Metso NORDBERG LT105 Page 36 Instruction Manual Download

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Chapter 7

Crushing

3/02

CRUSHING

7.1 CRUSHING LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.2 FEEDING MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7.3 DISCHARGE ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4

7.4 CRUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-6

7.5 BY PASS CHUTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-11

7.6 FEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-12

7.7 MINIMUM SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-13

7.8 CLEARING OF THE BLOCKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-14

7.9 REMOVAL OF THE STEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-14

7.10 RECYCLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-15

7.11 OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-15

7.12 INSTRUCTIONS FOR RADIO CONTROL (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-16

https://tractormanualz.com/

Summary of Contents for NORDBERG LT105

Page 1: ...NORDBERG LT105 LT105S INSTRUCTION MANUAL 140561 B https tractormanualz com ...

Page 2: ...ented to be used in recycling crushing applications in crushing plants Because of the continuous development of the product the manufacturer reserves a right to alter the technical specifications written in this manual without any advance information This is the second edition published in February 2002 in Tampere Finland Manufacturer Metso Minerals Tampere Oy P O Box 306 33101 Tampere Finland Tel...

Page 3: ...se and at the equipment s place of operation generally recognized rules for safe and professional operation must be observed This instruction manual must be read and used by each person who works with the equipment typically operations including installation startup operation application engineering materials handling site labour environmental engineering and safety departments maintenance includi...

Page 4: ...OPPING SAFELY 2 3 2 7 TIPS FOR SAFE MAINTENANCE 2 3 2 8 READ AND UNDERSTAND 2 3 2 9 WARNING TAGS 2 3 2 10 LOCKOUT ELECTRICAL SERVICE 2 3 2 11 CLOTHING SAFE PRACTICE 2 4 2 12 ALCOHOLIC BEVERAGES AND MEDICATION 2 4 2 13 WORK AREA 2 4 2 14 EQUIPMENT 2 4 2 15 FIRE HAZARDS 2 4 2 16 PRESSURIZED SYSTEMS HYDRAULIC OR AIR 2 5 2 17 REPORT NECESSARY REPAIRS 2 5 https tractormanualz com ...

Page 5: ... of the operator to know what specific requirements precautions and work area hazards exist and to discuss them with his supervisor A common understanding should be reached by all personnel to assure safe performance in operating the equipment The operator is the key to safe job performance and should study these safety tips to be aware of basic safety precautions to help prevent serious injury an...

Page 6: ... loose parts in a tool box Use only non flammable solutions for cleaning Know the weight limitations for any floors on which you will operate Know the clearances in the work area A little time spent checking side and overhead clearances including power lines can save a lot of trouble later Be careful of dust smoke or fog which may obscure your vision ARE YOU PREPARED FOR EMERGENCIES Plan ahead sta...

Page 7: ... DO NOT take a chance with a defective machine REPORT IT TO YOUR SUPERVISOR 2 5 REPORT A DEFECTIVE MACHINE Inspect your machine daily check for loose worn or damaged parts Report or correct any unsafe conditions immediately and do not operate the machine until they have been corrected Even a minor defect can become serious report any machine defects to your supervisor 2 6 STOPPING SAFELY Be sure C...

Page 8: ... for ice and snow Wet spots especially near electrical equipment are dangerous 2 DO NOT let material lay and build up on or around the Crusher 3 3STORE dangerous fluids in a suitable place away from unauthorized personnel ALLOW NO SMOKING IN THE AREA 4 NEVER start a diesel or gasoline engine within an enclosed area unless there is adequate ventilation Exhaust fumes can kill 2 14 EQUIPMENT 1 Use th...

Page 9: ...raulic or air pressure lines valves fittings etc 2 Check for worn hoses or damaged lines 3 High pressure oil can be dangerous USE QUALITY PARTS A replacement part for any item should always be of comparable SIZE TYPE AND QUALITY as the part being discarded 2 17 REPORT NECESSARY REPAIRS If your daily check uncovers any item that need attention repair replacement or adjustment REPORT IT NOW The most...

Page 10: ... 3 2 3 4 CRUSHER 3 2 3 5 FEEDER 3 2 3 6 MAIN CONVEYOR 3 2 3 7 SIDE CONVEYOR OPTIONAL 3 2 3 8 MAGNETIC SEPARATOR OPTIONAL 3 2 3 9 HYDRAULIC VALVE LOCATION 3 3 3 10 HYDRAULIC SETTING CONTROL OPTIONAL 3 4 3 11 FEED HOPPER FOLDING 3 4 3 12 ENGINE MODULE 3 5 3 13 HYDRAULIC TANK 3 7 https tractormanualz com ...

Page 11: ...UCTION MANUAL 3 1 MAIN COMPONENTS CHAPTER 3 3 1 MAIN ASSEMBLY 1 Diesel engine 2 Tracks 3 Crusher 4 Feeder 5 Main conveyor 6 Side conveyor optional 7 Magnetic separator optional Figure 3 1 Main assembly 1 2 3 4 5 6 7 https tractormanualz com ...

Page 12: ... into the crusher The feed material smaller than the opening of the feeder grizzly goes through the grizzlies passing the crusher This increases the capacity and prevents material packing in the crusher 3 6 MAIN CONVEYOR The main conveyor transfers the crushed material from the crusher to the stock pile or to the next process 3 7 SIDE CONVEYOR OPTIONAL The optional side conveyor transfers the mate...

Page 13: ...ydraulic outlet 5 Magnetic separator 6 Left track 7 Right track 8 Feeder 9 Side conveyor hand valves 10 Side conveyor turning up down 11 Side conveyor extension in out 12 Main conveyor turning up down 13 LS pressure gauge 14 Engine coolant drainage 15 Engine oil drainage 16 Hydraulic outlet PTO 17 Hydraulic oil drainage Figure 3 9 Hydraulic valve location https tractormanualz com ...

Page 14: ...DRAULIC SETTING CONTROL OPTIONAL 1 Manual valve 2 Adjustment wedge movement 3 Return rod pressurizing 4 Return rod pressure sensor 3 11 FEED HOPPER FOLDING 1 Left side wall lifting and lowering 2 Rear wall lifting and lowering 3 Right side wall lifting and lowering https tractormanualz com ...

Page 15: ... drive pump return line when crusher running to normal direction b Crusher drive pump charge pressure c Crusher drive pump pressure when crusher running to normal direction 2 Engine primary fuel filter and water separator 3 Dipstick 4 Oil fill port 5 Oil filter 6 Charger 7 Coolant expansion tank 8 Crusher circuit filter 9 Hydraulic pressure filter https tractormanualz com ...

Page 16: ... MAIN COMPONENTS Figure 3 12 b Engine module 1 Air cleaner 2 Air precleaner 3 Fuel filter secondary 4 Mechanical fuel transfer pump 5 Engine electronics 6 Hydraulic pressure filter 7 Coolant expansion tank 8 Batteries 9 Crusher circuit filter https tractormanualz com ...

Page 17: ...02 02 3 38 B NORDBERG LT105 105S INSTRUCTION MANUAL 3 7 CHAPTER 3 MAIN COMPONENTS 3 13 HYDRAULIC TANK 1 Hydraulic return filter 2 Breather 3 Hydraulic oil sight glass https tractormanualz com ...

Page 18: ... Control panels 3 02 CONTROL PANELS 4 1 OPERATING PANEL SWITCHES BUTTONS 4 1 4 2 DRIVE CONTROL BOX 4 2 4 3 REMOTE CONTROL 4 3 4 4 HYDRAULIC MODULE CENTER 4 4 4 5 IC500 CONTROL SYSTEM 4 5 https tractormanualz com ...

Page 19: ...TION MANUAL 4 1 CONTROL PANELS CHAPTER 4 4 1 OPERATING PANEL SWITCHES BUTTONS 1 Emergency stop 2 Lubrication unit 3 Radio key 4 Water pump 5 Display 6 Process ON 7 Key switch 8 Signal horn 9 Process OFF 10 Work light https tractormanualz com ...

Page 20: ...LT105 105S INSTRUCTION MANUAL 4 38 B 02 02 CHAPTER 4 CONTROL PANELS 4 2 DRIVE CONTROL BOX 4 2 1 DRIVING CONTROLS 1 Track left hand 2 Track right hand 3 RPM of diesel engine 4 Emergency stop https tractormanualz com ...

Page 21: ... PANELS 4 3 REMOTE CONTROL 1 Emergency stop 2 Feeder stop 3 Feeder start 4 Feeder speed 5 Feeder speed 6 Crusher stop 7 Crusher start 8 Crusher counter clockwise swing 9 Crusher clockwise swing 10 Crusher setting increase 11 Crusher setting decrease https tractormanualz com ...

Page 22: ...05S INSTRUCTION MANUAL 4 38 B 02 02 CHAPTER 4 CONTROL PANELS 4 4 HYDRAULIC MODULE CENTER 1 Safety switch for conveyors 2 Fuel pump optional 3 Socket for screen module 4 Emergency stop 5 Hand valves https tractormanualz com ...

Page 23: ...N MANUAL 4 5 CHAPTER 4 CONTROL PANELS 4 5 IC500 CONTROL SYSTEM Please refer to a separate IC500 Instruction Manual for information on usage of this control system The manual is attached to this Instruction Manual folder https tractormanualz com ...

Page 24: ...nd stopping 3 02 STARTING AND STOPPING 5 1 BEFORE STARTING 5 1 5 2 STARTING THE DIESEL ENGINE 5 2 5 3 STOPPING THE DIESEL ENGINE 5 2 5 4 ADJUSTING DIESEL ENGINE RPM SPEED 5 2 5 5 EMERGENCY STOP 5 3 https tractormanualz com ...

Page 25: ...sel engine coolant water diesel engine oil level Turn the light pole up figure 5 1 1 if necessary Figure 5 1 1 Turn the light pole up Check the crusher V belt tensions The belt deflection is 22 mm 4 5 when force is 50 N 11 lb figure 5 1 2 Figure 5 1 2 Check crusher V belt tensions 1 2 3 MAIN SWITCH 22 mm 0 86 50 N 11 lbs https tractormanualz com ...

Page 26: ...urn the key switch to START position and hold it that way until the engine is running NOTE Hold the key switch at start position until the diesel engine starts NOTE If you use manual control be especially careful The fact is that manually activated device will not run until the diesel engine is running But the device will start to operate immediately when the engine is started if the manual contro...

Page 27: ...ss emergency stop button to stop the machine or the conveyor The buttons are shown in the drawing 5 5 1 Operating of emergency relay ref chapter 10 Figure 5 5 1 Location of the Emergency stop buttons EMERGENCY STOP BUTTON FUNCTION A Stops the machine B Stops the discharge conveyor C Stops the main conveyor https tractormanualz com ...

Page 28: ...NSURE THAT THE SUCTION VALVES OF THE HYDRAULIC TANK ARE FULLY OPEN If the suction valves are not fully open the position switch of the suction valves will cause emergency stop function Figure 5 1 2 Ensure that the suction valves of the hydraulic tank are fully open https tractormanualz com ...

Page 29: ... Transport 3 02 TRANSPORT 6 1 SAFETY WHILE TRACKING 6 1 6 2 TRACKING SPEED 6 1 6 3 DRIVING THE LT105 6 2 6 4 TRANSPORT FROM SITE TO SITE 6 4 6 5 DRIVING ON TO OFF LOW LOADER TRAILER 6 5 https tractormanualz com ...

Page 30: ...smooth enough differences in altitude and road inclination do not prevent driving Whilst tracking the machine the maximum inclination allowed is 5 degrees sideways and 15 degrees length ways Make sure that the load bearing capacity of the ground is at least 15 000 kg m2 3072 lbf sq f Start the engine as instructed in chapter 5 2 6 2 TRACKING SPEED The tracking speed varies according to the diesel ...

Page 31: ...ntrol cable into one of the cable connecting sockets figure 6 3 1 and 6 3 2 The Lokotrack can now be moved in either direction using drive control levers in the remote control unit figure 6 3 2 Always check the surroundings of Lokotrack before moving it Figure 6 3 1 Plug the drive control cable into one of the cable connecting sockets Figure 6 3 2 The LT105 can be moved in either direction using d...

Page 32: ...longer moves over 100 m 328 ft LT105 must be driven feeder end first That is to keep the track chain tight and to prevent the chain from jumping over drive pulley teeth If no crushing is required stop the engine as instructed in chapter 5 3 If you start crushing see section 5 2 Some hints to make turning the LT105 easier LT105 turns easier on hard than soft ground If the LT105 can not be turned wh...

Page 33: ...ic road take care that it has the necessary permissions from authorities for special transport Check the local regulations as they vary in each country EQUIPMENT NEEDED Low loader min capacity 40 t 44 st MEASURES BEFORE TRANSPORT 1 Turn down additional side walls of the feeder ref 7 4 2 Turn the side conveyor up ref 7 4 https tractormanualz com ...

Page 34: ... 6 5 DRIVING ON TO OFF LOW LOADER TRAILER Drive LT105 onto and off loader trailer very carefully Fix suitable ramp against the trailer so that the maximum inclination does not exceed 1 in 4 when driving the LT105 up onto the trailer The LT105 may be driven onto the trailer forwards or backwards depending on trailer type https tractormanualz com ...

Page 35: ...s due to manufacturing tolerances WEIGHT OF THE BASE UNIT WITHOUT FUEL LT105 35600 KG 78480 LBS AND LT105S 39600 KG 87480 LBS Total weight of LT105 with options kg lbs Side conveyor H 5 5 600 1320 Bracket for magn separator 300 660 Magnetic separator 1100 2420 Feed hopper 9m3 570 1255 Hydr setting adjustm 100 220 Recycling plate 85 187 Long conveyor H10 15 1765 3890 Dust cover 140 310 Hammer Pedes...

Page 36: ...ARGE ARRANGEMENT 7 4 7 4 CRUSHING 7 6 7 5 BY PASS CHUTE 7 11 7 6 FEED CONTROL 7 12 7 7 MINIMUM SETTING 7 13 7 8 CLEARING OF THE BLOCKAGE 7 14 7 9 REMOVAL OF THE STEEL 7 14 7 10 RECYCLING 7 15 7 11 OPTIONAL EQUIPMENT 7 15 7 12 INSTRUCTIONS FOR RADIO CONTROL OPTIONAL 7 16 https tractormanualz com ...

Page 37: ...harge machinery a wheel loader or excavator and a lorry figure 7 1 2 Figure 7 1 1 First shape the material pile Figure 7 1 2 General measures taken on the site The location where the crusher is to be placed must be even The machine must not be allowed to sway The surface below the crusher must be levelled and evened out Spread some fine grained material on the ground distributing it evenly figure ...

Page 38: ... direction figures 7 1 5 and 7 1 6 Figure 7 1 5 The maximum lateral inclination permitted during the crushing process is 1 degree Figure 7 1 6 The maximum longitudinal inclination permitted during the crushing process is 2 degrees For purposes of maintenance it is recommended that you dig a hole under the LT105 unit figure 7 1 7 Figure 7 1 7 Dig a hole under the LT105 for purposes of maintenance m...

Page 39: ...e metal pieces before they are able to enter the crusher LOADING USING A WHEEL LOADER The LT105 can only be loaded from the rear Maximum bucket width is 3200 mm 126 If required use the feed material to make a loading ramp to ease access to the feeder Drive the LT105 as close to the pile as possible to make loading quick and easy NOTE The feeder has two basic applications stabilising the feed rate ...

Page 40: ...ce between the pile and the conveyor must always be at least 200 mm 9 figure 7 2 1 When discharging with the help of the wheel loader be careful not to damage the conveyor Discharge from the side do not push the material under the LT105 unit The material emitted from the vibrating chute can be directed to either the main conveyor or the side conveyor with the help of the control plate Figure 7 3 1...

Page 41: ...n of the side rubbers in both of the joints Deactivate the manual valves FROM CRUSHING TO TRANSPORT Activate hand valves Turn the hydraulic output switch ON ref 4 1 and 12 Remove crushing position locking pins at from their places Lift the conveyor slightly to allow easy locking pin removal Lower the conveyor drivehead to transport position Mount transport lockings at their place Deactivate hand v...

Page 42: ...down with the help of the controls located in the hydraulic valve section figures 7 4 1 and 7 4 2 Figure 7 4 1 Turn the side conveyor down with the help of the control levers Figure 7 4 2 Conveyor control switches 1 Side conveyor up down 2 Side conveyor in out 3 Main conveyor folding NOTE The control switch for manual valves refer to Chapter 3 9 https tractormanualz com ...

Page 43: ... with the crane phase 1 and position the wedges When positioning the wedges the crane must not make any corrective measures If the wedge cannot be fitted in its place the mechanic must move away from the side wall and give new instructions to the crane attendant After this place the wedge first at the crusher end phase 2 and then at the feeding end phase 3 Once the wedges are fitted in their posit...

Page 44: ...that the crusher is securely stationed so that there is no risk of its inclination Operation of the crusher is only permitted when all necessary protective and safety devices e g guards emergency stop devices silencers aspirators etc are in place and in full operating condition Before starting the crushing process make sure that no one is on next to or under the crusher Before starting the machine...

Page 45: ...gine The termination of the crushing process takes approximately 1 minute 1 Process options eg side conveyor magnet separator or hydraulic PTO must be selected before the process start Process options are editable during the process 2 You can stop the feeder and crusher in order to safely remove uncrushable objects from the feeder Crusher and feeder can be restarted from the service platform Load ...

Page 46: ...er This may overload and damage the crusher Also make sure that no explosives are allowed to enter the crusher Figure 7 4 7 Emergency stop buttons for more information refer to 5 5 NOTE The side conveyor must not be switched on if it is in transport position Figure 7 4 8 Do not switch the side conveyor on while it is in a transport position https tractormanualz com ...

Page 47: ... deck materials larger than the mesh can be directed towards the main conveyor fig 7 5 3 Turn the lever to change the direction of the material flow When using the centre position lock the lever in place using a bolt Figure 7 5 1 The chute has been directed towards the main conveyor Figure 7 5 2 The chute has been directed towards the side conveyor Figure 7 5 3 The flow of materials has been scree...

Page 48: ...tem will ask to carry out a cold start of the process The feeder will not start until the temperature of the oil has reached a certain temperature In order to stabilise the feed rate the feeder always starts at minimum speed regardless of the speed setting After a while the speed changes to the set value In order to control the capacity the feeder speed can be adjusted using the crusher speed swit...

Page 49: ...below 10º C 50º F and the bitumen content is low Slag 0 550 mm 22 The size of the material is measured as illustrated in figure 7 7 1 Figure 7 7 2 Setting adjustment Figure 7 7 1 Measurement of the material dimensions 7 7 2 SETTING ADJUSTMENT Manual setting adjustment refer to the C Jaw Instruction Manual for instructions on setting adjusment Hydraulic setting adjustment Settings can be adjusted o...

Page 50: ...der and the crusher will not function You can swing the crusher clockwise and counter clockwise with the buttons 8 and 9 fig 7 8 1 of the remote control box located on the service platform When the cavity is clear switch on the crusher using the Crusher start button 7 figure 7 8 1 Start the feeder 7 9 REMOVAL OF THE STEEL Always stop the machine feeder crusher conveyors and engine before removing ...

Page 51: ...evel indicator is to control the feed material level that enters the crusher The indicator stops the feed process and emits a light signal when the material level is too high The indicator resets itself automatically Keep the level indicator clean to ensure that it functions proper function Refer to the IC500 Instruction Manual for further information on switching the level indicator to ON or OFF ...

Page 52: ...eiver two batteries charging device for the batteries two key switches power outlet adapter for 24VDC 1 Engine rpm UP DOWN feeder ON OFF 2 Battery 3 Feeder speed increase decrease 4 Remote STOP 5 Left track forward backward 6 Battery voltage level indicator 7 Selector switch tracking crushing 8 Right track forward backward 9 Key switch https tractormanualz com ...

Page 53: ...ched on again if radio control is required 7 12 4 BATTERY VOLTAGE LEVEL 1 Voltage level indicator LED indicator 6 indicates the voltage level by flashing When the voltage level decreases the flashing becomes less frequent The radio will not function if the voltage level decreases too much Try to utilise the full capacity of the batteries in order to increase the battery lifetime 2 Voltage level al...

Page 54: ...5 MANUAL CONTROLS WITH SCREEN UNIT 8 6 8 6 FOLDING THE SCREEN UNIT TO CRUSHING POSITION 8 6 8 7 PROCESSING WITH THE SCREEN UNIT 8 9 8 8 TRACKING ON SITE WITH LT05S 8 9 8 9 FOLDING THE SCREEN UNIT TO TRANSPORT POSITION 8 11 8 10 DISCONNECTING THE SCREEN UNIT FROM THE LT105 8 13 8 11 CONNECTING SCREEN UNIT TO LT105S 8 16 8 12 PERIODICAL MAINTENANCE 8 16 https tractormanualz com ...

Page 55: ...utomatically when the electrical socket is connected Crushing process of the LT105S starts with the screen if the socket and hydraulic hoses are connected WARNING MAKE SURE THAT ALL HYDRAULIC CONNECTIONS ARE PROBERLY CONNECTED BEFORE STARTING THE DIESEL ENGINE 1 H8 8 oversize conveyor 2 Screen TK11 30S 3 H6 5 4 undersize conveyor 4 Mechanical legs 5 Hydraulic legs 6 Cylinder for H8 8 up down movem...

Page 56: ... refer to fig 8 1 1 3 2 Connection socket for screen module control panel located on the hydraulic module of the screen unit refer to fig 8 3 1 Figure 8 1 1 Hydraulic control module HCM panel 1 Connection socket for the service light 2 Fuel pump optional 3 Connection socket for screen module 4 Emergency button 5 Switch for hand valves 6 Safety switch for conveyors https tractormanualz com ...

Page 57: ...lve block 3 Return line of H8 8 conveyor 4 Load sense line from valve block 5 Screen drive motor leakage 6 Line conveyor leakage NOTE Connect or disconnect the quick connectors only when the diesel engine is shut off Mechanical connection Screen unit is mounted with 4 pins to the Lokotrack frame Pins are secured with lock rings https tractormanualz com ...

Page 58: ...1 Pressure relief connection section 2 H6 5 4 and H8 8 conveyor drive valves 3 Screen drive valve 4 H8 8 conveyor swing left right 5 H8 8 conveyor swing up down 6 Left hydraulic support leg 7 Right hydraulic support leg 8 Junction box 24 VDC 9 Connection socket for screen module control panel 10 Pressure relief valve https tractormanualz com ...

Page 59: ...ght b H8 8 conveyor swing left down c Hydraulic support leg up down at hydraulic module side d Hydraulic support leg up down at conveyor side Control panel socket is located on the hydraulic valve module NOTE Make sure that all hydraulic connections are proberly connected before using Control panel for screen unit https tractormanualz com ...

Page 60: ...enu refer to the IC500 Instruction Manual 8 6 FOLDING THE SCREEN UNIT TO CRUSHING POSITION 1 Connect the screen module control panel for folding to the control socket LT105 control panel 2 Release transport lockings 3 Lift the drive end of the H8 8 conveyor slightly upwards in order to allow the conveyor to swing above the support 4 Swing the H8 8 conveyor 30º downwards from the vertical position ...

Page 61: ...N MANUAL 8 7 CHAPTER 8 SCREEN UNIT 5 Straighten the conveyor H8 8 6 Release the support leg and lower the conveyor H8 8 above the support 7 Release the hydraulic support legs and support screen module against the ground https tractormanualz com ...

Page 62: ...8 Lift conveyor H8 8 side walls on their place and lock the conveyor joint with the locking pin 9 Remove the screen transport locking 10 Remove the conveyor belt rubber strap 11 Start the crushing process and observe belt tracking and support leg balance https tractormanualz com ...

Page 63: ...ction of the screen is against the material flow direction Due to reduced material flow it might reduce the tonnage of the unit Standard rotation direction is along the material flow this will give highest tonnage The direction of the screen unit can be selected from the process options window Refer to the IC500 Instruction Manual Maximum feed to the screen unit is 200 mm 8 Minimum mesh hole size ...

Page 64: ... 8 SCREEN UNIT 2 Turn the support leg of H8 8 conveyor to rest position and secure with a locking pin 3 Lower the H8 8 conveyor until the weight rests on the steel cables 4 Raise the hydraulic support legs 5 Unit is ready to be moved on site https tractormanualz com ...

Page 65: ...de walls of the H8Ä8 conveyor from their place 2 Remove the locking pin of the H8 8 conveyor from it s position Swing prevention 3 Assemble the rubber strap to the conveyor H8 8 to prevent conveyor belt from sliding out it s place 4 Lift the conveyor 5 Raise the support leg of the H8 8 conveyor and lock to rest position https tractormanualz com ...

Page 66: ...RG LT105 105S INSTRUCTION MANUAL 8 13 B 02 01 CHAPTER 8 SCREEN UNIT 6 Raise the support leg of the H8 8 conveyor and lock to rest position 7 Swing the conveyor downwards above the support https tractormanualz com ...

Page 67: ...tion 8 10 DISCONNECTING THE SCREEN UNIT FROM THE LT105 NOTE Find a plain surface to disconnect the screen unit 1 Fold the screen unit to crushing position 2 Release the mechanical support legs a and mount the support arms with locking pins c to their places Furthest legs must be pulled b out to middle position before locking them to vertical position 3 Extend the hydraulic legs as farout as they c...

Page 68: ...that both of the furthest mechanical support legs are properly supported to the ground The frame of the screen unit is now no clearance free against the LT105S frame and the upper pin locking ring pair can be removed from their place 6 Extend the hydraulic cylinders fully Lower the nearest mechanical support legs down and lock them to next position from the ground 7 Retract the hydraulic cylinders...

Page 69: ...ses between the screen unit and LT105S 9 Disconnect the electrical plug and socket arrangement between the screen unit and LT105S 10 Disconnect the steel cables between LT105S frame and H8 8 conveyor 11 Drive the LT105S directly away from the screen unit Use crawling speed and observe that the unit moves directly and does not damage to the frame of screen unit https tractormanualz com ...

Page 70: ...and store them properly 8 Lift mechanical support legs to upright position 8 12 PERIODICAL MAINTENANCE Maintenace intervals NOTE Connect or disconnect the quick connectors only when the diesel engine is shut off ITEM daily weekly every month 6 months H8 8 CONVEYOR Belt tracking tension x Greasing 10 g 40 h each bearing x Check roller condition x Greasing folding joints x H6 5 4 CONVEYOR Belt track...

Page 71: ...to water cold 30 22 F and hot continuous operating temperature 100ºC 212ºF The grease must not oxidize easily and it must contain EP additives Don t use grease containing molybdenium The minimum viscosity of the base oil must be 160 mm2 s cSt in 40ºC 104ºF and minimum viscocity index 80 Please consult TK11 30S instruction manual for more detailed information https tractormanualz com ...

Page 72: ...PACER REMOVAL ASSEMBLY TOGGLE PLATE CHANGE 9 5 9 7 FILLING VOLUMES 9 6 9 8 TRACKS 9 7 9 9 LUBRICANT RECOMMENDATION 9 8 9 10 CRUSHER 9 8 9 11 FEEDER SCREEN 9 8 9 12 TRACK GEAR 9 8 9 13 GREASE 9 8 9 14 ADDING HYDRAULIC FLUID 9 8 9 15 ADDING ENGINE FLUIDS 9 9 9 16 REMOVING ENGINE HYDRAULIC FLUID 9 9 9 17 ENGINE FUEL FILTER REPLACEMENT 9 9 https tractormanualz com ...

Page 73: ...ird time X See the engine operating manual for other maintenance X JAW CRUSHER Check V belt tension X Check the tightness of the jaw bolts daily during the first 40 operating hours after jaw installation Then weekly X X Check the tightness of cheek plate bolts X Check the side guide plates and the protection rubber of the toggle plate X Lubricate crusher drive jack shaft 10g 40h bearing X Check we...

Page 74: ... device X Check the rubber covers X AUTOMATIC LUBRICATING DEVICE Check operation and grease amount add grease if necessary X VIBRATOR UNIT Oil change 1000h Ref 8 7 X X Check oil level X Replace breather 1000 h X FEEDER Clean vibration unit from outside X Check tightness of vibration unit joints X Check the wires hoses X Check tightness of screen deck mountig bolts X CONVEYORS Lubricate the bearing...

Page 75: ...Change oil X BATTERY Check fluid level X Check the cleanliness of the battery terminals X TRACKS Check tension of track chains X Check tightness of track bolts X MAGNETIC SEPARATOR Lubricate the bearings 3g 40h Bear X Check the belt tension X FUEL TANK Breather replacement X Fuel fill pump filter replacement optional X First oil change Daily Weekly Monthly 200 h Every 6 months Every 12 months When...

Page 76: ...h this oil type is about 65ºC 149ºF and min allowable starting temperature is about 30ºC 86ºF Attached some examples of oil brands meeting these requirements BP Energol SHF 32 Esso Univis N 32 Mobil DTE 13 Shell Tellus Oil T 32 Teboil Tebo Hydraulic Oil 32 S In summer time e g in hot climate conditions when the ambient temperature exceeds 35ºC 95ºF the use of a special hydraulic oil of ISO VG 68 c...

Page 77: ...s ISO VG 220 9 5 FUEL LEVEL The fuel level can be checked from the fuel amount indicator in the display figure 9 5 1 Fuel tank capasity 600l 160gal NOTE The system will inform about a low fuel amount by a display alarm but it will not prevent the machine from running out of fuel 9 6 CRUSHER SPACER REMOVAL ASSEMBLY TOGGLE PLATE CHANGE Please refer to the C105 manual Figure 9 5 1 Checking the fuel l...

Page 78: ...UG Engine is equipped with oil grade plug refer to the C 9 Operation and Maintenance Manual Factory filled oil type 10W30 plug position 1 LT105 AMOUNT TYPE Hydraulics 520 l 140 gal ISO VG 46 Final drive 4 5 l 1 2 gal ISO VG 220 Fuel tank 600 l 160 gal Feeder vibr unit 4 l 1 gal ISO VG 150 CATERPILLAR C9 Engine oil 28 l 7 5 gal Water 36 l 9 5 gal OIL GRADE DETECTION Plug Oil Grade 1 10W30 2 15W40 h...

Page 79: ...inder with a grease gun Correspondingly the tracks are loosened by letting grease flow out through the opened grease nipple and moving the Lokotrack if needed Check track shoes for damage Frame Check the welded structure for cracks or weld failures and carry out any necessary repairs as soon as possible Track shoe bolt torque With lubricant 304 358 Nm 224 264 ft Lb Without lubricant 365 430 Nm 269...

Page 80: ...mended brands are e g AGIP Blasia 220 ARAL Degol BG 220 AVIA Gear RSX 220 BP Enersyn HTX 220 CASTROL Alphasyn T 220 Aplha ZN 220 DEA Trion EP 220 Intor HCLP 220 ELF Reductelf SP 220 Elf Epona Z 220 FINA Giran L 220 FUCHS Renolin AWD 220 KLÜBER Lamora 220 KUWAIT Q8 Goya 220 El Greco 220 MOBIL Mobilgear 630 SHC 220 PANOLIN EP Gear Synth 220 TEXACO Syngear 220 TOTAL Varter EP 220 9 13 GREASE The grea...

Page 81: ... valve make sure that the drain pan will be able to hold all the fluid see 9 7 Filling volumes dispose oil according to local regulations Drainage plugs are shown in the figure 3 9 14 coolant water 15 engine oil 17 hydraulic oil 9 17 ENGINE FUEL FILTER REPLACEMENT Please refer to the Caterpillar C 9 Operation and Maintenance Manual Fuel System Primary Filter Water Separator Drain refer 3 10 figure...

Page 82: ...9 10 NORDBERG LT105 105S INSTRUCTION MANUAL 9 07 B 05 01 CHAPTER 9 MAINTENANCE https tractormanualz com ...

Page 83: ...ructions 3 02 SERVICE INSTRUCTIONS 10 1 GENERAL 10 1 10 2 BATTERY MAINTENANCE 10 2 10 3 OTHER ELECTRICAL EQUIPMENT 10 3 10 4 WELDING 10 3 10 5 PRESSURE ACCUMULATOR 10 3 10 6 CRUSHER SPEED SENSOR 10 4 https tractormanualz com ...

Page 84: ...g fluid Use solvents of accepted quality only Always stop the engine during maintenance unless it is mentioned in the instruction manual to keep the engine running Do not check for leaks with a bare hand use suitable cleaning cloth Never adjust any hydraulic valve beyond the pressure recommended by the manufacturer Always ensure adequate ventilation when running the engine in a confined area Remem...

Page 85: ...re around 20ºC 68ºF Batteries must always be maintained as far as possible at full charge If the charge is allowed to remain low the plates will become sulphated reducing the capacity and efficiency of the whole battery Remember that a half charged battery will freeze at a temperature of 25ºC 13ºF and a flat one at only 10ºC 14ºF Never use an open flame when checking the acid level of a battery Th...

Page 86: ...e start make sure that batteries have the same voltage the correct poles are connected Starter circuit Normally the starter circuit requires little attention but all components should be kept clean and electrical connections tight The batteries are an essential part of the electrical system and are required to be kept fully charged clean and topped up properly to maintain the acid level Battery ca...

Page 87: ...r behind the pitman The sensor is mounted on its support with a plastic clamp The correct distance from the sensor end to the pitman is 3 5 mm The minimum distance while the crusher is running When replacing the sensor there is no need to adjust the sensor itself Sensor has a LED indicator The function can be controlled from this led indicator Possible reasons if the speed sensor is causing an ala...

Page 88: ...k ECM XM1 input 15 with radio control Check DCM XM3 input 22 with cable control Hydraulic oil temp Main valve Alarm 16 Check ECM XM2 input 18 Check suction valve position Oil level Closed Alarm 10 Check ECM XM2 input 17 Check actual oil level at hydraulic tank add oil if needed Alarm 17 Check ECM XM3 input 13 Check cooler and hydarulic oil temperature OK Down Yes Yes High Open OK No No No Check Fu...

Page 89: ...emergency relay Remote stop Engine stopping Remote stop alarm Check ECM XM1 input 15 with radio control Check DCM XM3 input 22 with cable control Hydraulic oil temp Engine stopping Alarm 17 Check ECM XM3 input 13 Check cooler and hydarulic oil temperature Yes Yes High Engine start continue No No OK Check DCM XM1 input 4 Check the key switch contact Check ECM XM2 output 7 Check fuse 2F04 relay 2K06...

Page 90: ... at hydraulic tank Down Engine start continue J1939 bus fault Engine stopping Alarm 11 Check fuse 2F07 Check fuse 2F06 Check ECM XM2 output 6 relay 2K03 Yes OK OK No Yes No Engine start motor is running but engine does not start Check fuel amount Fill and bleed fuel system Manifold preheater function Check fuse for preheater side by the engine Check active diagnostic code from the DCU page 5 3 2 E...

Page 91: ...Alarm 16 Check ECM XM2 input 18 Check suction valve position Hydr oil level down Engine stopping Alarm 10 Check ECM XM2 input 17 Check actual oil level at hydraulic Yes Yes Yes Yes Engine running Emergency stop Engine stopping Alarm 28 ES from control panel Check HUB XH4 input 11 repair wiring or contact Alarm 29 ES Service platform Check HUB XH4 input 12 repair wiring or contact Alarm 30 ES from ...

Page 92: ...lay Process running Screen enable Alarm 22 Check HCM XM1 input 19 If not active repair wiring or switch Screen not enable Forced control of screen and screen conveyors is possible from display Yes Yes Yes Yes Safety switch under size off Alarm 23 Check HCM XM1 input 20 If not active repair wiring or switch Yes https tractormanualz com ...

Page 93: ...p wire switch Check steel cable tension HCM XM1 input 23 1 ok 0 not ok Check wiring contact Alarm 19 Main conveyor not enable Reset trip wire switch Check steel cable tension HCM XM1 input 22 1 ok 0 not ok Check wiring contact Alarm 21 Main conveyor not enable Check position of the maintenance switch Check contacts 1 2 feed back contact 5 6 solenoid Main conveyor enable https tractormanualz com ...

Page 94: ...rm 3 Material in the cavity Start crusher from service platform Fault Yes No Yes No Yes Yes Crusher start from process Start OK Clamping pressure not between limits Yes Crusher not enable Contact to Metso mierals service dept Yes Yes No Crusher not enable Alarm 41 Check wiring if ok Replace sensor Crusher not enable Alarm 4 Low Alarm 5 High Alarm 36 Probe failure Check charging circuit operating c...

Page 95: ...ng normal direction Swing reverse direction Yes No Yes No Run crusher to reverse direction Stop crusher Run crusher to normal direction Yes Yes No No Fault Engine control Crusher Stopping Swing reverse direction 1 Yes No 1 If swing normal direction and reverse direction are activated simultaineously https tractormanualz com ...

Page 96: ... operating charging valve manually does the pressure change at UCD page 1 2 if not check sensor Check HCM XM2 output 22 if on check the voltage in the Danfoss valve plug if ok the danfoss valve control head failured Alarm 41 Crusher stopping Crusher not enable Check wiring if ok Replace sensor Alarm 8 Crusher stopping Crusher not enable Check crusher V belt tension Check used setting open if neses...

Page 97: ...d pre valve ON if pressurization needed else OFF Increase setting DO Return rod pre relief valve ON DO Setting increase valve ON DO Return rod pre valve OFF Yes Decrease setting No DO Return rod pre relief valve ON DO Setting decrease valve ON DO Return rod pre valve OFF Yes No DO Return rod pre relief valve OFF DO Setting increase valve OFF DO Setting decrease valve OFF DO Return rod pre valve ON...

Page 98: ...od pre valve OFF Yes Decrease setting DO Return rod pre relief valve OFF DO Setting decrease valve ON DO Return rod pre valve ON if pressurization needed else OFF Yes DO Return rod pre relief valve OFF DO Setting increase valve OFF DO Setting decrease valve OFF DO Return rod pre valve ON if pressurization needed else OFF No No https tractormanualz com ...

Page 99: ...ge Crusher overload Alarm 33 Yes Yes Crusher load normal No Ultrasonic sensor movement over 8 mm Crusher pressure high No DO Return rod pre relief valve OFF DO Setting decrease valve ON DO Return rod pre valve ON if pressurization needed else OFF Alarm 2 Crusher stopping Page 9 https tractormanualz com ...

Page 100: ...ot enable Reset left side safety switch HCM XM1 input 21 1 ok 0 not ok Check wiring contact Alarm 25 Side conveyor not enable Reset right side safety switch HCM XM1 input 4 1 ok 0 not ok Check wiring contact Alarm 21 Side conveyor not enable Check position of the maintenance switch Check contacts 1 2 feed back contact 3 4 solenoid Side conveyor enable https tractormanualz com ...

Page 101: ...r control ON Feeder running Feeder not able to start Fault Yes Yes radio contrtol on active Yes Yes Yes Feeder ready for material feed Yes Check feeder power HCM XM2 output 5 1 ok 0 not ok Measure voltage at terminal 3X3 81 Check feeder control measure voltage at terminal 3X3 43 17 19 V ok if Udc 27 5 V Check manually valve operation Replace valve control head if nesessary No https tractormanualz ...

Page 102: ...der start from process Feeder power OFF Yes Yes Yes Yes Yes Yes Yes Second LT alarm stop Yes Alarm 35 Check sensor wiring HCM XM3 analog input 7 4 20 mA ok Replace sensor if nesessary Alarm 40 Check the reason for high pressure Material leakage under the conveyor If hydraulic pto is on are the hoses connected If magnet selected on is it running Alarm 10 Add fuel Check fuel sensor operation wiring ...

Page 103: ...ting open if nesessary Check adjust the crushing speed Parameter C1 increase the mA value Crusher should run 300 rpm avg with the crushed material Check the cleanness of the sensors Check the function of the crusher level detector Check used setting open if nesessary Check adjust the crushing speed Parameter C1 increase the mA value Crusher should run 300 rpm avg with the crushed material Check hy...

Page 104: ... Crusher speed low Crusher level high Crusher pressure high Hydraulic oil temperature high Crusher overload Secondary LT level high Feeder running Feeder stopped Engine control Fault Yes No No No No No No No Yes Yes Yes Yes Yes Yes https tractormanualz com ...

Page 105: ...in conveyor enable Screen enable Yes No Side con veyor connected Side conv eyor enable Yes Process stop Process not enable to start Process enable to start Yes No No Page 5 Page 6 Return rod pressure not correct manual valve position Cruher drive circuit pressure sensor not in range Page 13 https tractormanualz com ...

Page 106: ...pping Screen conveyors hydr valve ON Screen hydr valve CW CCW ON Magnetic separator present Magnetic separator output ON Hydraulic outlet on mode Hydraulic outlet valve ON Main conveyor enable Main conveyor hydraulic valve ON Process stopping Process start continue Process stopping Fault Yes Yes Yes Yes Yes No No https tractormanualz com ...

Page 107: ...veyor enable Process stopping Side conveyor hydraulic valve ON Start crusher Process running Crusher enable Process stopping Start feeder Crusher pressure rise too fast at start Process start continue Process stop Process stopping Yes Yes Yes Yes Yes No No No Yes No No https tractormanualz com ...

Page 108: ...esent Stop side conveyor Crusher running Stop crusher Stop main conveyor Hydraulic outlet on mode Stop hydraulic outlet Magnetic separator present Stop magnetic separator Screen module connected Stop screen and conveyor Engine to min rpm Process stopped Yes Yes Yes Yes Yes Yes https tractormanualz com ...

Page 109: ...in running mode Engine control Crusher enable Screen module connected Main conv enable Screen enable Side conveyor connected Process stop Process running Process stopping Side conveyor enable Fault Yes Yes Yes Yes Yes No No https tractormanualz com ...

Page 110: ...o or process control Radio left track forward Radio left track backward Radio right track forward Radio righttrack backward No No No No Engine control Hand valve on Screen connected Track control Track drive not enabled Process running Yes Yes Fault No Yes https tractormanualz com ...

Page 111: ...ox connected Drivebox left track forward Drivebox left track backward Drivebox right track forward Drivebox righttrack backward No No No No Engine control Hand valve on Screen connected Track control Track drive not enabled Process running Yes Yes Fault No Yes https tractormanualz com ...

Page 112: ... or control Display left track forward Display left track backward Display right track forward Display righttrack backward No No No No Engine control Hand valve on Screen connected Track control Track drive not enabled Yes No Process running Yes Yes Yes Fault No https tractormanualz com ...

Page 113: ...TROUBLESHOOTING CHAPTER 11 26 Track control Process running Yes Yes Normal driving Track speed according to engine RPM Driving with slow speed https tractormanualz com ...

Page 114: ...2 Off Stop 3 Connecting 4 Disconnecting 5 Increase 6 Decrease 7 Stepless adjustable movement 8 Warning 9 Warning pressurized 10 Warning electric danger 11 Grease lubrication point 12 Oil lubrication point 13 Running hours 14 Lifting point 15 Horn 16 Level https tractormanualz com ...

Page 115: ...ing 20 Check 21 Max temperature 1 General symbols 2 Electric symbols 1 Remote control 2 Battery charging indicator 3 Lights 1 Work light 2 Driving lights 4 Engine 1 Engine emergency stop 2 Stopping of engine 3 Engine running speed 4 Combustion engine https tractormanualz com ...

Page 116: ...07 00 APPENDA 3 APPENDIX A SYMBOL IDENTIFICATION 5 Starting of engine 4 Engine 5 Fuel 1 Fuel volume 2 Fuel pressure 3 Fuel filter 4 Fuel shut off 5 Fuel refill https tractormanualz com ...

Page 117: ...SYMBOL IDENTIFICATION 6 Engine oil 1 Oil level 2 Oil refill 3 Oil pressure 4 Oil temperature 5 Oil filter 7 Cooler system 1 Coolant refill 2 Coolant level indicator 3 Coolant pressure 4 Coolant temperature https tractormanualz com ...

Page 118: ...ission oil 1 Oil refill 2 Oil level indicator 3 Oil pressure 4 Oil temperature 5 Oil filter 6 Testing point oil pressure 9 Hydraulic oil 1 Hydraulic oil refill 2 Hydraulic oil level 3 Hydraulic oil pressure 4 Hydraulic oil temperature https tractormanualz com ...

Page 119: ...ing 7 Shut off valve 9 Hydraulic oil 10 Air 1 Air intake 2 Air pressure 3 Air filter 11 Symbols not included in the ISO standard 1 Tensioning of power transmission belt 2 Tightening of nuts and bolts 3 Remove install transport locking 4 Check tighten concave bolts https tractormanualz com ...

Page 120: ...t service platform Equivalent A weighted sound pressure level LAeq 96 106 dB ISO 11202 1995 at the distance of 1 m and height of 1 6 m around the LT maximum level by the crusher Equivalent C weighted peak sound pressure level LCpeak 120 128 dB ISO 11202 1995 at the distance of 1 m and height of 1 6 m around the LT maximum level by the crusher Property Measured value Standard Notes Weighted r m s a...

Page 121: ...ls such as oil battery acids and cleaning fluids etc must be removed carefully using suitable containers to prevent any hazard to people animals or environment The hazardous material must be removed to a suitable waste collection plant for disposal or recycling FIRE The Manufacturer has not provided this machine with a fire extinguisher and recommends that the user equips the machine with an extin...

Page 122: ...rial Remove the metal objects from the feed if possible At least remove the loose metal The metal objects larger than the crusher setting must not enter the crusher When removing the metal objects be very careful Never go to the feeder when the machine is running Observe the feed material Never let the uncrushable objects enter the crusher 3 Removal of the blocking Be very careful when clearing th...

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Metso NORDBERG LT105, Instruction Manual

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