Hi-C40 Operators Handbook
Contents
1. L d Fo a rr J 235 JANET Idd Ld t 1809 1S31 NSS l 00W17 gt e S00MLI d z e Be GE Ap d 9 54 Operation Safety Maintenance 10 2005 Issue 5 NOTES 552. MOVE CL 01085 LU ML IHH 0 I HA FM datam 3 diy CL 351 VILIS NO UNI aU nA mn dad ADA TH 3a 3NISIN FALT Elo Ju Ad Jl IHT CR LL JIONWSIOS aura Gz L AF CL AAT FU An 3d s L dad GEL 734 07144 VOL O Gz L ACH IE E S S Jo 66 OG Gd OOOO MOOD Make nou n W HD bv dass az AHAN s gd ara VOL Seb HOLY IAS yaz gsn SEKT vci aam G trio zs 53 10 2005 Issue 5 Operation Safety Maintenance GO EO EZ 3ivQ ON ALS 2901 d9L ON SAM 0 WODNA JAL AMAA AA EEZFE TEIFE AFA A AOGA TePTpt HL VG BAD X35883 NOOWW i YIHSNAD FAW IOA salva aya IJISAYNG SI s3rITwHQAMH3HSOH2 JLLWW3HOS JUIL Ar INE Td Nonam lo HOT FL H ZATZA TOS LNCO NIVW 9400 09 me I 2v E SOON gt BRZ Jesi ARYL ANYL 84307 1 JATA JOYLNOI YIHSNYD 00 09 t YOLOW uOASANO2 6 00 09 IK mu f 437009 110 6000 19 G NOAJIW G2 lt gt 1 dWnd 21 ZY00 09 9 f NODIW Sz HAL TI NOLLINS 5000 9 Wda 000 AIH Hdd 2328 4 0 NOWIW DI 3114 NYNLIY 1000 9 8 da add 3 9E12 ALD NOLLdIYIS3A ON Ltd ANIHA WALT
3. Operators and Servicemen must be safety conscious and alert to recognise potential operating or servicing safety hazards at all times and take necessary precautions to ensure safe operation and servicing of the machine Operation Safety Maintenance 10 2005 Issue 5 All information illustrations and specifications contained in this publication are based on the latest product information available at the time of publication The right 1s reserved to make changes at any time without notice Continuing improvement and advancement of the design may cause changes to your machine that may not be included in this publication This Handbook contains lubrication and routine servicing instructions most of which can be performed in the field Service manual containing repair and rebuild procedures are available from the factory Transporting the Crusher If the Crusher cannot be driven onto its transport vehicle a hoist can be used to place it onto the vehicle Use the two lifting points shown i e lifting eye on main chassis and the cross bar of the fixed grizzler to ensure that the Crusher lifts evenly Never use the tie down points THESE ARE NOT LIFTING POINTS CHOTSTING POINT TEE DOWN POINTS AM HOISTING POINT 14 Operation Safety Maintenance 10 2005 Issue 5 Machine Identification Whilst reading this handbook you will notice references to controls
4. admin a bryco diesel engines co uk www bryco diesel engines co uk C M H LTD Maudlins Industrial Estate Monread Road Naas Co Kildare Eire Tel 00 353 458 76225 Fax 00353 459 7476 cmhltd Qgofree indigo ireland Hurley Engine Services Unit 7 The Maltings Industrial Estate Brassmill Lane Bath Somerset BA1 3JL Tel 01225 336812 Fax 01225 442477 info hurleyengines co uk Operation Safety Maintenance 10 2005 Issue 5 J amp E Motor Engineers 23 Polmont Road Laurieston Falkirk FK2 900 Tel 01324 633266 Fax 01324 633870 jem engines btopenworld com John A Sparks amp Co Ltd Western Industrial Estate Caerphilly CF83 1BQ Tel 02920 807080 Fax 02920 8707081 kevinashworth a sparks com Wwww a sparks com Meetens Industrial Engines Ltd 261 269 Coombe Lane Wimbledon SW20 ORH Tel 0208 9464244 Fax 0208 9472595 sales ameetens COM Northern Lift Trucks Northern Ireland Ltd 1 Flush Park Knockmore Road Lisburn BT28 2DX Tel 02892 673111 Fax 02892 660618 info northern group co uk Phoenix Power Services Unit 12 Thames Trading Centre Woodrow Way Irlam Manchester M44 6BP Tel 0161 775 4053 Fax 0161 776 2047 phoenixpower btclick com Sean Cleary amp Son Eng Ltd I D A Industrial Estate Dublin Road Loughrea Co Galway Eire Tel 00 353 91 841420 Fax 00 353 91 842823 paddycleary eircom net Sleeman amp Hawken Ltd Bridge Road Shaldon Dev
5. 30215 2100 16 VE TL NIQ dit SID 0100 20 SE wzewne ZI00 1G u3HSVA lwij9W 1100 20 BE 1108 135 02 XBW S000 10 SE 49 A 8 QO TZ Vir EINIVELS Isis 5000 7 er 2 I 2 EX T OL gl ER ES N mz EZ Operation Safety Maintenance 10 2005 Issue 5 EFE AL ON SAC DEEEF TETEK 2068 1291 TRI HOE SELVE FA SKIES Av nto MIT LAV TA NOLLIMNLSNGD HOTAVL d SLA ALJJYS OPI IH JUU ALO NOlLdlMOS30 ON LHvd I uv3u HD avd AL3dvs 8900 16 Em WY Ha sva ALIJVS 8500 16 ES UNOX HT sva ALdJVS 6600 16 I CLINOJ HB uvg ALIJYS 6600 76 I Hu HOLES ALIAVWS 2000 22 EM HT HJLIMS AL3dVS 8000 24 Em HILIMS AL3JVS UAN TSNAL t100 24 Em 31812 ALJvS 43132 3 2100 22 g dT ALS3JYS 38WTHL 100 22 H2LTAAS ALISVS 31872 6000 24 50 Operation Safety Maintenance 10 2005 Issue 5 Qhi d3 L ON SAMA WOO M da ARA DEEEF TETEK 2068 1291 EL FIG 5642 3892 ND TW Qqwou SELVE and ESANG VS NYA NOLLINULSNGS HOTAYL ALD NOLLdIHISIG ON LSVd ON WILI I ILITdWOJ YOABANOD 5000 2 I PZJ 1139 32104 9 0100 2 2 EG S RILS NOISN1I2X3 50002 2 SWAY LYOddNS SOAANOO 2900 16 p 2 WR VdS SSOP UOASANO2 5900 5 9 E v LAVHS LYOddNS YOAZANOD 9900 16 9 waddOH YOAIANOD 900 16 HT 839NIYH UOARANOD 1900 16 8 He
6. Lubrication and Servicing 33 Operation Safety Maintenance 10 2005 Issue 5 SAFETY PRECAUTIONS Do not allow unauthorised personnel to service or maintain this machine Study the Operator s Handbook and Service Manual before staring operating or servicing this machine Always follow procedures and safety precautions detailed 1n this manual Do not work under or near an unblocked or unsupported machine Do not work under or near any unblocked or unsupported linkage or any part of machine Always shut down machine according to the procedure described under Stopping The Engine before cleaning lubricating or servicing the machine Always relieve pressure before servicing any pressurisation system Always attach a DO NOT OPERATE or similar warning sign to 1gnition switch or a control before cleaning or servicing the machine LUBRICATION AND SERVICING Lubrication 1s an essential part of preventive maintenance It 1s important that the instructions regarding types of lubricants and the frequency of their application be followed to prolong the useful life of the machine Periodic lubrications of moving parts reduce to a minimum the possibility of mechanical failures Thoroughly clean all fittings caps plugs etc to prevent dirt from entering the system while servicing Lubricants must be at operating temperatures when draining Do not operate any system unless oil level is within the operating range as indicated on
7. Y3SNYH SOASANOO 2900 18 6 217 1d LNNOW uOASANO2S 7900 16 OT 7138 Nid UALSYW 7700 2 IT Nid 32Ino 8170 11 2T Operation Safety Maintenance 10 2005 Issue 5 A 74 0001 LOGO PLC 1 73 0004 BATTERY LEADS PAIR 1 73 0003 WIRING LOOM TWO SPEED 1 73 0002 WIRING LOOM KUBOTA 1 60 0039 HYDRAULIC DRIVE MOTOROLLER 1 73 0007 WIRING CRUSHER 1 72 0029 PRESSURE TRANSMITTER 1 72 0019 N O CONTACT BLOCK 2 72 0018 N C CONTACT BLOCK 1 E 72 0015 GRENN PUSH BUTTON 1 in 72 0014 EMERGENCY STOP SWITCH 1 3 80 0017 DECAL WARNING CONVEYOR 4 3 80 0016 DECAL HI LOW CONTROL PANEL 1 z 80 0019 DECAL EMERGENCY STOP 1 S 80 0018 DECAL ADJUSTACRUCH 2 60 0041 CONTROL VALVE 1 51 0132 BATTERY CLAMP 2 HE PART NO DESCRIPTION QTy CJ Z Operation Safety Maintenance 10 2005 Issue 5 SO 20 TE ERR IA 190T d2 L AN AMG 131002 110 F NMOULNHS dO 2ILvVW3H2S TILL WOD Nadal MAAM CREEPS IZ Sree 4058 TZT PHTI 6W2 X3553 NOT Qro g31v8 aa HISAN e l RT LAT LENE HO dl Cl ADVI ONO dr SL ZL AHALLYO CB xA BHA od ADS Gz L Awg HSU Hnd 10 CL ADVI Cb BH FTA Cl XO DUET and I HOLO HAL LS BHAA CL AY HA UIT INET HAHA 10 za SLUMS DEI CL NYYD 9 SS ROLLAG ad CL iBH ZANUITT3A YCE 3804 TA
8. 91 sale sep ou com REVERSE REVERSE www tcp eu com stop a o Fax 44 011621 843330 REVERSE DECREASE 1 ENSURE ALL SAFETY INTERLOCKS ARE IN PLACE AND OPERATIONAL BEFORE USE LIFTING EYE S W L 1000 Kg IMPORTANT READ AND UNDERSTAND THE OPERATOR S MANUAL BEFORE USE CONVEYOR FUEL FILLER FORWARD FORWARD FORWARD INCREASE e 4 Mates e e SPEED c o TRACKING j SPEED PRESS SWITCH TO ENGAGE H SPEED j HI SPEED CAN ONLY BE ENGAGED ON THE MOVE j TOP 101 View of the control panel 2003 fig 3a FORWARD BEVERSE CONTROLS gt CONVEYOR ON OFF Oo CONVEYOR SPEED CONTROL CRUSHER START STO EMERGENCY STOP ne Ui UR lt ADTUSTACRUSED View of the controls and adjustments 2003 fig 3b Engine Accelerator 24 STABILIZERS Operation Safety Maintenance 10 2005 Issue 5 This is mounted on the left hand side of handlebar assembly and 1s operated by the hand Press the lever down as required to 1ncrease fuel flow to accelerate the engine Do not place engine under full load at full speed immediately after starting Always allow the engine to fully circulate lubricant and warm up gradually before operating at full speed and full load Operate the engine at top rated speed when maximum power is needed for maximum speed and load Steering Via Hydrostatic Drive The steering is performed by A WARNING e
9. Charging Loading 31 Operation Safety Maintenance 10 2005 Issue 5 The most common methods of loading this type of machine is with hydraulic excavators or by hand this unit has been designed to be loaded mainly from one side however it can be loaded from either side Ideally excavators should require 90 or less swing Do not load with machines that are over large and would allow material and fill to fall from the bucket missing the hopper This can be dangerous to both operator and the unit Only load material that the machine 1s capable of crushing avoid reinforced concrete and large volumes of bitumous materials When tracking the machine pay attention to site conditions to avoid rocks holes or other obstacles Such obstacles present hazards to safe operation but also can needlessly damage tracks 32 Operation Safety Maintenance 10 2005 Issue 5 Loose Density Fill Factor kg m Ib yd Sugar beet 530 894 100 Fertilizer Mixed 1030 1737 85 Coal Anthracite 1046 1764 100 Earth Dry Loose 1150 1939 100 Nitrate Fertilizer 1250 2180 85 Sodium Chloride Dry Salt 1300 2192 85 Cement Portland 1440 2428 100 Limestone Crushed 1530 2580 100 1600 2698 10 1650 2782 85 Clay Wet 1680 2832 110 Sand Wet 1890 3187 110 Fire Clay 2080 3507 100 Ready Mixed Concrete 2194 3698 85 Copper Concentrate 2300 3878 85 Slate 2500 4721 10 0 Magnetite 3204 5402 100 Specific Gravity fig 4 5
10. LJJHS SISSYHJ OFJ IH TULL ON SAC WOO M da ARRA OEECHA TETEK 2068 129 EL FIG GHD 3893 NOT TW WYCH SSL vg aru ESANG MIT LAV TA NOLLINHLSNOS HOTAYL NOLLdle OS Ad ON ldvd ON WILLI ASSY SISSYH2 TINA 5000 05 t ara gu 5000 15 2 343 SNILJTI 6000 16 1104 A38 02 X BW 6000 10 F u3HSVA LY SW 1700 20 3 QVv3M dv2 02 X GW 9700 10 9 ITI Tang 9000 16 4 dY and 2000 16 g u3Hsnu 42018 SATIVA 000 09 6 0112 3S0H 000 6 01 3S0H Tang 8200 29 IT SINJXEINSI 31 1S 323N TANA 0100 9 21 v LOSl 2000 21 T YOLdYIY dWNd 6100 16 pl SNISNOH dWfid GQ00 09 GI 22 3LY LS dWfd 2270 S qQqAH 9000 09 9r 132202045 JAINA 000 02 9T MARIOS FIH LINI05 1100 70 61 6100 15 02 4000 20 T2 8000 20 22 1108 92 X OTW OTOO TO 62 3 1000 60 ra 48 10 2005 Issue 5 EFL dIL oN M WOJ i MAM OEECHA TETEK 2068 129 FG 6W2 Jes NOY WYCH SSL vg aru ESANG dO e 133H5 Operation Safety Maintenance oe SLUVd SISSVHO OFITH ULL MTINVId NOLINKLSNOJ HOTAVL ALO OMe ao SAG ON LHVd ON Wait 2 535102 LNOUS QITA SSY 8900 5 G2 OF 1735 000 02 92 NOVEL 836808 1000 22 i SNIY S 00 0b 82 SNS 310 1000 Or e L108 135 OE XBW 2100 10 DE JOTAN SW 2000 10 TE 301 5 5100 5 ze ITXW ANOS 2200 16 EE
11. Operation Daily Every 50 Hours of Operation Every 1 000 Hours of Operation Every 2 000 Hours of Operation Replacement of Rubber Track Operation Safety Maintenance 10 2005 Issue 5 Operation Safety Maintenance 10 2005 Issue 5 Operation Safety Maintenance 10 2005 Issue 5 Warranty Policy and Procedures Foreword Thank you very much for purchasing this Taylor Construction Plant Ltd product We believe that it will serve you without fail Ensure that you read the Operator s Manual carefully before use With proper handling and maintenance this TAYLOR CONSTRUCTION PLANT Ltd product will provide excellent service over an extended period of time Registration Each machine supplied by TAYLOR CONSTRUCTION PLANT Ltd is accompanied by a registration card This card must be completed in full and returned to Warranty Manager email warranty tcp eu com Taylor Construction Plant Ltd Quayside Industrial Park Bates Road Maldon Essex CM9 5FA Failure to register your machine may invalidate the manufacturer s warranty Liability The warranty period begins when the product 1s delivered to and installed at the first purchaser Only genuine parts may be used to carry out repairs Failure to use only genuine parts may invalidate the Manufacturers Warranty TAYLOR CONSTRUCTION PLANT Ltd will not be held responsible if 1 the machine has been used to perform tasks that demand more than it s design and strength limit
12. and ensure ALL potential users are correctly trained in its use e Always perform Pre Operating Checks described In this manual to ensure the machine 1s ready for operating e Ensure crusher 1s on firm level ground with clearance for loading and stock piling or removal of crushed material e A safety RING FENCE has been designed and fitted to this equipment for the operators safety DONOT operate without this 1n place or override the safety interlocks to which it connects e The ring fence cable should be adjusted using the tension turnbuckle with sufficient tension to hold the interlock switches 1n the green band the blue reset buttons can then be pulled out and set for the machine to operate NB Both interlocks must be set 20 Operation Safety Maintenance 10 2005 Issue 5 The emergency stop button is interlocked with a key the button should be pulled up for operation and the key removed we recommend the key 1s kept with the ignition key for the equipment Check on a regular basis the operation of the ring fence by applying pressure to the safety cable and ensuring the crusher immediately ceases crushing and shuts down the engine Further protection 1s afforded to the operator by the sprung loaded grizzler bars fitted inside the hopper these have been designed to prevent and warn operatives of potential serious injury areas of the machine If the grizzler bars are distorted or non operational 1n any form the crusher should N
13. charge by placing metal objects across battery posts e Use jumper cables only as recommended Improper use can result In battery explosion or unexpected machine motion e Never operate engine starter for more than 15 seconds and allow 30 seconds between cranking periods for cooling An overheated starter could cause a fire Pre Starting WARNING e If engine is to be started and run indoors ensure proper ventilation to remove deadly exhaust gases e Always perform Pre Starting Inspection instructions described in this manual to ensure the machine is ready for operation 19 Operation Safety Maintenance 10 2005 Issue 5 Starting e Do not start the engine or operate any control if there isa DO NOT OPERATE or similar warning sign attached to any control e Use jumper cables only as recommended Improper use can result In battery explosion or unexpected machine motion e Always obey Starting the Engine instructions e Start and operate the machine only from the operator s station Operating e The HiC40 has been designed to efficiently and safely crush a variety of otherwise waste building materials to size which makes them suitable as a fill material There are hazards with this type of operation and equipment that we have assessed and addressed by various methods from warning labels to the safety ring fence and interlocks you MUST ensure you are familiar with ALL the safety features of this equipment
14. cleaner will seriously reduce engine life THESE INSTRUCTIONS MUST BE ADHERED TO IN ORDER TO ASSURE CONTINUANCE OF ENGINES WARRANTY e Carefully inspect tracks for cuts or other damage and correct spring preload e Inspect for any leaks whether fuel engine oil or hydraulic oil e Check fuel level Fuel tank should be filled at end of each shift e Check conveyor for damage tension and tracking e Check safety ring fence for correct tension and operation e Check sprung grizzler bars for damage and operation Engine Operation 26 Operation Safety Maintenance 10 2005 Issue 5 A WARNIN Do not place engine under FULL LOAD at FULL SPEED IMMEDIATELY after starting ALWAYS allow the engine to fully circulate lubricant and warm up gradually before operating at full speed and full load Operate engine at top rated speed when maximum power Is needed for the load NEVER IDLE THE ENGINE FOR MORE THAN 5 MINUTES AT A TIME SHUT IT OFF If operated outside its normal operating range shut engine down immediately and report to service or maintenance personnel WARNING Never start the engine indoors unless proper exhaust ventilation is provided to remove deadly exhaust gases Once the engine 1s running move the machine outdoors as soon as possible Exhaust gases are hazardous and can cause unconsciousness and death Operating the engine beyond high idle speed can cause severe engine damage The engine speed must not exceed 3 600
15. rev min under any circumstances When descending a steep grade use a combination of lever and engine speed Starting the Engine 27 Operation Safety Maintenance 10 2005 Issue 5 1 Make sure that all levers are In the neutral position and emergency stop button 1s pulled out and the key removed 2 Insert switch key and turn clockwise to position 1 to switch on the ignition Run position 3 If engine is cold turn to pre heat position 2 and hold for 20 seconds 4 Turn key further clockwise against spring pressure to position 3 to crank engine release key as soon as engine starts firing NOTE Never crank the engine for more than 15 seconds continuously Allow starter at least 30 seconds cooling time between cranking periods to avoid overheating Starting the Engine with Jumper cables To access the battery you will be need to remove the cover plate over the crusher controls remove the bolts that secure tt to the crusher body once this has been done you can remove the plate and locate the battery WARNING CHARGING OF ODYSSEY BATTERIES Check for polarity connections of the discharged battery Do not exceed 15 volts during charge Excessive booster voltage and or incorrect jumper cable connections will destroy working plates inside battery Keep all sources of ignition away from batteries Do not lean over batteries Do not allow the battery to become full discharged you may find that it can not be recover f
16. sent to the head office of the purchaser copies are available on the request of purchaser 12 Operation Safety Maintenance 10 2005 Issue 5 1 Introduction Please read carefully and understand before operating the equipment This Handbook 1s provided as a guide to familiarise the operator and service engineer with the controls recommended inspections start up operating and shutdown procedures for H1C40 range of equipment Safety Precautions This piece of equipment is designed as a compact tracked jaw crusher At no time should loads larger than the design capacity be crushed Only operate the crushing mode when the unit is stationery Keep arms hands clear of moving parts at all times FAILURE IO COMPLY WIIH WARNINGS COULD RESULT IN SERIOUS PROPERTY DAMAGE AND POSSIBLE PERSONAL INJURY The machine should be properly operated and maintained to keep it 1n safe efficient operating condition Ensure that all controls are free of mud grease or other matter that might cause slips hazardous to the operator serviceman or other personnel or equipment Report all malfunctions to those responsible for maintenance Do not operate the equipment until corrected Normal service or maintenance performed as required can prevent unexpected and unnecessary down time This handbook describes general inspections servicing and operation with the normal safety precautions required for normal servicing and operating conditions
17. 10 hours of operation Daily Walk Around Inspection 39 Operation Safety Maintenance 10 2005 Issue 5 Engine Visually check engine for damage loose bolts and listen for any unusual noises Engine Air Cleaner Inspect and remove any obstructions from the air cleaner inlet with the engine stopped Check Engine Crankcase oil level and add oil if low see Lubrication Charts With the engine off the oil should be just over the last thread at filler do not overfill Lubrication greasing periodic lubrications of moving parts will help reduce to a minimum the possibility of mechanical failures see Lubrication Charts NOTE Service air cleaners more often when operating under extremely dusty conditions Do not wash the air cleaner element out with detergent replace with new After first 50 hours of operating new or rebuilt components Replace the hydraulic oil filter Install new element each time do not reuse Remove dipstick amp filter element oil should be visible 100mm below the tube 1n the base of the filter housing If oil low fill through the filter housing until the level is 100mm below the tube in the base of the filter housing DO NOT OVER FILL Check Engine crankcase drain oil replace as per lubrication chart check oil level the oil should be just over the last thread at filler do not overfill Lubrication greasing Periodic lubrications of moving parts will help reduce to a minimum the possibility of mechani
18. Capabilities Lubrication Chart fig 5 Grease Nipples Lubrication Layout fig 6 Operation Safety Maintenance EGET 2 8v6 lt o pm me eta del xu EEE CRIC Re v ae 10 2005 Issue 5 Operation Safety Maintenance 10 2005 Issue 5 Basic Overall Dimensions fig 7 General Specification 37 Operation Safety Maintenance 10 2005 Issue 5 Hi C40 ELLEN safety Interlocks With Engine Shutdown Quantity Max Gradeability 35 Turning Circle Without Conveyor Fitted mm ins 2000 78 5 High Speed Reverse Kph Mph 4 2 5 Aoise Level Lwa 101 General Specification fig 8 Miscellaneous Bolt amp Nut Torque Specification Operation Safety Maintenance 10 2005 Issue 5 Friction coefficient total 0 14 for screws and nuts without after treatment as well as for phosphate nuts Tighten by hand If nothing special 1s indicated select correct torque limits from the following tabulations Metric ISO Thread DIN 13 Size 6 9 8 8 10 9 12 9 Some Engine Bolts Standard Hex Bolt Some Engine Bolt Standard Cap head Ns pm Nu w Nm fm Je ue Bs fo mw 3 y e moa o 8 Gn O 8 ea wm m eD 6 jes m es s 069 Ma us es fis 80 fa 20 qo 262 Mx pe ms ja 380 je 0 59 Mau 8o 43 70 E 99 jas 20 85 M30 1200 885 1450 1070 2000 1475 2400 1770 M0 gt Uo aaa Torque Settings fig 9 Every
19. ISED AND UNTRAINED PERSONNEL 30 Operation Safety Maintenance 10 2005 Issue 5 WARNING Check tracks hoses wiring tubing and fittings for cuts abrasion fraying or other damage or deterioration Inspect for damage to the crusher conveyor or chassis Attach warning signs to the controls to alert others if lubricant has been drained batteries removed etc Operating the Crusher Always position the machine on a level firm surface for loading and leave the loading area clear Before starting the crusher ensure that the stabiliser legs have been lowered and adjusted The machine must be stable During normal operation the crushing cycle can be started and stopped by pressing the Green Crusher Jaw push button on the Control Panel see fig 3b Note On cycle start the crusher jaw will always retract to its fully open position even if the Emergency Stop has been actuated Operating the Conveyor The conveyor 1s operated by moving the control lever forward for normal operation moving the control lever right back will reverse the conveyor Conveyor speed can be controlled by adjusting the Speed Controller Adjustacrush To alter crushed material size remove top retaining pin move packing plate s to either Increase or decrease jaw gap Both sides must be released together Operate machine to move jaw Reinsert packing plate and reinstall retaining pin Note The red packing plates must never be removed or moved
20. OT be used until this 1s corrected The green push button on the operating console commences and stops the crushing mode Only feed the crusher with material that will readily pass through the protected hopper opening max 400mm x 400mm Do not overfill the feed hopper material may snag and jam 1n the hopper reducing the efficiency of the machine In the event of material Jamming in the hopper always shut down the machine before clearing the jam Use the emergency stop button NB After the use of the emergency stop button on restarting the crusher ts designed to ALWAYS start with a withdrawal stroke this is an important safety feature that may be needed to remove unsuitable material from the crushing zone The crusher jaw gap can be altered to produce different sizes of crushed material 20mm 60mm The unique Ajustacrush system is covered in a separate section of this manual When crushing relatively thin materials 1 e waste paving slabs always crush to a size less than the thickness of that material Conveyor belt damage and Jamming could otherwise occur Tracking the machine the HiC40 can be moved both with the safety ring fence in place or removed In the removed condition the machine will only operate the track drive system will start and stop on the ignition key NEVER track the machine whilst in crushing mode The machine has as default a slow inching speed for safe tight manoeuvring a higher speed can be engaged using the red high s
21. Operation Safety Maintenance 10 2005 Issue 5 Operating Manual amp Routine Servicing HiC 40 Compact Tracked Jaw Crusher Taylor Construction Plant Ltd Quayside Industrial Park Poes sad Mallen Essex CMo sA el aa 0 1621 850777 Lax t44 0 621 843330 mail tcp eu com www tcp eu com Operation Safety Maintenance 10 2005 Issue 5 Operation Safety Maintenance 10 2005 Issue 5 Table Of Contents sample certificate of conformity I INTRODUCTION Introduction safety Precautions Machine Identifications Theft Deterrent Practices 2 SAFETY PRECAUTIONS General Transporting Preventing Fire Hazards Precaution Electrical Hazard Pre Starting Starting Operating Lubrication and Servicing Decals 3 CONTROLS AND OPERATING Operating Controls Diagram Accelerator Steering the Machine Reversing the Machine 4 OPERATING Pre Starting Inspection Component Checks Engine Operation starting the Engine With Jumper Cables Moving and Stopping Stopping the Engine Parking Crusher Operation Conveyor Operation AdjustacrushO Charging Loading Operation Safety Maintenance 10 2005 Issue 5 5 LUBRICATION AND SERVICING Safety Precautions Lubrication and Servicing Miscellaneous Servicing Information Recommended Lubricants Lubrication Chart Overall Size Dimensions Vartous Basic Vehicle Details Miscellaneous Bolt amp Nut Torque Specification Every 10 Hours of
22. To steer the machine apply differing pressure to the control levers e Apply equal pressure on both levers to the forward position will make the machine move forward in the desired direction at speed e The machine will turn only when more or less pressure 1s applied to either lever proportional to the lever movement To operate in the opposite direction The Reverse procedure is performed by A WARNING e Apply equal pressure on both levers to the reverse position will make the machine move backward in the desired direction at speed e 2speed operation e The machine will stop and hold any position when the both levers are released Dead man Brake 29 Operation Safety Maintenance 10 2005 Issue 5 4 Operating Operating Pre starting Inspection A WARNING e Before the engine is started ensure the machine is ready for operation e The machine should be in a level position to permit accurate checking of fluid quantities 1n the engine and other components e Walk around the machine and carry out the Inspections and Components Checks described on the following pages Daily Component Checks e Reference should be made to engine manufactures handbook e Engine With engine off check oil level The level should be just over the last thread at filler Add oil if low See lubricant chart for correct oil e Inspect the engine air cleaner for any damage replace immediately Using an engine with a damaged air
23. acking speed press the red high speed button on the operators console whilst drive 1s engaged 5 To stop the machine release the control levers slowly and release the accelerator as the machine slows until 1t stops 29 Operation Safety Maintenance 10 2005 Issue 5 6 Stopping the Engine WARNING 1 Cool a hot engine by operating the engine at 1 000 rev min and then slowly decelerating 1t over a 5 minute period until the engine 1s idling Let it idle for at least 2 minutes ALWAYS COOL A HOT ENGINE GRADUALLY BEFORE SHUTTING IT OFF 2 Turn ignition key switch off to shut off fuel and stop engine Parking A WARNING When parking the machine overnight or for an extended period the following procedure In addition to that given in Stopping the Engine will help maintain 1 in good condition for subsequent use 1 Fill the fuel tank completely before parking the machine overnight or for extended periods to prevent condensation If security kit is supplied keep it locked 2 Always park on level ground where possible If it must be parked on a slope position machine at right angles to the slope and block tracks securely 3 Remove key to a place of safety 4 Push 1n emergency stop button to 1solate the machine ensure key 1s removed to a place of safety 5 We would also recommend tripping the ring fence safety interlock switches 6 NBIT IS IMPORTANT THAT THIS EQUIPMENT CANNOT BE STARTED OR USED BY UNAUTHOR
24. and equipment that may not be found on all machines It 1s Important that you know your machine and its equipment and how to operate tt properly Information regarding the machine model code and chassis serial number 1s on the unit serial number plate This plate 1s on the rear Left hand side the machine model and serial number should always be referenced 1n any correspondence with your dealer or factory PJ 7 Tel 44 0 1621 850777 FG Fax 44 0 1621 84330 4 j www tcp eu com MODEL NO SERIAL NO ENGINE TYPE ENGINE SERIAL NO YEAR OF MANUFACTURE Data Plate fig 1 Theft Deterrent Practices The owner operator should take the following precautions to discourage theft to aid In recovery 1n the event that the machine 1s stolen or to reduce vandalism Actions to Discourage Theft and vandalism e Remove all keys any time the machine 1s left unattended e Immobilise the machine by removing a critical electrical or starting system device e Upon receipt of a machine record the machine serial number and the serial numbers of all major components and attachments Keep this list up to date and filed 1n a safe location for fast retrieval e Place a decal or notice on the machine stating that all serial numbers are recorded 15 Operation Safety Maintenance 10 2005 Issue 5 e Discourage the thief Inspect the gates and fences of the machinery storage yard or construction site Keep machines in well lit area
25. ations or 1 the machine has undergone modifications not approved by TAYLOR CONSTRUCTION PLANT Ltd or 111 conditions of use have been abnormal or iv normal maintenance with regard to requirements as set out and detailed by the manufacturer have not been adhered to TAYLOR CONSTRUCTION PLANT Ltd will not pay for normal maintenance or servicing nor any materials used to carry out routine servicing The warranty liability of TAYLOR CONSTRUCTION PLANT Ltd 1s limited to diagnosis repair or replacement of the defective part and actuating the repair depending on the product terms and conditions this will be free of charge TAYLOR CONSTRUCTION PLANT Ltd shall be under no liability whatever to the customer for ant indirect loss and or expense including loss of profit suffered by the customer arising out of a breach by TAYLOR CONSTRUCTION PLANT Ltd of this contract Operation Safety Maintenance 10 2005 Issue 5 Warranty Audits and Surveys TAYLOR CONSTRUCTION PLANT Ltd reserves the right to carry out audits and inspections from time to time in relation to any reimbursed or outstanding warranty claims in order to determine that all relevant details and 1nformation 1s correct Service and Warranty Training Service and warranty training for service fitters can be requested In writing Initial training 1s to be carried out at an appropriate TAYLOR CONSTRUCTION PLANT Ltd workshop Once this initial training has been carried out yo
26. battery fluid levels or when checking for fluid leaks Use a flashlight or other safe lighting only e Shut off engine and use extra caution if engine is hot when refuelling Never smoke while checking or adding fuel or other fluid or handling fluid containers and lines e Use care and do not stand downwind when adding fuel or other flammable fluids to tanks and reservoirs to avoid fluids being blown or splashed onto clothing e Close fuel tank shut off valves if used before servicing fuel system e When preparing machines or components for storage seal and tape all openings and close containers tightly to seal 1n all volatile inhibitor fluids and compounds used e Follow manufacturer s recommendations when handling and using engine starting fluids and disposing of spent containers Do not puncture or burn empty containers These fluids are explosive and highly flammable Operation Safety Maintenance 10 2005 Issue 5 Precautions Electrical Hazard WARNING e Never smoke or allow open flames or sparks near batteries e Leave battery box open when charging batteries in machine for adequate ventilation of explosive gas Hydrogen produced e Always disconnect batteries before repairing electrical system to avoid danger of fire causing sparks Disconnect battery ground cable first and reconnect last e Always disconnect batteries and alternator leads before carrying out any welding on the machine e Never check battery state of
27. cal failures Every 100 hours or operation Monthly Engine crankcase drain oil replace as per lubrication chart check oil level the oil should be just over the last thread at filler Lubrication greasing periodic lubrications of moving parts reduce to a minimum the possibility of mechanical failures General inspection check entire unit for leaks loose bolts and nuts or damaged parts Examine the body particularly the chassis for cracks or broken welds Repair where necessary Engine air intake Check air intake system for wear or damage to piping loose clamps and leaks 40 Operation Safety Maintenance 10 2005 Issue 5 e Drain fuel remove filter screen replace the assemble install new filter screen and refill tank If contaminated fuel 1s suspected frequency may need to be increased Every 300 hours of operation e Drain fuel and replace fuel filter e Lubrication greasing Periodic lubrications of moving parts reduces to a minimum the possibility of mechanical failures Every 1 000 hours of operation 6 Months e Lubrication greasing Periodic lubrications of moving parts reduces to a minimum the possibility of mechanical failures e Replace hydraulic oil filter install new element each time do not reuse Every 2 000 hours of operation Annually e Lubrication greasing Periodic lubrications of moving parts reduces to a minimum the possibility of mechanical failures e Hydraulic Oil Tank Drain oil rem
28. e of installation not invoice date SERIAL NUMBER Serial number of unit ENGINE NUMBER Serial number of engine HOURS USED Sate hours used on hour clock Please do not guess the hours used DETAILS OF FAILURE Give a full report on the failure ORDER NUMBER An order number will be required Note the order number is to cover the diagnostic and call out time as well as to determine the following 1 That the failure 1s to be covered under the terms and conditions of warranty If this 1s the case then the costs will be covered by TAYLOR CONSTRUCTION PLANT Ltd and the order number will not be used 11 If the failure 1s determined to be of a non warrantable nature further authorisation to continue will be sought before any rectification work takes place The information above must be provided even if your warranty claim 15 a parts only claim An invoice will be raised for the exchange parts The reported faulty defective part must immediately be returned to TAYLOR CONSTRUCTION PLANT Ltd and full inspection of the parts carried out if the failure 1s covered under the terms and conditions of warranty a credit note corresponding to the invoice will be despatched to the customer If the failure 1s deemed to be of a non warrantable nature the invoice should be settled immediately Kubota UK Engine Dealers Bryce Group Ltd Daimler Close Royal Oak Industrial Estate Daventry Northants NN11 5QJ Tel 01327 876166 Fax 01327 300244
29. hat weather changes can create on the job Know proper procedures to follow when a severe rain or electrical storm strikes e Never attempt to operate or work on a machine when not feeling physically fit e Know what safety equipment Is required and use it Such equipment may be hardhat safety glasses reflector type vests respirators and earplugs e Never wear loose clothing rings and watches etc that might catch levers and controls and cause loss of control e Keep hand controls free from water grease and mud to assure non slip control e Handle fuels and lubricants carefully and clean up spills to avoid fire and slipping hazards e Never rush Walk do not run 17 Operation Safety Maintenance 10 2005 Issue 5 Preventing Fire Hazards A WARNING General Fire Precautions e Clean all dirt oil grease and other fluids from systems and components to minimise fire hazards and aid in spotting loose or leaking lines fittings etc e Check the engine for rubbish oily rags or other debris that could cause fires before starting the engine Safely dispose of greasy oily rags or similar hazards e Flammable Fluid Precautions e Don t use diesel fuel or other flammable fluids for cleaning purposes Use approved non flammable solvents e Make sure all fluid systems caps drain valves fittings lines etc are secure and leak free e Never use an open flame match lighter etc when checking fuel lubricant coolant and
30. nger Keep Clear 2 8 80 0016 HiLow Control Panel 1 80 0017 Warning Conveyor 10 80 0018 Adjustacrush 2 11 80 0019 Emergency Stop 1 12 80 0020 Starting Instruction 1 Decal Layout fig 2 23 3 Controls and Operating Operation Safety Maintenance 10 2005 Issue 5 Operating Control Diagram CRUSHER OF ERATION w sa EMERGENCY STOP DSL THAT THE PF RIP D La BUTTON MUST BE PULLED OUT WITH KEY SAFETY IHTERLOCKS CAP AND INTERLOCKS ARE SET HEMED BEECHRE OPERATING CRRA THE MARKER MUT BE IN GREEM BAND WITH THE BLUE enn stag a BUTTON PULLER Cat nire DERGA CRUSHER BEFORE OPERATING CRLISIHER DE EN HART W SAFETY INTERLOCKS THE BULA LUST EF Fi fu THE BLUE KIT TO PLK TI T ou BEF OSE CALERA 2 DO NOT OVER CRANK ENGINE 15 SECONDS MAX 3 GRADUALLY IDLE A HOT ENGINE BEFORE SWITCHING IT OFF l l MAINTENANCE 4 THIS WORK STATION HAS BEEN DESIGNED FOR SINGLE HAND OPERATION 5 WHEN REVERSING PAY CAREFUL ATTENTION TO CRUSH ZONES PERSONNEL AND OBSTRUCTIONS 1 NEVER PERFORM ANY MAINTENANCE WORK WITH ENGINE RUNNING 2 CLEAN ANY BUILD UP OF MATERIAL FROM MOVING PARTS WASH IF NECESSARY 3 CHECK FUEL DAILY ONLY USE CLEAN FUEL 4 CHECK OIL DAILY 5 GREASE DAILY MAXIMUM GRADE 35 DIESEL DRIVE l 3 Lwa 104 NEUTRAL NEUTRAL PR ae a VIBRATION o o Tel 44 01621 850777 ah w 6
31. on TQ14 ODD Tel 01626 872750 Fax 01626 873767 keithmason sleeman hawken demon co uk Trucks Morley Ltd Bruntcliffe Road Morley Leeds LS27 0JZ Tel 0113 2526777 Fax 0113 2380310 trucksmorley tiscali co uk Universal Engine Power Ltd Unit 9 Flitch Industrial Estate Chelmsford Road Great Dunmow Essex CM6 1XJ Tel 01371 875331 Fax 01371 874777 info unipower uk com www unipower uk com Wood Leigh Power Equipment Ltd Unit 20 Highcroft Industrial Estate Enterprise Road Horndean Waterlooville Hants POS OBT Tel 02392 571360 Fax 02392 592056 enquiries woodleighpower free online co uk www woodleighpower co uk Yardbury Kinetics Ltd Altens Trade Centre Hareness Circle Aberdeen AB12 3L Y Tel 01224 897947 Fax 01224 872374 a huntley yardburykinetics com 11 Operation Safety Maintenance 10 2005 Issue 5 CERTIFICATE OF CONFORMITY We declare that this product complies with the following Standards Directives Machinery Directive 89 392 EEC as implemented by The Supply of Machinery Safety Regulations 1992 Amended 1994 BS EN500 Mobile road construction machinery Safety Product Tracked Crusher Model HiC 40 Serial No HiC Bxxxx Manufacturer Date xx xx 2002 Signed T Ped Date xx xx 2002 Mr Paul Drew Development Manager This is a sample certificate of conformity inserted in this manual for reference each machine is issued with a bespoke certificate
32. ove and clean filter screen assemblies Reinstall filter screens and refill tank e Hydraulic Oil Filter Clean filter housing and install new element after a year or 2 000 hours of operation whichever comes first All information contained in the Lubrication and Service Chart is extracted from the relevant manufactures Operators Manual and was correct at time of publication User should ensure that information contained 1n this chart regarding engines and hydraulics reflect the information shown in the relevant manufacturers Operators Manuals supplied with the machine Maintenance procedures should be carried out in conjunction with any additional procedures contained in the relevant manufacturers Operation and Maintenance Manual at the intervals specified Lubrication and Miscellaneous Servicing Small circles on the illustration represent points at which lubrication or servicing must take place at the intervals indicated on the left hand side of the lubrication chart 41 Operation Safety Maintenance 10 2005 Issue 5 Note 1 The use of low viscosity oils such as 10W or 10W 30 can be used to aid in starting the engine and providing sufficient oil flow at ambient temperatures below 5 C 23 F Continuous use of low viscosity oils can decrease engine life due to wear Note 2 Operation below the minimum temperatures listed for the oil used without proper preheats or warm up results 1n greatly reduced life Proper
33. peed button as instructed on the operating decal Only use the higher speed when you are confident of ground conditions obstacles and a route clear of other personnel or equipment Always try to face or look in the direction the machine 1s travelling Always operate straight up or down slopes whenever possible Side hill operation can cause sideslip and possible rollover Slow down when moving In congested areas Lubrication and Servicing 2 Operation Safety Maintenance 10 2005 Issue 5 WARNING e Do not allow unauthorised personnel to service or maintain the machine Study the Operator s handbook and Service Manual before starting operating or servicing the machine e Do not work under or near unblocked or unsupported machine e Do not work under or near any unblocked or unsupported linkage part or machine e Always relieve pressure before servicing any pressurised system 22 Operation Safety Maintenance 10 2005 Issue 5 Decals Decals fitted to machines may vary from country to country to sutt local needs These pages contain a brief description and the location of the decals and control plates that may appear on this machine Ref Part Part Name Oty Number 1 80 0001 Serial Data Plate do 2 800000 Warning Crush Zone 1 1 3 80 0004 Warning Hot Exhaust 1 4 80 0005 Hydraulic Oil Filler 1 80 0006 Fuel Filler 6 800007 CEMarking 1 7 _ 80 0009 Da
34. rom this state rendering it unserviceable 28 Operation Safety Maintenance 10 2005 Issue 5 A WARNING Do not jump start a vehicle by using arc welding equipment Currents and voltages are dangerously high and cannot be sufficiently reduced to make the method safe NOTE Ensure machines are not touching each other Use cables that are equal to cable size on the machine If jumper cables are used to start an engine be sure to follow this procedure Connect one end of a jumper cable usually coloured red to the discharged battery POSITIVE post Connect the other end of the same cable to the POSITIVE post on the booster or charged battery Connect one end of the second cable usually coloured black to the NEGATIVE post of the booster battery Connect the other end of the NEGATIVE cable to machine frame for grounding so that if a spark occurs it is away from battery fumes explosive hydrogen Check for cause of failure on the dead battery Moving and Stopping A WARNING 1 Make sure the area around the machine is clear of personnel and obstructions before moving off 2 In the first few minutes of travel check carefully for the required controls for maximum operating safety select the driving direction and the required engine speed 3 Move levers to the required position apply more engine acceleration until the required speed has been reached 4 To engage higher tr
35. s and ask the local law enforcement authorities to make frequent checks around the storage yard or work site e Establish liaison with neighbours and ask them to watch equipment left at job sites and to report any suspicious activities to local law enforcement authorities e Make frequent inventories of machines to promptly detect losses or vandalism Actions to aid in recovery of stolen machines In the event of theft immediately notify the law enforcement authorities having jurisdiction Provide the investigating officer with name type of equipment chassis and serial numbers of major attachments and components It would be helpful to show the investigating officer an Operator s Handbook photographs and advertising to familiarise him with the appearance of the machine Report the theft to the insurance company Provide the model and all serial numbers Report the model and serial numbers of the stolen machine to a dealer handling the respective line of equipment Request that the dealer forward this same information to the equipment manufacturer 16 Operation Safety Maintenance 10 2005 Issue 5 2 Safety Precautions General WARNING e Read this operator s Handbook and learn the operating characteristics and limitations of the machine Know what operating clearances the machine requires e Know clearances of all side and overhead obstructions such as wires etc for operating safety e Beaware of operating hazards t
36. the dipstick or level plug All change and service periods are recommendations based on average operating conditions Lubricants showing evidence of excessive heat oxidation or dirt should be changed more frequently to prevent these conditions Lubricants change and service periods must be established on the basis of individual job conditions Miscellaneous Servicing Information 34 Operation Safety Maintenance 10 2005 Issue 5 When required e Hydraulic Tank Cold Oil Level e Hydraulic oil dipstick 1s not used to checked oil it 1s there to allow the air 1n the tank to be displaced when filling e To add oil remove red top of filter pull out filter and remove dipstick 1f low fill through the filter housing until the level is 100mm below the tube 1n the base of the filter housing DO NOT OVER FILL mes a k ma 1 v i wes gt r E p k 27 r 1 r F i e a Recommended Lubricants Note Do not mix Lubricants Component Lubricant Specifications API SAE Code Grade Engine Engine Oil with Crankcase and 1 85 max CC CD 10W 30 Filter Sulphated ash limit HV 36 or Hydraulic Bio Degradable wetem Hydraulic oil Liquimatic BVG 6743 4D 36CS 1 36 Plantosyn 36 HVI A S T M No 2 Diesel Fuel Oil with Diesel Fuel at sub max Sulphur 0 5 zero temp blend No 2 with No 1 Stern Tube Grease i Fueltank No 2 Consistency Extreme Pressure C W Extreme Lithium No Moly Pressure
37. u are responsible to carry further training as required by your own service centre or depot network Service Bulletins TAYLOR CONSTRUCTION PLANT Ltd may from time to time Issue service bulletins to keep you up to date as to any improvements or changes that may take place on the complete assembly or component parts Operation Safety Maintenance 10 2005 Issue 5 Warranty Terms for Machines Model Terms TAYLOR CONSTRUCTION PLANT Hi T500 tracked dumper One year or 1200 hours whichever occurs first from date of installation TAYLOR CONSTRUCTION PLANT Hi C40 mobile crusher One year or 1200 hours whichever occurs first from date of installation ALL ENGINE WARRANTY ISSUES MUST BE DIRECTED TO THE ENGINE MANUFACTURER OR THE MANUFACTURERS APPROVED APPOINTED ENGINE DEALER General Exclusions THE FOLLOWING ARE WARRANTY EXCLUSIONS AS DETERMINED BY KUBOTA Service items including lubricants coolants filters glow plugs fan belts fuel 1njection equipment stop solenoid leaks oil water and air IN ADDITION paintwork wear parts and tracks Operation Safety Maintenance 10 2005 Issue 5 Warranty Claim Submission Procedures Claims must be reported accurately and all relevant details given as follows OWNERS NAME AND ADDRESS full name and address of customer and site location 1f different MACHINE TYPE State machine type 1 e Hi T500 tracked dumper Hi C40 crusher DATE OF FAILURE INSTALLATION DATE The actual dat
38. warm up requires 20 minutes minimum with engine at part throttle before operating Note 3 Hydraulic Oil meeting specification 1s the only oil suitable for use 1n this hydraulic system Replacement of Rubber Drive Track In the event that the drive Track being displaced during operation follow the procedure listed below Operation Safety Maintenance 10 2005 Issue 5 Operation Safety Maintenance 10 2005 Issue 5 Remove blanking plug Remove securing bolt Slide drive track and Idler on shaft Insure Idler 1s fally home Operation Safety Maintenance 10 2005 Issue 5 Install securing bolt torque 49Nm Replace blanking plug Remove any blocking under chassis run and test 45 Operation Safety Maintenance 10 2005 Issue 5 a OOe eTet aw 46 Operation Safety Maintenance 10 2005 Issue 5 IFFT a2 ON SAA9 NOLLAIGISIJ Java ANEL ON Lid WOO M dar MAA OEECHA TETEK 2068 1291 EL FIG 642 ISSA ND TW UFO SSL vg eA ESANG MIT LAV Td NOLLINYLSNOD HOTAVL AHS FMA G3QNOS F T Ild NI aG AHEM Q3QNOS IVY ZI W nP E wF E IYW mW P L PAL IW TW ub n GIRISYM Q3QNOS wr ITYW ITYW FFE nP E dsl TIE NONS eS VA 1172 SW 7000 29 AHS YA INTIS SW Oe X OW 1100 Las 000 20 47 Operation Safety Maintenance 10 2005 Issue 5 eL dIL 2 JO I
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