with pacemakers or othe

Personal safety hazard: electrical current.

Danger of serious or fatal injuries.

Never perform work on the electrical system if specifications.p

Only qualified electricians may perform work o

Use only tested and certified lifting equipment

SideIII. SAFETY

caustic fluidscaustic fluids.

er electronic medical devices to enter the danger zone.

you are not thoroughly familiar with all technical details and

on the electrical system.

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These symbols call attention to various regulatsituations, as well as highlight special manufac

SideIII. SAFETY

tions and prohibitions to prevent damage and avoid hazardous cturer's instructions for correct machine operation.

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OPERATING INSTRUCTIONS (continued):

Personal protective equipment must be worn in

In the event of changes to the operating state oIn the event of changes to the operating state omust be stopped and brought to a standstill animmediately rectify the fault or have it rectified,

No changes and assembly or conversion workmanufacturer. This applies in particular for mecwork on load-bearing components.

Replacement and wearing parts must correspois always guaranteed for original and wearing p

Specified schedules and/or those cited in the o

SideIII. SAFETY

n compliance with the regulations to the extent necessary.

of the machine (insofar as these are safety-relevant) the systemof the machine (insofar as these are safety-relevant), the system nd the fault reported to the person responsible; the latter must , and return the system to its correct operating state.

k may be carried out on the machine without authorisation by the chanical, electrical and hydraulic safety devices as well as for welding

ond to the technical requirements specified by the manufacturer. This parts.

operating instructions for recurrent tests must be adhered to.

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OPERATING INSTRUCTIONS

The operating instructions must always be with

Universally applicable statutory and other bindUniversally applicable statutory and other bindenvironmental protection (supplementary to the

These obligations can also concern handling has well as road transport regulations.

The operating instructions must be supplemenwith regard to special operational circumstanceemployed etc.

All persons authorised for work on the machinecommencing work. This applies in particular foexample during maintenance or assembly wor

Reg larl check that the personnel are orkingRegularly check that the personnel are workingwith the operating instructions.

All safety and hazard indications must be easiland hazard instructions from the system is striy

Personnel must tie back long hair and may notfor example, if the hair or clothing becomes camachine are personally responsible for complia

SideIII. SAFETY

hin easy access at the site of operation of the machine.

ing regulations/laws concerning accident prevention anding regulations/laws concerning accident prevention and e operating instructions) must be observed/complied with.

hazardous materials; or providing and wearing protective equipment

nted by instructions including supervisory and reporting obligations es, for example with reference to workflows, work organisation, staff

e must have read and understood the operating instructions before or individuals who only occasionally work with the machine, for k on the machine.

g ith an a areness of the safet and ha ard aspects in complianceg with an awareness of the safety and hazard aspects in compliance

ly visible and legible and must be observed. Removal of the safety ctly prohibited. y p

t wear loose clothing or jewellery (also rings). There is risk of injury, aught or pulled into the machine. Personnel authorised for work on the ance with the regulations.

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OPERATING PERSONNEL:

Operating personnel must be instructed in corraccessories.

Work on/with the machine may only be carriedexperience in working with machines. Observe

Clearly specify areas of responsibility for persoetc.

Ensure that only authorised personnel work on

Also specify responsibilities for machine transpAlso specify responsibilities for machine transpthat drivers do not receive instructions contrary

Personnel who are to be trained or instructed omachine under continuous supervision by an e

Work on the electrical system of the machine mpersonnel under the guidance and supervisionconcerning electrical engineering.

Work on the hydraulics of the machine may onsystems.

SideIII. SAFETY

rect and safe operation of the system and its accompanying

d out by reliable, trained and instructed personnel who have e the statutory minimum age.

onnel in regard to operation, assembly, maintenance, commissioning

n the machine.

portation drivers in respect to road-transport regulations, and ensureportation drivers in respect to road transport regulations, and ensure y to safety by third parties.

or who are currently receiving general training may only work on the experienced person.

may only be carried out by qualified electricians or by instructed n of a qualified electrician in accordance with the regulations

nly be carried out by personnel with specialist knowledge of hydraulic

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BEFORE COMMENCING WORK OPERATIN

...be instructed in the work to be performed by

…be advised of the dangers.…be advised of the dangers.

...check all safety relevant covers and casings

...be informed about safety functions, like f.i. ththem in any case of emergency.them in any case of emergency.

…be familiar with all moving parts of the syste

have read and understood the operating inst...have read and understood the operating instoperating instructions as well as all other saf

...take sufficient time to examine in detail and btheir significance and consequence.

SideIII. SAFETY

G PERSONNEL MUST:

means of a specialist training.

on their correct position

he EMERGENCY OFF switch, in order to be able to use

m, in order to beware of these.

tructions together with all warning/safety instructions in thetructions together with all warning/safety instructions in thefety-relevant warning/safety instructions for the product.

become familiar with the warning instructions,

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HYDRAULIC SYSTEMS AND THEIR COMPO

Only persons with special knowledge and expe

Return all control valves to the neutral positionReturn all control valves to the neutral positiondisconnecting or removing hydraulic pipes, tan

Replaced hydraulic components must correspocorrectly mounted.

Beware of leaking hydraulic pipes. Pressurisedeyes. Leaks in pressure pipes may not be visibUse an aid, such as cardboard for example.Use an aid, such as cardboard for example.

Always wear goggles. If hydraulic oil comes int

Immediately replace defective hydraulic pipes.pipes correspond to the specifications of the opipes correspond to the specifications of the o

Never exceed safety limits. Never set overpres

Never exceed safety limits. Never set overpres

SideIII. SAFETY

ONENTS:

erience may work on the hydraulic units.

n (discharge system pressure) Switch off the motor beforen (discharge system pressure). Switch off the motor before nk covers, hydraulic filters or couplings. Disconnect the power supply.

ond to the same standard and quality. Ensure that the parts are

d hydraulic oil can penetrate through the skin or cause injury to the ble to the naked eye. Never check leaks with your hands or fingers.

to contact with the eyes, seek medical advice immediately.

Fires can result from leakages. Ensure that the replaced hydraulic riginal Ensure that the hydraulic pipes are correctly mounted and laidriginal. Ensure that the hydraulic pipes are correctly mounted and laid.

ssure valves higher than the default settings.

ssure valves higher than the default settings.

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ELECTRICAL SYSTEMS AND MOTORS:

In case of electric incidents of safety relevant cswitch and protect the machine against re-star

Never carry out work on the electrics of any coNever carry out work on the electrics of any co

Only qualified electricians may carry out work o

If work on the live parts is necessary, a secondi it h ith h t l i th tor main switch with shunt release in the event

Electrical equipment within the system must berepaired immediately. Use original fuses of thep y g

Lead connections or connections containing lematerials are carcinogenic. Observe the manu

Never short-circuit the battery poles A short-ciNever short circuit the battery poles. A short ci

Battery acid can cause injuries. Avoid contact w

E h t t i h f l b tiExhaust gases contain harmful combustion proexhaust gases into the open air.

Do not touch the motor and exhaust parts. Givstarting maintenance and repair work.g p

Never refuel while the motor is running. Do notsources in the vicinity.

Do not spill any fuel or completely fill the tank

Side

Do not spill any fuel or completely fill the tank.

III. SAFETY

components, immediately switch off the diesel engine, the battery rt by external persons.

omponents without familiarising yourself with these.omponents without familiarising yourself with these.

on the electrical system of the machine.

d person must be present who can operate the EMERGENCY OFFf O l lt i l t d t lof an emergency. Only use voltage-insulated tools.

e checked regularly. Damaged cables or loose connections must be e specified length and power.p g p

ead are contained in the battery poles and accessories. These facturer’s instructions of the battery. Always wash your hands.

ircuit can cause fires and damage the electrical systemircuit can cause fires and damage the electrical system.

with the skin or eyes. Always wear gloves and goggles.

d t W k ith th t i i t di t thoducts. Work with the system in an open environment or divert the

ve the motor and exhaust system sufficient time to cool down before

t smoke while refuelling. Ensure that there are no exposed light

Spilt fuel must be removed properly and immediately

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Spilt fuel must be removed properly and immediately.

MAGNETIC FIELDS:

There is a risk of magnetic radiation in systems

o Persons with heao Electronic deviceo Electronic deviceo Electronic storag

Entry into the hazard zone can cause damage

Personnel must be informed of these hazards

Explain this hazard to persons outside the com

Keep persons with heart pacemakers away froKeep persons with heart pacemakers away fro

DUST, VAPOUR AND SMOKE:

Grinding b rning or elding ork ma onl beGrinding, burning or welding work may only be(danger of explosion).

Clean the system and its environment of dust aburning, welding or grinding (danger of explosig g g g ( g p

Safety guards must be fitted on the devices soimmediate surroundings. Ensure that no dust ecrushed.

Recommended procedures for eliminating dus

o Dust protection ao Dust removal wit

SideIII. SAFETY

s which are equipped with magnetic separators. This affects:

art pacemakersesesge media

to health or irreparable damage to electronic appliances.

accordingly during instruction.

mpany.

om the system.om the system.

e carried o t on the machine if this is e pressl a thorisede carried out on the machine if this is expressly authorised

and flammable substances and ensure sufficient ventilation before ion).)

o that dust/materials cannot harm the machine user or persons in the enters the air when loading, adjusting or removing the material to be

t are:

and dust extractionth water

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NOISE:

The noise protection equipment must be in the

Wear the specified personal ear protectionWear the specified personal ear protection.

OILS, GREASES AND OTHER CHEMICAL S

Observe the safety regulations applicable for tObserve the safety regulations applicable for tsubstances.

Caution when working with hot operating and p

BLASTING:

The use of wireless remote control is strictly pry pexplosion.

The use of a wireless remote control device is

The machine must be removed from the hazarThe machine must be removed from the hazar

Ensure that no explosive material can enter the

SideIII. SAFETY

e protective position during operation.

SUBSTANCES:

he product when working with oils, greases and other chemicalhe product when working with oils, greases and other chemical

process materials (burning or scalding hazard).

rohibited even during preparation work for blasting. Acute danger of g p p g g

prohibited during blasting owing to the danger of explosion.

rd zone before blastingrd zone before blasting.

e system.

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FIRE FIGHTING:

FIRE FIGHTING:

If the slightest signs of fire occur, proceed as fo

o Warn persons whoo Shut down the mao Turn off the powero Ensure that there o Begin fire fighting o Remove the macho Fire fighting.o Fire fighting.

If the unit has already caught fire, proceed as fo

o T rn off the macho Turn off the macho Warn persons whoo seek sheltero Ensure that there

place.po Call the fire depar

SideIII. SAFETY

llows, depending on the situation:

o are in the vicinity.achine.r with the main switch.is no hazard for persons, and lead everyone in the vicinity to a safe place.and, if necessary, call the fire brigade.

hine from the hazardous area, if possible.

ollows, depending on the situation:

ineine.o are in the vicinity.

is no hazard for persons, and lead everyone in the vicinity to a safe

rtment, firefighting

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OPERATING THE SYSTEM:

Only specialists or trained/instructed personne

Refrain from carrying out any work steps that mRefrain from carrying out any work steps that m

Before positioning the machine and bringing it for possible obstructions. The load bearing cap

The operating instructions must have been reasystem; spare some time to become familiar w

Note that the system has sharp corners and ed

Check and ensure that all system parts are fulo Check for defective and missingo Ensure that all panelling is alwa

are functioning. o Dail maintenance ork m st bo Daily maintenance work must b

list, see the service plan.

Walk round the machine before starting work, or in danger areas. All persons who are in the g pOnly start the machine if no persons are on or

Keep all handles, steps, railings, platforms, sta

Never climb onto over and/or under running coNever climb onto, over and/or under running coprovided for this.

The belt and chain tension must never be chec

SideIII. SAFETY

el may operate the system.

may pose a risk to safetymay pose a risk to safety.

into operating position, the work environment must be carefully checked pacity of the ground and traffic arrangement must also be checked.

ad and understood before commissioning. Several labels are on the with the warning instructions.

dges as well as rough surfaces in part.

ly functional.g parts. Immediately repair or replace these parts.ays correctly mounted and that all EMERGENCY OFF switches

be carried o t in accordance ith the ser ice plan For a detailedbe carried out in accordance with the service plan. For a detailed

and ensure that no person(s) are on or under the system or in its vicinity immediate environment are to be informed if the system is to be started. yunder the system or in its vicinity. All doors must be closed and locked.

ages and ladders free of dirt, in particular ice, snow, oils and greases.

onveyor belts Always use the ascending aids and catwalks designed andonveyor belts. Always use the ascending aids and catwalks designed and

cked while the system is running.

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OPERATING THE SYSTEM (continued):

Do not work or linger in the vicinity/environmen

Never stay in the loading or unloading zone asNever stay in the loading or unloading zone as

Always wear a protective helmet, for example

Always observe all safety regulations. Operatein direction.

Only press EMERGENCY OFF switches in em

Check the machine for external signs of damagCheck the machine for external signs of damagmay have occurred to the person responsible.

The system must be shut down if malfunctions

On and off s itching processes as ell as monOn and off switching processes as well as moninstructions.

Parts of the power transmission system, such etc, must be provided with safety guards so thp y g

Never remove material blockages if the machin

Before ending work, it must be ensured that thNever leave material on the machine OtherwisNever leave material on the machine. Otherwis

SideIII. SAFETY

nt of system parts; these can rise or lower.

s long as the system is being loaded or unloadeds long as the system is being loaded or unloaded.

as protection against stones falling/flying from the machine.

e all buttons and levers gently. Avoid jerky movements or sudden changes

mergencies or during safety exercises.

ges and defects at least once per shift. Immediately report changes thatges and defects at least once per shift. Immediately report changes that If required, immediately switch off the machine.

s occur. Faults must be rectified immediately.

nitoring displa s m st be obser ed in accordance ith the operatingnitoring displays must be observed in accordance with the operating

as the pulley of the drive shaft, flywheels, switches, V-belt pulley, V-belts at nobody is endangered by rotating parts. y g y g p

ne is running.

he feeding hopper, crusher feed and conveyor belts are free of material. se the system will be overloaded on restartingse the system will be overloaded on restarting.

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MAINTENANCE WORK:

Only specialists or trained/instructed personne

Maintenance and repair work should always beMaintenance and repair work should always bealone.

Take personal safety precautions. Always weaequipment. Do not wear wide and baggy clothing and jeweTie back long hair.

Move the system to an even and firm surface.Move the system to an even and firm surface. Depressurise the hydraulics. Secure hydraulic Disconnect the power supply before commenc

Never carry out adjustment or repair work whil

Pay attention to the overrun of rotating parts.

Only remove panelling which actually blocks a

Never leave the system unattended if the paneKeep bystanders away from the system.

Raised system parts must always be properly

If you are working at a height over than 2 m, yoUse the catwalks, work platforms or other suchprovided for this. Do not use ascending aids or

SideIII. SAFETY

el may operate the system.

e carried out by at least two persons We recommend to never worke carried out by at least two persons. We recommend to never work

r a helmet, goggles, ear protection and other requisite protective

ellery. This can become caught and/or pulled into the machine.

Turn off the motor and remove the starter key.Turn off the motor and remove the starter key. components.

cing maintenance work.

e the motor is running.

ccess. Remove oil or grease that has escaped.

elling is removed and the housing is open.

secured. Never work below system parts that have not been secured.

ou must wear an EN/ANSI tested safety harness.h safety (EN/ANSI) tested ascending aids and work platforms.r work platforms that have not been secured and/or approved.

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MAINTENANCE WORK (continued):

Only operate the motors in a well ventilated en

Caution when looking for leakages in the hydracause injury to the eyes. Leaks in pressure piphands or fingers; use an aid, such as cardboar

Always wear goggles. If hydraulic oil comes int

Damaged, illegible or missing warning signs m

Special attention must be paid to the moving pSpecial attention must be paid to the moving pworn or incomplete parts can fall out. This can

Before finishing the maintenance work, all boltmounted. Replace or repair damaged covers o

Only fill or refill pressure systems with the specActivate all control levers and ensure that the s

After completing the tests, check the system fop g y

Check all fluid levels before starting work.

SideIII. SAFETY

nvironment – toxic hazard resulting from exhaust gases.

aulic systems. Pressurised hydraulic oil can penetrate through the skin or pes may not be visible to the naked eye. Never check leaks with your rd for example.

to contact with the eyes, seek medical advice immediately.

must be replaced or cleaned.

parts during maintenance work; these must be checked. Any damaged,parts during maintenance work; these must be checked. Any damaged, lead to injury or death.

s, connections and joins must be tightened. All panelling must be or panelling.

cified fluids. Start the motor and check for leakages. system functions correctly.

or missing spring cotter pins, washers, lock nuts etc.. g p g p

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IV TECHNICALIV. TECHNICAL R800 JAW CRUSHER

SideIV. TECHNICAL DATA

CONTENT:



DATAV-belts Side 55Jaw crusher Side 56Welding preparations Side 57Oil level monitor Side 60Service plan Side 62 Recommended oil qualities Side 64DATA Recommended oil qualities Side 64VIII. Standard forms Side 65Rockster warranty registration Side 66CAT warranty registration Side 67Warranty claim Side 68Terms and conditions Side 69

e 26


1. Crawler gear2. Drive motor3. Drive system4. Feeding hopper5. Vibration feeder6. Pre-screening with

reversible chute

9

reversible chute7. Crusher cover8. Jaw crusher 9. Main discharge belt10 Sid di h b l

11

10. Side discharge belt11. Magnetic belt

12. V-belt protector13. Flywheel14. Panelling15. Diesel tank16 Hydraulic tank16. Hydraulic tank

17. Catwalk18. Hydraulic switchbox19 El t i it hb

20

19. Electric switchbox20. Remote control


81317

18 19

710

1

18 19

4

5

612

3

5

14

16

1

215

16

1

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BUILDING GROUPS:

CRAWLER GEAR:The crusher system is mounted on a caterpillaenables the system to move at two different senables the system to move at two different sof 49 x 3-rib plates with 400 mm width.

DRIVE MOTOR:Motor: see Original - CAT 7.0/187 kW || JOHNThe motor is housed in noise-insulated housin

COMBI-COOLERThe blower wheel is mounted directly on the econtrol valve.

OIL-COOLERThe blower wheel is driven hydraulically and lim

DRIVE SYSTEM:DRIVE SYSTEM:Both the hydrostat for the crusher as well as tgear unit which is flange-mounted on the drive

FEEDING HOPPER:Th f di h i d f hi hlThe feeding hopper is made from highly rear re

VIBRATION FEEDER:The vibration feeder guarantees even materialsteel plates. The preliminary screening is integp p y g gvibration drive, which is driven hydraulically. Thby remote control. The speed of the vibration f


ar crawler. The caterpillar crawlers are driven via a 2-stage gear which peeds The maximum hill climbing ability is 34° The chain tread consistspeeds. The maximum hill climbing ability is 34 . The chain tread consists

N DEERE 6068/181kW - Manualg. All filter and fluid displays are easily accessible.

ngine. The water cooler has an additional equalizing tank with a pressure

mited to 230bar.

the hydraulic pump for the operating hydraulics are driven via a distributor e motor.

i t t H d 400 t l Th it f th f di h i 4 ³esistant Hardox 400 steel. The capacity of the feeding hopper is 4 m³.

feeding into the hopper. It is lined with highly wear resistant Hardox 400 grated in the vibration feeder. The vibration feeder is driven via the ghe vibration feeder can be activated or deactivated using the hand lever or feeder is controlled infinitely via a hydraulic valve.

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PRE-SCREENING WITH REVERSIBLE CHUT

The screening area of the preliminary screeninThe standard gap width of the zigzag grid is 35The pre-screened material can be directed ontThe pre-screened material can be directed ontor is directly routed onto the main conveyor at

CRUSHER COVER:

The crusher cover covers the crusher feed frommay be opened only if the rotor is switched off (by wireless remote control or manually) and sscreen and rubber skirt. An irrigation strip is int

Picture IV.2: Reversible chutecontrol lever screen and rubber skirt. An irrigation strip is int

JAW CRUSHER R800:

The jaw crusher R800 is a single toggle jaw crThe gap idth of the ja s can be h dra licall

control lever

The gap width of the jaws can be hydraulicallyThe crusher speed can be infinitely adjusted. TThe jaws are made of high wear resistent Man

CRUSHER SPEED:

The granulation of the final product as well as speed. The crusher speed is adjusted by the sswitchboard No 2).


TE:

ng is 1200 mm x 900 mm.5 mm. to the side belt via a reversible chuteto the side belt via a reversible chute, the crusher.

Picture IV.1: Reversible chute

m above. The crusher cover serves for maintenance purposes only and and protected against rotation. It can be opened and closed hydraulically

serves as protection against falling/flying stones when closed with a chain tegrated in the crusher cover.tegrated in the crusher cover.

usher equipped with one moveable and one fixed crushing jaw. adj sted from 30 120 mm adjusted from 30 - 120 mm.

The direction of rotation can be changed e.g. in case of blockage.ngan steel.

the wear behavior can be individually affected with the help of the crusher switch “Crusher Speed” (see page 35, picture V.2: Electrical

e 29

MAIN DISCHARGE BELT:The main discharge conveyor is a solid steel cg y

Length (centre line distance)Width (belt width)Height (discharge height)

The conveyor belt of the main discharge conveThe conveyor belt of the main discharge conveSANPRO plates. The absorbing impact plates absorbing the impact effects.The conveyor belt is manufactured in RIP-STOThe drive is hydraulic. The operating pressure The entire construction can be folded up hydra

Attention: Before folding release main belt Retighten belt before operation!

Attention: when changing the belt, make sure another belt with different qualitiesDamages resulting from this will no

SIDE DISCHARGE BELTSIDE DISCHARGE BELT:The side discharge conveyor is a solid steel co

Length (centre line distance)Width (belt width)Height (discharge height)g ( g g )

The drive is hydraulic. The operating pressure The entire construction can be folded up hydra

Attention: Before folding release main beltAttention: Before folding release main belt Before operation, tighten safety necessary, Reset!


construction with the dimensions:7900 mm1000 mm3170 mm

eyor is located under the crusher where it is protected from impacts byeyor is located under the crusher where it is protected from impacts by are fixed on rubber buffers (rubber mountings), which are additionally

OP quality.is limited with 220 bar.

aulically for transport purposes.

(open tensioning spindle of driving drum).

to use an original RIP-STOP-belt from the manufacturer. If using s than the original, a smooth operation can not be guaranteed. ot be issues of warranty or guarantee.

onstruction with the dimensions:4100 mm

500 mm2300 mm

is limited with 210 bar.aulically for transport purposes.

(open tensioning spindle of driving drum)(open tensioning spindle of driving drum).screws, retighten belt and check that belt runs centrally and, if

e 30

MAGNETIC BELT:The magnetic conveyor belt is mounted over th

Side-conveyor: Safety screw

The magnetic conveyor belt is mounted over thcrushed material and discharges the metallic imThe gap between the magnetic surface and maThe magnetic conveyor belt should have arounThe drive is hydraulic. The operating pressure

V-BELT PROTECTOR:The V-belt protector is a metal housing. The syThe V-belt protector an the side door must alw

PANELLING:The panelling on the crusher serves to provideremoved for maintenance and repair work. Cru

DIESEL TANK:DIESEL TANK:The diesel tank is equipped with an electrical rcovered with a filter cover. A diesel drain cock

The capacity is 330 litres.


he main conveyor belt. It separates all loose iron fragments from the

Side-conveyor: Safety screw

he main conveyor belt. It separates all loose iron fragments from the mpurities beside the main conveyor belt.aterial to be conveyed must be at least 200 mm.nd 25 mm of slack. Overtensioning can damage the bearings.is limited with 80 bar.

ystem must be shut down before checking or tensioning the V-belt. ways be closed and secured after working on the V-belt.

e operational safety and noise protection. It may only be opened and/or usher operation with dismounted panelling must be avoided at all times.

refuelling pump and is provided with a ventilation opening. This opening is is located on the bottom of the diesel tank.

e 31

HYDRAULIC TANK:The hydraulic tank is fitted with an inspection goff the vibration chute immediately if the level fthe oil temperature is too high. Time-delayed (c420 liters Upon filling the hydraulic tank 10 cm420 liters. Upon filling the hydraulic tank, 10 cmOn the underside of the tank a drain cock is loc

CATWALK:Catwalks serve for maintenance, revision and and do not have to be removed for transport.

HYDRAULIC SWITCHBOARD:The most important manual valves for controlli

ELECTRICAL SWITCHBOARD:All the operating elements relevant to the user

REMOTE CONTROLS:The wireless remote control can be used to moactivate/deactivate the vibration feeder The syactivate/deactivate the vibration feeder. The sythe machine. On both remote controls there ar


glass,a level sensor and a temperature sensor. The level sensor switches falls below the adjusted limit, the temperature sensor does the same, if ca. 30 sec.) also the operating hydraulics switches off. The capacity is m must be left from the upper edge (hydraulic tank) to the liquid levelm must be left from the upper edge (hydraulic tank) to the liquid level.cated.

monitoring of the system. The catwalks are firmly attached to the system

ing the system are located in the hydraulic cabinet.

r are located in the electrical cabinet.

ove the machine, open/close the crusher cover, activate the hydraulic and ystem can also be operated with the cable remote control but only to moveystem can also be operated with the cable remote control but only to move re EMERGENCY-OFF switch.

e 32

V START UV. START UR800 JAW CRUSHER

SideV. START UP

CONTENT:



UPV-belts Side 55Jaw crusher Side 56Welding preparations Side 57Oil level monitor Side 60Service plan Side 62Recommended oil qualities Side 64UP Recommended oil qualities Side 64VIII. Standard forms Side 65Rockster warranty registration Side 66CAT warranty registration Side 67Warranty claim Side 68Terms and conditions Side 69

e 33


OPERATION DEVICES:OPERATION DEVICES:

OPERATOR CONTROLS:

The operator controls required for operation ar

HYDRAULIC SWITCHBOARD:

1. Vibration feeder and side discharge belt1. Vibration feeder and side discharge belt

2. Main discharge belt

3. Side discharge belt - folding cylinder

4. Main discharge belt - folding cylinders

5. Gap-adjustment-beam - adjustment cylinder

6. Without function

SideV. START UP

re individually described in the following:

rs (main valve)

1 2 3 4 65

Picture V.1: Hydraulic switchboard

e 34

ELECTRICAL SWITCHBOARD:

1. Hydrostat left/right rotation (only valid, if Duplex S

2. Set rotor speed

3 A ti t h d li3. Activate hydraulics

4. Deactivate hydraulics

5. Warning lamp

6. Diagnostic lamp (drive engine)

7. Switchboard lock

8 St ti id8. Starting aid

9. Adjustment of engine speed

10. Switch for emergency mode (transport)

11. Screen box ON/OFF (option)

12. Water pump ON/OFF (option)

13 Vibration ch te ON/OFF (man al/remote control13. Vibration chute ON/OFF (manual/remote control

14. Engine – preheat lamp

15. Starter key

16. Tank display

17. Monitoring system (motor and crusher unit)

18 Headlight ON/OFF

SideV. START UP

18. Headlight ON/OFF

System)

5

62

3

4

171

7 8 9 101113

16

l)

Picture V.2: switch board

12 14 1518

l)

e 35

MOTOR MONITORING SYSTEM:

1 ESC-Button

2 Confirmation–Button

1 This button enables to return to a previous or higher le

2 With this button error messages can be confirmed.

3+4 Scroll – Button

5+6 + / - Buttons

3+4 Used for navigation between the various menu item

5+6 Allow to select a value or to change the indication-pdisplay (see point 9 ).

7 Thi b tt ff t th fi ti f l t d dj7 Enter – Button

8 Indication of engine speed

7 This button effects the confirmation of a selected adjusthe changing of indication of display to a selected mod

8 Indicates the current engine speed.

9 After selecting this indication item by using the scroll b

9 Indication of second parameter of engine

10 Indication of

g y gitem is going to be marked in grey colour. By pressing (5+ 6) the requested indication parameter (hours of optemperature, etc) now can be chosen. By pressing thethis selected parameter then remains active in the disthe condition of this parameter during operation of eng

crusher speed

11 Operating-information-display

10 After activating the crusher and running up the crushespeed-adjusting-buttons, the current crusher speed a

11 If the block “menu” is marked in grey and the enter-button (language). Within this menu field you can navigate with the

12 Indication of arising problems of diesel motor

12a Indication as per code number of

g g ) y gbutton (7). After e.g. selecting the menu field language thethen with the enter-button (7). In the menu field “alarms” thbutton (1) you can return from this level in the display to th

12 The current problem (indicated as plaintext) appears engine the error is cleared. In case of critical operatiocode number of

engine manual

13 Indication of arisingproblems of crusher control

engine the error is cleared. In case of critical operatioautomatically. An automatic cut-off due to lack of cooling w

12a Errors, which are not indicated as plaintext here appear w

13 These notices / errors are also indicated as plaintext.

SideV. START UP

evel in the display.89

12s in the display.

arameter in the

t t ll

10

12

131112astment as well as

de.

buttons (3+4) this14

( )the + or – button

peration, coolant e enter button (7)play and indicatesgine.

1

3

4 5

6 7 2

Picture V.3: motor monitoring systemer with the crusher-

appears in this indication.

(7) will then be pressed, you will get into a further submenu (inputs, outputs, alarm protocol ande scroll buttons (3+4). After selecting a menu field this one can be called by pressing the enter ( ) g y g requested language can be adjusted by pressing the +/- buttons. This one has to be confirmed he last 100 error messages can be called by pressing the scroll-buttons (3+4). With the ESC-e main menu (=standard indication).

in the display until the error is corrected or due to a change of the operating status of the on conditions (e.g. excess temperature of the cooling water) the diesel engine will stopon conditions (e.g. excess temperature of the cooling water) the diesel engine will stopwater is not provided (a regular control of the coolant level is necessary).

with the appropriate code number. The meaning of this code can be read in the engine manual.

If there are no notices, the display is empty.

e 36

ERROR MESSAGES OF ENGINE CONTR

Crusher overload: The pressure in the hydraulic circuit of crusher below the crusher limit value. The feeder stops no more overload (hydraulic pressure again at a

Hy. oil level too low: Indication, that the level of hydraulic oil in the oimmediately. After a short period of time (30 secthe oil level must reach a higher level (oil must

Oil temp. too high:Indicates, that the temperature of the hydraulic After a short period of time (30 seconds) also thhas cooled down and reached a lower tempera

Is indicated when the load at the main conveyoOverload of main con.:

S it h id

Is indicated, when the load at the main conveyoautomatically. For a further activation the hydrathe remote control (see page 35, picture V.2: el

This message is indicated, if the safety switch oSwitch side conveyor:

Limit switch:

g , yimmediately. For new start of hydraulics, this sa

Is indicated, when the limit switch at the crushebetween surface of switch and surface at crush

Level of water:

feeder will stop immediately and after some shodisappears (problem caused by bad contact or automatically.

Indicates, that the electric motor of water pumpLevel of water: , p pline (only if an optionally sprinkling pump was in

The last 100 error messages can be seen in the

SideV. START UP

ROL SYSTEM:

drive has exceeded the adjusted limit value or the crusher speed went immediately as long as this overload of crusher is active. When there is

a lower level) the feeder starts again automatically.

il tank has reached a level below the limit value. The feeder stops conds) also the complete hydraulics stops. To start again the hydraulics, be filled up in the tank or the function of level senor has to be checked).

oil has exceeded the adjusted limit value. The feeder stops immediately. he complete hydraulics stops. A new activation is only possible, if the oil

ature range (under the adjusted limit value).

or (pressure in the hydraulic circuit) is too high The feeder will stopor (pressure in the hydraulic circuit) is too high. The feeder will stop aulic –on –button has to be pressed on the electrical switchboard or on ectrical switchboard, item 3 or page 38, picture V.4 switch 9).

of side conveyor has been activated. The complete hydraulic stops y p y pafety switch has to be readjusted.

er cover or the switch board is not adjusted in the right position (distance her cover: 2 – 3 mm). If this happens during operating the crusher, the ort time delay (5 seconds) also the crusher switches off. If the error shaking of the plant) during this time, then the feeder will restart again

p of sprinkling unit has switched of because of lack of water in the suction p p gnstalled).

e error diagnostics (see page 36, point 11, operating-information-display).

e 37

WIRELESS REMOTE CONTROL:

Left caterpillar crawler moves forwards

Right caterpillar crawler moves forwards

1. Forwards left

2. Forwards right

Left caterpillar crawler moves backwards

Right caterpillar crawler moves backwards

3. Backwards left

4 Backwards right Right caterpillar crawler moves backwards

Both caterpillar crawlers move forwards simult

B th t ill l b k d i

4. Backwards right

5. Forwards fast

6 B k d f t Both caterpillar crawlers move backwards simu

Open crusher cover

6. Backwards fast

7. Crusher cover open

Close crusher cover

Press buttons 9 and 10 simultaneously for twoThe ON/OFF switch (no. 11) must be pulled.

8. Crusher cover close

9 – 10. Start

Activate operation hydraulics

Activate and deactivate vibration feeder

Pull for activating remote control

9. Hydraulic ON

10. Vibro on/off

Pull for activating remote control.Press to switch machine and remote control of

The remote control has to be activated before

11. EMERGENCY-OFF

SideV. START UP

1 2

3 4

5 6

aneously in fast motion

lt l i f t ti

7 8

ultaneously in fast motion

9 10

o seconds until LED blinks green.

11

Picture V.4: Wireless remote control

ff.

the start-up of the machine!

e 38

CABLE REMOTE CONTROL:

1. Forwards left

2 F d i ht

Left caterpillar crawler moves forwards

Right caterpillar crawler moves forwards2. Forwards right

3. Backwards left

Right caterpillar crawler moves forwards

For straight-ahead movement press both butto

Left caterpillar crawler moves backwards

4. Backwards right Right caterpillar crawler moves backwards

For straight backwards movement press both

5. Emergency OFFSwitch

Pull to activate the remote control. Press in order to stop the machine in an emer

CRUSH HAZARD: Particular caution must be chains when using the cable remote control.

Connecting the cable remote control to the crupoint, see picture V.6/7.

ATTENTION: Machine function is only guarancable remote control or the indu

SideV. START UP

21

3 4

2

5

ons (1,2) at the same timePicture V.5: Cable remote control

buttons (3,4) at the same time

rgency.

Picture V.6: Connecting point

exercised in respect to operating

usher at the industry connecting

Picture V.7: Connecting cable remote control

nteed, if the circuit is closed via ustry connecting point.

e 39

g

TRANSPORT:

UNLOADING THE SYSTEM:

Check machine on loose parts or material accumActivate remote control (see page 39) or plug inStart the motor (see Caterpillar Manual)Start the motor (see Caterpillar Manual).Press the hydraulic button on electrical switchboSet ascent angle of the low-loader ramps to notCarefully drive away from low-loader at low eng

LOADING THE SYSTEM:LOADING THE SYSTEM:

Check machine on loose parts or material accumFold and secure side conveyor and catwalk laddCarefully drive onto the low-loader at low engineFasten system with appropriate chains at the anFasten system with appropriate chains at the anAfter the loading reverse battery switch and pull

ATTENTION: Observe transport dimensions.Set ascent angle of the low-loadeUse adequate low loader rampsUse adequate low-loader ramps Make sure to have a stable grounRemove snow, ice and material fUse outriggers of the trailerMachine tilts when it passes the

SideV. START UP

mulations.n cable remote control (see page 40).

oard (see page 36, point 3).t more than 15° (or ratio 1:4).ine speed (below 1000 rpm).

mulations.ders.e speed (below 1000 rpm) – Observe angel of ascentnchoring pointsnchoring points.l off ignition key.

er ramps to not more than 15° (or ratio 1:4).(for steel chain crawlers)(for steel chain crawlers).nd during the loading and unloading process.from ramps and caterpillar crawlers.

ramp angle.

e 40

TRANSPORT SAFETY:

Observe the statutory transport dimensions cu

Secure the system against slipping at the eigh.

Picture V.8: lateral lashing ring

Picture V 10: front lashing ring

SideV. START UP

Picture V.10: front lashing ring

rrently applicable.

t anchoring points envisaged for this.

Picture V.9: backmost lashing ring

e 41

SYSTEM SET UP:

Ensure an even ground space, if necessary co

Bring the crusher into position. Move the syste

A suitable ramp must be tipped for loading withA clear view onto the hopper and crusher feedThe material to be crushed must be located in

Bring the main conveyor belt and side conveyoAttention: Fix saftey screws and tightening

Check that belt runs centrally and, if necessaryCheck that belt runs centrally and, if necessary

Check belt tension.

NOTE: The material cone under the main and DAMAGE TO THE DRIVE UNIT AND THE CO

SideV. START UP

ompact.

em as close as possible to the material to be crushed.

h a wheeled loader. must be provided for excavator loading.the rear part of the hopper for excavator loading.

or belt into the working position (see picture V.8; position 1+2)g screws!

y, reset (see chapter VII. maintenance).y, reset (see chapter VII. maintenance).

Picture V.8: Hydraulic switchboard

1 2

side conveyor belt must not rise above the driving drums. RISK OF ONVEYOR BELTS.

e 42

MATERIAL PREPARATION:The crushing material must be pre-crushed, deThe process material (recycling material) mustObjects that cannot be crushed must not enterRemove impurities such as iron, wood and simMetal objects larger than the gap width set muMetal objects larger than the gap width set mu

CAUTION:

Risk of damage to the conveyor belts – cut max. diameter 15 mm

REMOVING BLOCKAGES:Start engine.Start engine.Turn crusher speed to zero (switch 2, side 35 pChange direction of rotation (switch 1, side 35 Softly increase crusher speed to release blockStop crusher.Change direction of rotation backChange direction of rotation back. Start up again.

If blockage could not been removed. Switchalso the crusher. Open the inlet-cover.pSwitch off the machine, pull off ignition key(Protect machine against re-start by externaThe machine must always be switched off. The gap adjustment beam must be broughtsecured Remove the blockage with extremsecured. Remove the blockage with extrem

Never step into the crusher

Remove the blockage with extreme caution

SideV. START UP

epending on the machine type.t not exceed a max. length of 500 mm.r the crusher.

milar from the material to be crushed.st not enter the crusherst not enter the crusher.

iron pieces that are too long, max. length 500 mm,

picture V.2)picture V.2)age.

h off the main-conveyer-belt, side-conveyor-belt, the vibro and

y and battery switch.al persons).

t to a standstill before removing any blockages and must be me cautionme caution.

n.

e 43

1. A clear view onto the hopper a

Point 2

2. Material preparation: As far as possible, remove all impurities from the process material. Crush parts that are too small into the processing size.

SideV. START UP

and crusher feed must be provided for excavator loading.

Point 1

Point 3

3. The material cone under the main and side conveyor belt must not rise above the driving drums – Risk of damage to the drive unit and the conveyor belts.

e 44

GAP ADJUSTMENT:

The size of the final material is determined by

Gap reduction:Gap reduction:o Release spring (see picture V.9).o Reduce gap with adjustment cylinder (see po Open cover for the distance-plates.o Take of the safety screws, (see picture V.9.2o Mount additional distance-plates acc. requeo Move-in the adjustment cylinder till the cylino Secure the plates with the safety screws.o Readjust the tension of the spring and contr

(the Toggle-Plate must have a tight position(the Toggle Plate must have a tight position the pressed spring has a length about 250m

Gap enlargement:o Release spring (see pict re V 9)o Release spring (see picture V.9).o Reduce gap with adjustment cylinder (see po Open cover for the input plateso Take of the safety screws, (see picture V.9.2o Remove distance-plates and move-in the adp

requested gap width (cylinder is on block thro Secure the plates with the safety screws.o Enlarge gap with adjustment cylindero Readjust the tension of the spring and contr

(the Toggle Plate must have a tight position(the Toggle-Plate must have a tight position the pressed spring has a length about 250m

SideV. START UP

the gap adjustment.

picture V.9.1) to the requested size.

2)

Picture V.9: spring

sted gap sizeder is on block with distance plates.

rol tension during operationduring operation;during operation;

mm)

picture V.9.1) to the requested size.

)djustment cylinder to the

Picture V.9.1: spring

j yrough distance-plates).

rol tension during operationduring operation;during operation;

mm)Picture V.9.2: spring

e 45

VI OPERATIOVI. OPERATIOR800 JAW CRUSHER

SideVI. OPERATION

CONTENT:



ONV-belts Side 55Jaw crusher Side 56Welding preparations Side 57Oil level monitor Side 60Service plan Side 62 Recommended oil qualities Side 64ON Recommended oil qualities Side 64VIII. Standard forms Side 65Rockster warranty registration Side 66CAT warranty registration Side 67Warranty claim Side 68Terms and conditions Side 69

e 46


SPECIAL OPERATING INFORMATION:

VIBRATION FEEDERVIBRATION FEEDER:

Switch on the vibration feeder:The vibration feeder is manually activated in th(see page 35, picture V.2. Nr. 13, vibration feed(see page 35, picture V.2. Nr. 13, vibration feedThe ball valve (see picture VI.1) in the control The vibration feeder can be switched on and o

The rate governor (see picture VI.1) on the conrequired conveyor speed for the material on threquired conveyor speed for the material on thIf the vibration chute does not work, the green must again be pressed.

Switch on the vibration feeder via remote cThe vibration feeder can be activated via the reswitched on (see page 35, picture V.2, Nr. 13) The vibration feeder can be activated and deac

The ball valve must be closed in order to usThe ball valve must be closed in order to us

THE CRUSHER CAN BECOME BLOCKED IFTHIS CAN REDUCE PERFORMANCE, INCRECRUSHED MATERIAL.

CRUSHER COVER:The crusher cover can be opened and closed aThis procedure is necessary if process materia(observe process size) Opening the crusher c(observe process size). Opening the crusher ccrusher space. The crusher cover serves for mswitched off and protected against rotation.

DURING OPERATION OF THE MACHINE NEOUT BACKWARDS FROM THE CRUSHER!

Side

OUT BACKWARDS FROM THE CRUSHER!

VI. OPERATION

he “Manual” position der)der) panel is closed (closed=vertical)

off via the ball valve (see picture VI.1)

ntrol station is used to control the e vibration feeder Picture VI.1: Rate governore vibration feeder.“Hydraulic-ON” - switch

control:

Picture VI.1: Rate governor

emote control (see page 38) provided that the “Radio" position is and provided that the ball valve in the control panel is closed. ctivated via wireless remote control.

se the remote function of the vibration chutese the remote function of the vibration chute.

F THE VIBRATION FEEDER TRANSPORT SPEED IS TOO HIGH. EASE WEAR AND LEAD TO INFERIOR QUALITY OF THE

again by hand or by remote control, if required.al has become blocked in the infeed area of the impact crusher cover increases the infeed and the material is able to enter thecover increases the infeed and the material is able to enter the maintenance purposes only and may be opened only if the rotor is

EVER OPEN THE CRUSHER COVER. MATERIAL IS HURLED

e 47

SPECIAL OPERATING INFORMATION:

CRUSHER:Always check the crusher for free running befoThe quality of the final product can be controllespeed increases the degree of fines a lower rospeed increases the degree of fines, a lower ro

REVERSIBLE CHUTE:The reversible chute guides the pre-screened depending on requirements.Only operate the reversible chute if the materiaOnly operate the reversible chute if the materiaempty, otherwise the reverse mechanism may

MAIN DISCHARGE BELT:The main discharge belt is protected from overvibration feeder in the event of an overload. Foon the electrical switchboard or on the remote discharge belt are:

a) Blockages of concrete iron between belt anda) Blockages of concrete iron between belt andb) Accumulation of material due to slow belt sp

It is important to check the conveyor belt for iroseveral times during crushing. This minimizes Th i di h b lt l b t dThe main discharge belt can also be operated

MAGNETIC BELT:The ball valve (see page 50 picture VI.4) enabindependently of the manual valve (see page 35p y ( p gshort period by operating the manual valve in tbackwards movements can help release matethe magentic belt engine enables the change o

SideVI. OPERATION

ore starting operation.ed by fine adjustment of the crusher speed: a higher rotational otational speed makes the final product coarserotational speed makes the final product coarser.

material into the main discharge belt or the side discharge belt,

al flow for pre screening is interrupted and the hopper has becomeal flow for pre-screening is interrupted and the hopper has become become jammed.

rloads by a pressure switch. This pressure balance deactivates the or a further activation the “Hydraulic-ON” button has to be pressed control. The most frequent causes of overloading for the main

d crusher discharged crusher dischargepeed

on pieces and other impurities that may have become caught downtimes of the belt (gaps). i th di ti f h t i d if i din the reverse direction for a short period, if required.

bles the magnetic belt to be activated and deactivated 5, picture V.1, position 2). The magnetic belt can be reversed for a , p , p ) gthe opposite direction (spring offset). Short forwards and rial blockages. The exchange of the hydraulic quick couplings on of the direction of the magnetic belt.

e 48

PROCEDURE FOR CRUSHER OPERATION:IMPORTANT FIRST CAREFULLY READ THR

Step 1:Start motor

IMPORTANT: FIRST CAREFULLY READ THR"SPECIAL OPERATING INFORMATION".

See Caterpillar Manual.The starter key is located in the switchboard (seStart motor

Step 2:

y (In case of difficulties during the starting procedu(item 7) must be pressed during starting.

Press the hydraulic button in the switchboard (spStart hydraulic

Step 3:St t h d t t

Press the hydraulic button in the switchboard (sThe operating hydraulics are activated in the idl

Put the hydrostat switch (see picture VI.2 item 1itiStart hydrostat

Step 4:Start up crusher

position.

Increase the crusher speed with the rotary knobto appr. 50-100 rpm. The current rotor speed cap

Step 5:Start conveyor belts

pp p p

Switch on the conveyor belts at the hydraulic swby pressing the hydraulic valves.

Step 6:Increase motor speed

Increase the motor speed with the switch (see pThe crusher rotor goes to the pre-selected rotor

MOTOR SPEED DURING CRUSHING OPERA

SideVI. OPERATION

ROUGH THE SECTIONROUGH THE SECTION

ee picture VI.2 item 14).

5

62

3

4

171

2

3

4

1

p )ure, the button “Starting Aid“

see picture VI 2 item 3)

7 8 9 101113

7 813

see picture VI.2 item 3).e mode.

1) into the “Jaw crusher" Picture VI.2: switch board

12 14 1516

18 14

b (see picture VI.2. item 2) an be controlled at the display.p y

witchboard (see picture VI.3)

picture VI.2 item 8). r speed.

Picture VI.3: Hydraulic switchboardATION MAX. 2000 RPM!

e 49

PROCEDURE FOR CRUSHER OPERATION (

Step 7:

Adjust crusher speed

Set the required crusher speed, depending on with the rotary knob (see picture VI.2. item 2).

Step 8:

Start magnetClose the ball valve on the crusher frame (closed=lever is vertical to the direction of flow,

Step 9:

Start vibration feederTurn the switch “Vibro chute” (see page 49, picto “radio” or “manual” operation. Adjust the speat the operator console (see page 49 picture V

Step 10:

Feeding

at the operator console (see page 49, picture V

When choosing “radio” operation, the ball valvehas to be closed (closed=lever vertically to the

Th h i d f tiThe crusher is ready for operation. You can now start feeding the material.

The sequence described ensures that no mateProceed in the reverse order when stopping the

SideVI. OPERATION

(continued):

the required crushing material,

see picture VI.4).

cture VI.2, item 13)eed with the rate governor VI 1)

Picture VI.4: Ball valveVI.1).

e (see page 49, picture VI.1)e direction flow).

rial blockage forms in the system to interrupt the workflow.e system.

e 50

VII MAINTENAVII. MAINTENAR800 JAW CRUSHER

SideVII. MAINTAINANCE

CONTENT:



ANCEV-belts Side 55Jaw crusher Side 56Welding preparations Side 57Oil level monitor Side 60Service plan Side 62 Recommended oil qualities Side 64ANCE Recommended oil qualities Side 64VIII. Standard forms Side 65Rockster warranty registration Side 66CAT warranty registration Side 67Warranty claim Side 68Terms and conditions Side 69

e 51


HYDRAULIC SYSTEM:

Replacing the return flow filter and overFirst filter change 100 hours after first commfurther filter changes every 1000 hours or a

Turn off diesel motor.Clean filter housing (outer)

Picture VII 4: Return filter

Clean filter housing (outer).Remove filter cover.Pull out filter element (with disaInsert new filter element.

R l i th filt f th h d t tPicture VII.4: Return filter Replacing the filter of the hydrostat:First filter change 100 hours after first commfurther filter changes every 1000 hours (see

Changing the hydraulic oil:Change of hydraulic oil all 1000 hours oBring hydraulic oil to operating temperatureClose main cocks (see picture VII.1).Open drain cock (see picture VII.3).Drain oil.

Picture VII.3: Drain cockDrain oil.Close drain cock.Open main cocks.Clean filling cap – open. (see picture VII.2Pour in new oil until upper edge of inspectioV t (2 3 t ) til tiVent pump: open (2-3 turns) ventilation scr(see picture VII.5).As soon as oil leaks from the ventilation scStart system.Activate load (ventilation).

Picture VII.5: Ventilation Screw

( )Check oil level. (see picture VII.2.1)Shut down system. Fill up further with oil below level.

SideVII. MAINTENANCE

rflow oil filter:missioning, according to clogging indicator.

assembly handles).Picture VII.1: Main cocks

missioning, e picture VII.2).

or annually.e. Turn off motor.

.1)on glass.

Picture VII.2: Hydrostat filter

rew ass

rew, close it again.

Picture VII.2.1: filling gap and oil level indicator

e 52

oil-level indicator

Manometer 1 (picture VII.3: green arrow) :60 bar, shows the charge pressure of the hydrDuring operation the manometer has to show Manometer 2 (picture VII.3: red arrow) :600 bar, shows the operating pressure of the hDuring operation the pressure in this manome

Hydraulic oil cooler:In principle, the hydraulic oil cooler does not reout with compressed air from inside to outside

Attention: Danger of overheating if cooler is c

Charge Air-, Watercooler:Water level = the distance from filler to water hFor further maintenance instructions see CateCoolant temperature resistance has to be -35°pAfter refilling coolant check temperature resist

Attention: Danger of overheating when Coole

DIESEL MOTOR: see Caterpillar Manuels

VIBRATION FEEDER:Checking the oil:Correct oil level = Lower edge oil-level plug (seOpen oil-level plug – if no oil emerges, refill wi

Oil change:Open oil-level plug.Open oil drain plug.Drain oil.Cl d i lClose drain plug.Fill with new oil – up to lower edge of oil-level Close oil-level plug.

Check fastening bolts of vibration gear for firm


rostatic pumpbetween 28-34 bar.

hydrostatic pumpeter ranges from 90 to 420 bar.

equire maintenance. If required, blow e. Pay attention to a clean cooler mesh!

contaminated!

has to be 8 cm (Page 61, Picture VII.21)erpillar manual.°C

Picture VII.6: Manometers

tance

er is polluted

ee picture VII.7.1).ith oil (around 3,5 l).

plug.

m mounting once a week.

Picture VII.7.1: Oil level plugs

e 53

TRANSFER GEAR BOX:Open oil drain plug and bleeder screw.Drain oil.Close drain plug and bleeder screw.Fill with new oil (ca. 1 liter) - between mark (min

CATERPILLAR CRAWLER:CATERPILLAR CRAWLER:The crawler gear chain and 3-rib base plates areWeekly inspection for potentially loose bolts.The track rollers are maintenance-free.A weekly visual inspection must be carried out fof th d l Th d i h l it iof the duocone seals. The drive wheel unit is ma

the drive wheel with the sliding elements, the crospring assembly and integrated grease tension

A weekly inspection must be carried out for possof the drive wheel The grease tension cylinder hof the drive wheel. The grease tension cylinder hcrawler gear chain into the operating position.Feeding is achieved by means of grease filling (The chain is correctly tensioned if there is slack chain support. It must be noted that only the drivpp yinitiated with the grease tension cylinder; the spThe grease tension cylinder must be relieved byThe pressurised grease then escapes via a grooThe main ring gear is maintenance-free. A regular visual inspection must be carried outA regular visual inspection must be carried out,

Accumulating material can become trapped betwas well as the lead and drive wheels. This matergear parts from working together effectively, whiand chain breakage For this reason it must beand chain breakage. For this reason, it must be gear components are regularly cleaned and thataccumulated material are removed.

Crawler gear unitCorrect oil level with correct oil plug arrangemen

Side

Correct oil level with correct oil plug arrangemen

VII. MAINTENANCE

n and max) at the dip stick (see picture VII.7).

e maintenance-free.

or possible leakages in the areai t f It i t f

Bild VII.7: Messstab

aintenance-free. It consists of oss member with mounted cylinder.

sible leakages in the sliding elementshas the function of bringing thehas the function of bringing the

(via hand lever press).of approx. 25 mm on both sides of the

ve wheel feeding or chain tensioning is g gring travel of the spring assembly is not shortened.

y carefully unscrewing the filling valve.ove in the filling valve in order to loosen the chain.

as incorrect chain tensioning can lead to premature wear

Picture VII.8: Chain tension

as incorrect chain tensioning can lead to premature wear.

ween the track and carrying rollers rial then obstructs the crawler ich can lead to increased wear ensured that all crawlerensured that all crawler t foreign bodies and

nt (see side VII.10). Pi t VII 10 C l it

e 54

nt (see side VII.10). Picture VII.10: Crawler gear unit

CONVEYOR BELTS:

Check the conveyor belts for cracks, cuts etc aDamage can be caused by foreign bodies (e.gtrack rollers.Crushing material may also have accumulatedCrushing material may also have accumulatedthe belt running.Freezing temperatures in particular can lead toAll carrying rollers, track rollers, lower chord roThe tail pulleys of the main conveyor must be cAccumulated materials can cause the conveyoThis also applies for the driving drums of the mCheck the belt scrapers for correct mounting.Replace worn belt scrapers.Ensure correct belt tensioning.Ensure correct belt tensioning.

MAGNETIC BELT:

The belt m st be checked reg larl to ascertaiThe belt must be checked regularly to ascertaiThe bearings must be lubricated accordingly.Dedusting belts must be checked for damage a

V-BELTS:

Check V-belts for correct tensioning (see pictuD = 0,016 . x D....[mm] x .... [m] F To tension the V belts open the door for the mTo tension the V-belts, open the door for the mThe V-belts are tensioned by moving the hydraEnsure correct belt tensioning!


as part of the daily visual inspection.. iron pieces) which become caught in the belt frame or between the

d in the frame edges which can have a considerable adverse effect ond in the frame edges, which can have a considerable adverse effect on

o faults in and damage to the conveyor unit.ollers and side guide rollers must run freely.checked for free running.

or belt to stop and consequently lead to blockage in the crusher. main and side conveyor belts.

n hether it is r nning straight and if necessar correctedn whether it is running straight and, if necessary corrected.

and, if necessary, replaced.

re VII.10).= FORCE = 50-65 N

motor housingmotor housing.aulic motor backwards using slide rails

Picture VII.10: V-belt tension

e 55

JAW CRUSHER:

Moveable jaw:- Stop diesel motor, remove starter key and ba

Ignition key and battery switch have to be puhas to be protected against start-up by exterOpen eccentric bolts (see picture VII 11 1)- Open eccentric-bolts (see picture VII.11.1)

- Open bolts on back side of fixing wedge. (se- Remove fixing wedge.- Pull jaw out (see picture VII.11.3).- Clean the guide liners and contact surfaces.g- Visual inspection of side-wear-plates.- Replace jaw.- Put in fixing wedge and safe the wedge with - Adjust and fix and the jaw-position with the e- Check gap between jaw and side-wear-plate

Picture VII.11.2: bypass chute plate

Fixed jaw:- Stop diesel motor, remove starter key and ba

Ignition key and battery switch have to be pu

- Check gap between jaw and side-wear-plate- Tighten bolts of fixing wedges.

Ignition key and battery switch have to be puhas to be protected against start-up by exter

- Dismount pre-screen and access cover of by- Open bolts on back side of fixing wedge.- Remove fixing wedge.- Pull jaw out (see picture VII.11.3).- Clean the guide liners and contact surfaces.- Visual inspection of side-wear-plates.- Replace jaw.- Put in fixing wedge.

Picture VII.11.3: fixation point

Put in fixing wedge.- Check gap between jaw and side liners.- Tighten bolts of fixing wedges.- Close cover of bypass chute.- Install pre-screen.


attery key.ulled off, the machine nal persons.

ee picture VII.12)

Picture VII.11.1: eccentric-bolts

hexagon-nuts.eccentric-bolts.

es

attery key.ulled off the machine

es.

Picture VII.11: fixing wedges

ulled off, the machine rnal persons.ypass chute (see picture VII.11.2).

Picture VII 12: bolts fixing wedges

e 56

Picture VII.12: bolts - fixing wedges

Preparation before Welding

Step 1: (A till C)

•(A) Take care that all electrical connection-points to the diesel-engine ancontrol-unit are disconnected

•(B) Turn off the circuit breaker Nr.19 and 24 till 29

•(C) Disconnect both connector of the PLC (position 23)

A

B

Side

nd

AA

B

C

e 57 57

Preparation before Welding continuation

Step 2: (D till E)

•(D) Take off the main-fuse (pos. 31 and 34)

•(E) Turn off the main-battery-switch (pos. 32)

D

D

Side

D

E

e 58 58

Preparation before Welding continuation

Step 3: (F)

•(F) Pull out the connector for the remote-control

Side

FF

e 59 59

ÖLSTANDSKONTROLLE:

Diesel Motor

Bild VII.16: Messstab Diesel Motor

Vibrogetriebe

Bild VII 18: Ölstand Vibrogetriebe


Bild VII.18: Ölstand Vibrogetriebe

Hydrauliktank

Laufwerksgetriebe

Bild VII.17: Ölstand Hydrauliktank

e 60

Bild VII.19: Ölstand Laufwerksgetriebe

ÖLSTANDSKONTROLLE:ÖLSTANDSKONTROLLE:

Verteilergetriebe

Bild VII.20: Ölstand Verteilergetriebe


KÜHLWASSERSTANDKONTROLLE:

Ausgleichsgefäß

Bild VII.21: Kühlwasser-Ausgleichsgefäß

e 61

1000h orll 200 h 100 h 50 h daily SERVICE AND REPAIR PLAN:annually 200 h 100 h 50 h daily SERVICE AND REPAIR PLAN:

Jaw crusher:x Check jaw wear status

x Check crusher gapx Check wedge for firm mountingx Check wedge for firm mounting

x Check crusher housing reinforcex Check crusher housing reinforcex Lubricate shaft bearing (10 pump

Vibration feeder and gear, pre-x Check bolts and connections forx Check bolts and connections for x Check wear

x x Oil change (first after 100h, thenChutes and hoppers:

x Check material clearancex Check wearx Check wear

Main discharge belt:x Check conveyor belt for damagex Check conveyor route

x Lubricate bearings of the tail pullx Check setting and belt tensionx Check setting and belt tensionx Check safety guard

Side discharge belt:x Check conveyor belt for damagex Check conveyor route

x Lubricate bearings of the tail pullx Lubricate bearings of the tail pullx Check setting and belt tensionx Check safety guard

Magnetic separator:x Check belt for damagex Check conveyor routex Check conveyor routex Lubricate bearings of the tail pullx Check setting and belt tensionx Check safety guard


ed plating wear statused plating for firm mountingp lifts with grease press per each greasing point and lubrication interval)-screening:firm mountingfirm mounting

annually or after 1000h)

e

ley and the driving drum (1-2 pump lifts with grease press)

e

ley and the driving drum (1-2 pump lifts with grease press)ley and the driving drum (1 2 pump lifts with grease press)

ley and the driving drum (1/2 or every 2nd day 1 pump lift with grease press)

e 62

1000h orannually 200 h 100 h 50h daily SERVICE AND REPAIR P

Caterpillar crawler gear:x Visual inspection, accordinx Check chain tension (25mm

x Gear oil – change, first afteStructures and platforms

x Check structures and platfoDrive unit:Maintenance and repair wo

x Check V-belt tensionx Check firm mounting of co

C / fx Clean/Replace the air filterx Replace the air filter safety

Combi-Cooler:x Clean cooling elementx Check water level

Ch k th l t/ tifCheck the coolant/antifreezOil-cooler:

x Clean cooling elementHydrostat:

x x Replace filter first after 100L b i t h d t t b ix Lubricate hydrostat bearingHydraulics:

x x Change of return flow filterx x Change of overflow oil filtex Funnel-air-filter

x Check system for leakagesx Check system for leakagesPump transfer gear:

x Check oil-levelx x Oil change first after 100 h

V-belt drive:x Check V-belt and V-belt tex Check V-belt and V-belt te

x Check V-belt pulley for firmComplete electrical syste

x Check cable and connectinx Check components for firm

x Check emergency OFF sw


x Check emergency OFF sw

PLAN (continued):

ng to instructions in Maintenance/Crawler track Chapterm sag)er 500h, then annually or after 1000hs:orms for firm mounting

ork, see Caterpillar 7.0 Manual!

mponentsr inserty cartridge

( CAT M l)ze (see CAT-Manual)

0 h, then every 1000 hours or annually (concerining filter display)(3 lift ith l b i ti i t l)gs (3 pump lifts with grease press per lubrication interval)

r first after 100 h, then every 1000 hours or annuallyer first after 100 h, then every 1000 hours or annually

ss

, then annually or after 1000h

nsionnsionm mounting (one-time after 100h)em:ng plugs for firm mounting 8one-time after 100h)

m mountingwitch for correct functioning

e 63

witch for correct functioning

RECOMMENDED OIL QUALITIES:

Gear oil Hydraulic oil Gr

RECOMMENDED OIL QUALITIES:

Blasia 220Degol BG 220Energol GR-XP 220Alphamax 220Engranajes HP 220

Energol HLP 46Tellus HLP 46Renolin B15 VG 46OSO 46

AraBPLS-BeaCeEngranajes HP 220

Falcon CLP 220Epona Z 220Spartan EP 220Renep Compound 106Gearmaster CLP 220Kluberoil GEM 1 220

CeMoSheFetTrib

Kluberoil GEM 1-220Mobilgear XMP 220Ripress EP 220Gear HST 220Optigear BM 220Rembrandt EP 2S T 220Super Tauro 220Omala 220Meropa 220Carter EP 2201100-220

SideVII. MAINTAINANCE

ease Motor oil Antifreeze

alup HLP 2 Energrease -EP2acon EP2ntoplex 2

Vanellus-Multigrad 15 W 40 Vanellus C3Rimula Super 15 W 40Titan Universal HD 15 W 40Blitum T 15 W 40

Use only antifreeze who is suitable for all kind of metal (aluminium, steel) and complying with the standard ASTM D4985 or ASTM D6210ntoplex 2

obilux EP2ell Alvania EP tt 2bol 3030

Blitum T 15 W 40ECL Cat-anti-freeze

protectionRowe – Hightec AntifreezeArteco Havoline AFC

or ASTM D6210.

Arteco – Havoline AFCArteco – Havoline XLC

e 64

VIII.STANDARD FOVIII.STANDARD FOR800 JAW CRUSHER

SideVIII. STANDARD FORMS

INHALTSVERZEICHNIS:CONTENT:

I P f Sid 2INHALTSVERZEICHNIS:

I. Vorwort Seite 2

II. Verwendungszweck Seite 4

I. Preface Side 2II. Intended use Side 4III Safety Side 6 Safety hazard symbols Side 7Operating instructions Side 13

III. Sicherheit Seite 6 Sicherheits/Gefahrensymbole Seite 7Betriebsanleitung Seite 13Wartungsarbeiten Seite 24

p gMaintenance work Side 24IV.Technical data Side 26Overview Side 27Building groups Side 28V Start up Side 33IV. Technische Daten Seite 26Überblick Seite 27Baugruppen Seite 28

V. Inbetriebnahme Seite 34

V. Start up Side 33Operation devices Side 34Transport Side 40 System set up Side 42Gap adjustment Side 45

VI O ti Sid 46Bedienelemente Seite 35Transport Seite 41Aufstellen der Anlage Seite 43Spaltverstellung Seite 46

VI B t i b S it 48

VI. Operation Side 46Special operating information Side 47Procedure crusher operation Side 49VII. Maintenance Side 51Hydraulic system Side 52 Di l t Sid 53VI. Betrieb Seite 48Besondere Betriebshinweise Seite 49Vorgangsweise Brecherbetrieb Seite 51

VII. Wartung Seite 53Hydraulikanlage Seite 54

Diesel motor Side 53Vibration feeder Side 53Caterpillar crawler Side 54Crawler gear Side 54Conveyor belts Side 55V belts Side 55

ORMSHydraulikanlage Seite 54Diesel Motor Seite 56Vibrationsrinne Seite 55Laufwerk Seite 56Laufwerksgetriebe Seite 56Fördergurte Seite 58

V-belts Side 55Jaw crusher Side 56Welding preparations Side 57Oil level monitor Side 60Service plan Side 62Recommended oil qualities Side 64ORMS Keilriemen Seite 59Prallbrecher Seite 59Ölstandskontrolle Seite 60Wartungsplan Seite 62Schmiermittelübersicht Seite 64

Recommended oil qualities Side 64VIII. Standard forms Side 65Rockster warranty registration Side 66CAT warranty registration Side 67Warranty claim Side 68Terms and conditions Side 69

e 65


Sidee 66

SideVII. WARTUNG e 67

SideVII. WARTUNG e 68

Sidee 69

Sidee 70

manual r800 with mondial cat 7.0

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