METBERG T3000 Manuel utilisateur

CONTENTS

Page No.

Section 1.0 General Information. 4

1.1 Copyright 4

1.2 Foreword / Reservation of rights 4

1.3 Terms and Descriptions Used in this Manual 4

1.4 Warranty 4

1.5 Specification Alterations 5

1.6 Machine Specification 5

1.7 Familiarisation 6

1.8 Optional Equipment 6

1.9 Correct Use of the Machine 7

Section 2.0 Safety. 8

2.1 Safety Introduction 8

2.2 General Safety Rules 8

2.3 Hazard Warning Signs 9

2.4 Hazard Warning Signs on the Machine 11

2.5 Hazard Warning Signs in this Manual 12

2.6 Hazard Zone 12

2.7 Personal Protective Equipment 12

2.8 Plant Hazards – Working at Heights 12

2.9 Plant Hazards – Electrics 13

2.10 Plant Hazards – Hydraulics 13

2.11 Plant Hazards – Manoeuvring on site 13

2.12Plant Hazards – Nip Points 13

2.13 Plant Hazards – Material Falling from Heights 14

2.14 Safety Guards on the Machine 15

2.15 Emergency Stops on the Machine 15

2.16 “Lock Out” Procedure 16

2.16.1 Before Carrying Out Any Work on the Machine 16

2.16.2 After Carrying Out Any Work on the Machine 16

2.17 Emergency Shut Down Procedure 17

2.18 Restart Procedure after Emergency Shutdown 17

2.19 Testing the Emergency Stops 17

2.20 Safety Before and During Setup 17

2.21 Safety Before and After Setup 18

2.22 Safety Before and During Maintenance 18

2.20 Safety Before and During Transport 19

Section 3.0 Initial Setup. 20

3.1 Safety Before and During Setup 20

3.2 Initial Inspection 20

3.3 Machine Location Considerations 21

3.4 Measures Before Setup 21

3.5 Initial Setup 21

3.5.1 Starting the Machine 21

3.5.2 Fold Out Oversize Conveyor 22

Section 4.0 Standard Operation Procedures. 23

4.1 Safety Before and During Operation 23

4.2 Pre-Operation Checks 23

4.3 Initial Setup 24

4.4 Starting the Machine 24

4.5 Manual Tracking with Umbilical Handset 25

4.6 Normal Operation 26

4.7 Shutting Down the Machine 26

Section 5.0 Maintenance. 27

5.1 Safety Before and During Maintenance 27

5.2 Regular Maintenance 28

5.3 Check Fuel Level and Top up 28

5.4 Adjusting Trommel Brush 29

5.5 Tracks 29

5.5.1 Track Tension 30

5.5.2 Track Gearbox Oil Level 31

5.5.3 Cleaning the Tracks 31

5.6 Control System 31

5.7 Daily Maintenance 31

5.8 Weekly Maintenance 32

5.9 2 Weekly / 100 Hour Maintenance 32

5.10 Monthly / 500 Hour Maintenance 32

5.11 1000 Hour Maintenance 33

5.12 2000 Hour Maintenance 33

5.13 CAT 2.2 Engine Maintenance 33

5.13.1 When Required 33

5.13.2 Daily 33

5.13.3 Weekly 34

5.13.4 Every 250 Service Hours 34

5.13.5 Every 500 Service Hours 34

5.13.6 Every 1000 Service Hours 34

5.13.7 Every 1500 Service Hours 34

5.13.8 Every 2000 Service Hours 34

5.13.9 Every 3000 Service Hours 34

5.13.10 Every 4000 Service Hours 35

5.13.11 Every 6000 Service Hours 35

5.14 Lubrication Schedule 36

5.14.1 Tail and Drive Drum Bearings 36

5.15 Hydraulic System 37

5.15.1 Adding Hydraulic Oil 37

5.15.2 Changing Hydraulic Oil 37

5.16 Belt Adjustment – Safety Precautions 38

5.16.1 Belt Tracking 38

5.16.2 Belt Tensioning 38

5.16.3 Belt Alignment 39

Section 6.0 Transportation. 40

6.1 Safety Before and During Transportation 40

6.2 Removing Machine from a Low Loading Trailer 40

6.3 Putting the Machine into Transport Position 42

6.3.1 Folding the Oversize Conveyor to Transport Position 42

Section 7.0 Fault Finding. 43

Section 8.0 Spare Parts. 44

8.1 Spare Parts Ordering Information 44

The manufacturer, Metberg Ltd., declares under our sole responsibility that the

assembled equipment:

TROMMEL T3000 SCREENING PLANT S/N 007-01-2020

Complies with the provision of Council Directive: Machinery 98/37/EC as amended, and

with the regulations transposing it into national law.

Complies with the provisions of the following harmonised standards: EN 294:1992; EN

349:1993; EN 1050:1996; EN ISO 12100-1:2003; EN ISO 12100-22003.

The hereby declaration is valid provided that the described instructions and guidelines in

the manuals are respected, particularly those related to safe operation.

Created at : MetbergLtd.

136CorkillRoad

Eskra

Co.Tyrone

N.Ireland

Dated: 6 t h J a n u a r y 2 0 2 0

Name of Signatory:

Liam O

Liam OLiam O

Liam O’

’’’Hanlon

HanlonHanlon

Hanlon

ManagingDirector

EU DECLARATION OF CONFORMITY

SECTION 1.0 GENERAL INFORMATION

1.1 COPYRIGHT

No copies or reproductions may be made from this manual without prior consent of Metberg

Ltd. This manual, complete or in part, must not be loaned to a third party.

Additional copies of this manual are readily available; however, a charge may be made to

cover printing and administrative costs.

1.2 FOREWORD / RESERVATION OF RIGHTS

This manual has been produced to assist you to promote safe, correct and efficient

operation and maintenance of the plant, during its operating life time. By following these

instructions, you will help to reduce the risk of accidents, keep repair costs to a minimum and

increase plant reliability.

We strongly recommend that the customer, their Health and Safety Staff, plant operators

and maintenance staff should read and understand all aspects of this manual. Particular

attention should be paid to the safety and maintenance sections.

Keep a copy of this manual at the operational site at all times.

All information, illustrations and specifications in this manual are based on the latest

information available at the time of publication.

While all attempts have been made to ensure that the information contained in this manual

are correct, some variations exist between different plant designs, due to customer

specifications. Therefore, some of the information contained within this manual may not be

specific to every customer’s plant.

1.3 TERMS AND DESCRIPTIONS USED IN THIS MANUAL:

This manual refers only to the machine supplied by Metberg. Feed and discharge systems

connected by the customer and / or not supplied by Metberg, are not covered by this

manual.

Where Metberg Ltd have supplied but not installed the machine or any of the components

specified in this manual, it will take no responsibility for any incident, accident, injury, loss or

damage howsoever caused during installation or due to improper or incorrect installation or

set-up.

The following terms have been used throughout:

(i) Trommel

This refers to the group of components which go together to make up the machine supplied

by Metberg Ltd.

(ii) Customer

This refers to the individual, group or company who have purchased the machine from

Metberg Ltd.

(iii) Customer Connection Points

This refers to the points where the customer connects the feed and discharge systems. For

example, the point at which the material is fed onto the machine is a customer connection

point.

(iv) Machine Operator

This refers to the person/s who are authorised to operate and /or maintain the machine

whether it be the owner of the plant, their employees or their representatives. Metberg Ltd.

will take no responsibility for accidents, injuries, damage or loss to or by unauthorised

persons operating, maintaining and /or tampering with the machine.

1.4 WARRANTY

All parts and components supplied by Metberg Ltd, related to any products or services, are

supplied in accordance with the terms set out in the standard terms and conditions of sale.

The company shall endeavour to ensure that all products are manufactured to the highest

standards of the industry and carry a 12-month warranty from the date of delivery, or 2000

hours from the plant commissioning date, whichever is sooner.

The company shall in no circumstances be liable for damages of any kind whether direct or

consequential (including but not limited to the loss of profit, expenditure incurred, or delay in

the execution of any work being carried out by or for the customer) arising out of, or in

connection with the manufacture, or servicing, or failure to perform the servicing or failure to

return the equipment or any act done in connection therewith, except:-

Nothing in this clause shall limit the company’s liability for death or personal injury arising out

of negligence.

1.5 SPECIFICATION ALTERATIONS

At the time of initial design Metberg engineers will have determined the correct specification

of the plant to provide the required product and throughput. This specification will have been

determined through consultation with a representative of the customer where process

variables such as throughput, material type, working environment etc, will have been

determined. At the time of commissioning, the plant will be set and verified as providing the

required throughput etc. If, however, at any time in the future the customer wishes to

change any settings on the plant or the parameters in which the plant is operating i.e. the

material being processed, they must first consult Metberg Ltd. Written authorisation must be

received from Metberg before any changes take place.

Where any unauthorised alterations to the settings of the plant or the parameters in which

the plant is working, by the customer, their representative or any other person/s takes place,

warranty will automatically be invalidated. Metberg Ltd, will not be held responsible for any

direct or indirect damage, accident, injury or loss etc. arising from such unauthorised

alterations. Nor will it be held responsible for any loss in throughput, quality of output

material or decrease in plant reliability.

1.6 MACHINE SPECIFICATION.

General Dimensions

Transport Length: 10.8m (35’4”)

Operational Length: 12.4m (40’9”)

Width: 2.2m

Height: 3.2m

Weight: 9500kg

Capacities

Hopper: 2.5m3 (3.2yd3)

Fuel tank: 70 litres

Hydraulic tank: 265 litres

Engine

Type: Caterpillar C2.2 T

Power: 45.5kW

RPM: 2800-3000

Fuel: Diesel

Fuel consumption: 4 litres per hour

Feed Conveyor

Gearbox: Berma RT160

Torque ratio: 2000Nm / 1:8

Hydraulic motor: OMP315

Belt width: 1000mm

Belt length (drum centres): 3.4m

Belt: EP400 4-ply 5mm top

Adjustable speed: 0-13 RPM

Fines Conveyor

Hydraulic motor: OMT400

Belt width: 900mm

Belt length (drum centres): 14.5m

Belt: EP400 3-ply 5mm top

Oversize Conveyor

Hydraulic motor: OMT400

Belt width: 750mm

Belt length (drum centres): 8.5m

Belt: EP400 3-ply 5mm top

Drum

Diameter: 1.5m

Length: 3.7m

Hydraulic motor OMT500

1.7 FAMILIARISATION

The following names and descriptions have been used throughout this operation manual to

describe components and their locations.

1.8 OPTIONAL EQUIPMENT

Machines can include optional equipment and/or special features additional to the standard

specification. These may affect the information given in this manual. Look in the

appendix of this operations manual for any addendum which may relate to additional

equipment or variations to the standard specification. Take note of any variations to the

standard procedures and/or component specifications.

Hopper / Feeder Drum

Fines Conveyor

Oversize Conveyor

Tracks

Control Valves

FRONT

REAR

1.9 CORRECT USE OF THE MACHINE

(i). This machine should be used for loading, conveying, screening and stockpiling of

recyclable and aggregate type materials, e.g. Sand, gravel, chalk, ore, topsoil, green waste,

demolition, etc.

This does not include hot materials that could damage the belt etc.

(ii). The machine should be run in a well-ventilated area.

(iii). Appropriate space should be allowed for the loading of the machine and for the

stockpiles of materials that are created.

(iv). The machine should only be loaded via the hopper.

(v). Before operating the machine ensure that it has been properly setup, see section 3.0

(vi). The machine must be levelled across the undercarriage and along the chassis during

installation.

(vii). The machine must be properly maintained as per the maintenance procedures given in

section 5.0.

(viii). The machine must always be properly lubricated as per the lubrication schedule given

in section 5

(ix). Before shutting down the machine, other than in emergency situations, always run all

the material out of the machine. Re-starting the machine with a full load may damage the

drive system.

SECTION 2.0 SAFETY

DANGER

Failure to thoroughly read, understand and carry out these safety instructions could

result in death or serious injury

2.1 SAFETY INTRODUCTION

These safety instructions should be read, understood and implemented by the machine

owner, supervisor, operators and/or any other person/s who carries out work on the plant.

All personnel who operate, maintain, repair or carry out any work near or on Metberg

equipment, must be properly trained in the correct and safe procedures for operation, safety,

maintenance and repair etc.

It remains the responsibility of the owner of the machine to ensure the Health and Safety of

all persons who are viewing, operating or carrying out any work on or close to the machine.

This safety section in no way replaces any laws or other binding accident prevention and

environmental protection regulations.

2.2 GENERAL SAFETY RULES

Before operating, maintaining, repairing or carrying out any work on this machine, all

personnel must:

(i). Have read and understood all aspects of this manual and be familiar with all safety

instructions.

(ii). Be aware of all the hazards associated with this machine.

(iii). Know the location of safety features such as remote stop buttons and safety guards etc.

(iv). Know the location of the respective control panel for the machine and operating

features

(v). Have received specific and adequate training for any task to be carried out.

(vi). Be completely familiar with all parts and operation of the machine.

(vii). Be aware of all moving parts on the machine.

(viii). Have read and understood any “on-site” safety manual produced by the site owner.

(ix). Be aware of the performance limits of the plant

(x). Use the machine only as it was intended to use.

(xi). Carry out all safety instructions regardless of how unimportant they may seem.

(xii). Ensure that all “Personal Protective Equipment” is worn.

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