LT1213 TRAINING MATERIALConstructionTechnical performanceNP FeaturesFeederNP1213Control panelTransportStarting and stoppingMaintenanceCrushingHydraulicsDanfossElectric

FeederCrusherDiesel engineMain conveyorSide conveyor (optional)TracksMagnetic separator (optional)

Dimensions in transport position14700340028282980

1470018200Dimensions in crushing position and extension conveyor (optional)43954220

Pump for crusher driveMax. pressure 440 bar (6382 Psi)Max. output flow @ 97% efficiency 485 L (128 gal) / minute.Close CircuitCrusher drive485 l/min (128 gal) @2000 rpm of the engineCrusher idling speed 450-600 rpmFlow according pump angle.

Pump for LT1213 componentsMax. pressure 280 bar (3983 Psi)Max. output flow @97 efficiency 252 l/min AppliesMain conveyor (l: 10m w: 1.2m), 55 l/min (15 gal)@ designed speed 1.9 m/s.Side conveyor (l:5m w:0.5) 35 l/min (9.5 gal)@ designed speed 2.7 m/s.Conveyor of permanent magnet 20 l/min (5.5 gal)@designed speed 1.7 m/sFeeder (Vibrating machinery V150), 30 l/min (8 gal)Free capacity 100 l/min (26 gal).

Electric ControlsPLC controlledAll controls 24 VDCSelf diagnostic via monitor deviceAdjustmentPLC values via monitor deviceCavity level controlIntermediate cable available as an option

EngineVolvo TWD 1231 VE308 Kw @ 2000 rpmCat 3196 ATAAC317 Kw @ 2000 rpmMounted lengthvise to the LT1213Hydraulic cooler mounted side of the engine cooler. No separate cooler motor.Maximum allowed high idle 2000 rpmHydraulic pump max 2000 rpm.

Main Control Panel with Volvo Engine11. Emergency stop26. Process 0/135. Key switch48. Work light59. Track drive610. Discharge conveyor 0/177. Diagnostic82. Crusher speed93. Feeder autom. speed101111. Magnetic separator 0/112134. Signal horn1413. Radio control15161715. Monitor display17. Socket for the screen mod-power18. Control socket for the screen module-control1816. Engine tachometer/hour counter12. Hydr. outlet14.Pre-heater19. Pre-heater clock19

Main Control Panel whit Caterpillar Engine123456789101112131415161718191. Emergency Stop2. Crusher speed3. Feeder autom. Speed4. Scroll display5. Signal horn6. Key switch7. Process8. Work light9. Track drive10. Discharge conveyor11. Magnetic Separator12. Hydr. Outlet13. Radio control14. Pre-heater15. Pre-heater clock16. Monitor display17. Caterpillar Alarms/Display18. Socket for screen module-power19.Socket for screen module-controlCATERPILLAR

Caterpillar Alarms/DisplayCoolant temp.Intake ManifoldAir temp.Fuel Temp.Battery VoltageAccessory temp.Accessory PressureEngine Deratefor Monitoring or AltitudeEngine OilpressureFuel PressureCoolant LevelScroll DisplayEngine speedPercent engine loadFuel rateEngine BoostBattery voltageCoolant temp.Intake manifold tempFuel tempAccessory tempEngine oil pressurefuel pressureAccessory pressureEngine running hours

11. Track left hand22. Track right hand43. RPM of the diesel engine34. Emergency stopDrive control box

STOPSTARTEmergency stopCapacityFeeder stopFeeder startFeed gate open/close

Remote control

1. Feeder2. Mag. separator3. Side conveyor4. Main conveyor5. Crusher

Override controls can be used to temporarily overrun the usually logic-driven functions: To override failed PLC-control or to clear a blockage. The feeder, crusher, discharge conveyor, main conveyor and magnetic separator can be used separately without starting the whole crushing process.

NOTE! Override control panel must be disconnected during the crushing process. If the process is controlled by the PLC, the connected override control will bypass the feeder speed control.12345Override Controls

Turn the light pole up, if necessaryCheck the crusher V-belt tension. The belt reflection is 30 mm when force is 110 N (24 lbs).

STARTING THE DIESEL ENGINEStart the diesel engine as follows:1 Turn the main switch on.2 Turn the key switch in the main control panel to ignition ON-position. 3 Make sure that the safety and emergency circuit is operational.4 Make sure that the temperature and level of the coolant water in the diesel engine are normal.5 Press signal horn button #4 to caution all persons close the unit.6 Wait until the self monitoring period (10s.) of the PLC is over. 7 Turn the key switch to start position and hold it there. Wait until the diesel engine starts.NOTE! Glowing delay according to the engine temperature. NOTE! Hold the key switch at start position until the diesel engine starts.

STOPPING THE DIESEL ENGINEStop the diesel engine by turning the key switch to "OFF" position.

NOTE! Before stopping the diesel engine, make sure that the engine idles for few minutes.

ADJUSTING DIESEL ENGINE RPM SPEED

The automatic PLC control of the machine monitors and adjusts the diesel engine RPM during the start and the crushing process. During this time, the user cannot adjust the RPM speed. When the process is not running, the RPM speed of the diesel engine can be controlled with the RPM control switch located in the drive control box. If the machine has radio control (optional), the RPM speed of the diesel engine can be adjusted with radio control in the same way as with the drive control box.

EMERGENCY STOPIn case of emergency press emergency stop- button to stop the machine or the conveyor. The buttons are shown in the drawing. ENSURE 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.Stop the machineStop the mainconveyorStop the sideconveyor

SAFETY WHILE TRACKING

Pay special attention to transport and moving of the unit because of its dimensions and weight.Normally the LT1213 can be moved on the site in its working position by driving on tracks.Before driving make sure that:- the driving route is 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.

SELECTING THE DRIVING SPEED RANGE

It is possible to use three different speed ranges; fast, slow and crawl. Select the speed range with the Drive speed-switch located in the main control panel.Recommended driving speeds:Slow: Driving the Lokotrack to/off a trailer, or when accurate and careful handling is needed.

Crawl: The most effective force to move the unit. Crawling speed is used in daily operations.

Fast: Fast speed is used when tracking distance is considerably long. Distances over 500 m and there is no need to turn the unit.

Drive the LT1213 with the drive controls in the drive control box. If the machine has radio control (optional), the driving is also possible with radio control, in the same way as with the drive control box.Always check the surroundings of lokotack before moving it

Plug the drive control cable into one of the cable connecting socketsThe Lokotrack can now be moved in either direction using drive control levers in the remote control unitDriving The LT1213Note! Do not keep the drivecontrol panel plugged during the processing

Turn down additional side wall of the feederTurn the side conveyor up

Place the light pole into the transport positionTransport from site to siteLower the conveyor drivehead to transport position.See extended discharge conveyor.

Manual Valve FunctionsIn order to activate hydraulicpressure to manual valves the switch # 1 must remain in ONposition.

NOTE! Manual valve can notbe activated during theprocessing.Switch # 1for hand valve1. Side conveyor in/out

2. Side conveyor up/down

3. Not in use1-These valves are located in the hydraulic box.

Manual Valve Functions - Feed Hopper1. Left side wall of the feed hopper up/down

2. Rear wall of the feed hopper up/down

3. Right side wall of the feed hopper up/downIn order to activate hydraulic pressure to the manual control valves of the feed hopper. The selector switch must be turned to clockwise position.

NOTE: The side conveyor must be in crushing position in order to operate feed hopper flanks.-These valves are located under the feeder.

1. H10-15 conveyor up/down2. Crusher setting assistance3. Crusher frame opening123Hydraulic module

1.Main conveyor2.Hydraulic outlet3.Magnetic separator4.track, left5.track, right6.Feeder7.Opening of the feed gate 8.Side conveyor driving/ operations of cylinder

Hydraulic Valve Function11233455667878

Driving on to/off low loader/trailerDrive LT1213 onto and off loader/trailer very carefully. Low loader, min. capacity 45 t.

Fix suitable ramp against the trailer so that the maximum inclination does not exceed 1 in 4 when driving the LT1213 up onto the trailer.

The LT1213 may be driven onto the trailer forwards or backwards depending on trailer type.Weight of the base unit (without fuel): LT1213 37500Kg / 82500 LBS

Weight of LT1213 with options

Kg

Lbs

Side conveyor H5-5

600

1320

Magnetic. Separator: STD

2200

4800

Feed hopper (9m)

570

1255

Hyd. Folding of feed hopper

110

240

Long conveyor H10-15

1900

3890

Shape the material pile for easyloadingEnsure that there is enough space for discharge pile.Spread some fine material on the ground, then rub it smooth. The machine must not sway.Make the ground solid by driving the LT1213forward and back on location.

During crushing

>200 mmThe excavator operator must have free visual field to thetop of the feeder. Load the materialin the feeder rear end on the solid bottom.The distance between the pile and conveyor must be always at least 200 mmLoading with wheel loader--If needed, make a loading ramp from the material to reach the feeder better.-Drive the LT1213 as near the pile as possible to make loading fast and easy.-Note! Dont hit material with excavator.-Note! Keep feed gate closed during operation.

FEEDINGNot recommendedoperating area.Risk of flying rock.Safe operating areaSafe operating areaFeed gateFeeder

EXTENDED DISCHARGE CONVEYOR TRANSPORT TO CRUSHING

-Activate manual valve-Remove transport locking. Lift the conveyor slightly to allow locking pin removal. (ref. Page 28)-Turn the conveyor drivehead to crushing position-Mount locking pins at their places. The head of the pin must be inside the conveyor frame-Reset trip wire switches. Adjust tightness if necessary-Secure side rubber position at both of the joints-Deactivate manual valve. CRUSHING TO TRANSPORT

-Activate manual valve.-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 locking at their place-Deactivate manual valve.

1. Remove the transport locking of the side conveyor.2. Turn the side conv down with the controls located in the hydr valve section.1.Turn the side walls of the feed hopper up.2. Lock with the wedges.

NOTE! Do not stand in side of the frame when mounting the wedge on its place. 1. Turn the rear wall up.2. Lock first with the lower wedge.3. Fasten the upper wedges and lock them with bolts.12Remove the transport locking of the feeder.Turn the lightpole up.

Starting the crushing process

Before starting always ensure that the crusher cavity is empty.

When the crushing process has started, the RPM speed of the diesel engine cannot be adjusted by the operator before the crushing process is stopped again.

Start the crushing process by turning process switch to 1.

NOTE! When starting the process, the automatic control takes care of starting the equipment, delays, watching for any troubles and adjusting the diesel engine RPM speed. The starting of the crushing process takes about one minute after the process switch has been turned.

- Connect the water supply (if needed). - Turn on the light if necessary. Stop the crushing process by turning "Process switch to 0.

NOTE! When stopping the crushing process, the automatic control takes care of stopping the equipment, delays, watching for any troubles and adjusting the diesel engine RPM speed. The stopping of the crushing process takes about one minute.

When the crushing process is running, the side conveyor (optional) can be stopped by turning the side conveyor switch to position 0 and restarted by turning the switch to position 1. The magnetic separator can be stopped by turning the magnetic separator switch to position 0. It can be restarted by turning the switch to position 1 despite of the state of the crushing process. Load some material on the feed hopper when the vibrating chute is running.

When loading with wheel loader, the feed hopper must be almost empty before loading more material in the hopper. When loading with excavator you can load more buckets at the time.

See the crusher instruction manual for details in crushing.

In case of emergency press "Emergency stop"-button to stop the LT1213.

Don't try to crush oversized feed, that is too large for the cavity. Having to reposition rock wastes time, reduces capacity, and imposes unnecessary loads on the crusher.

Clay, wood and any non-stone-based material must be prevented from entering the crusher. These could cause blockage in the crusher cavity and overloading which may damage the crusher. NOTE! If the crushing process is interrupted, use the monitor device to locate the cause.

NOTE! Side conveyor must not switched on if its in transportation position

Factory set speed

Pos.FeedCrusherHammerCrusher speed speed Idling

#1Asphalt/450 rpm 25 m/s 480 rpm Abrasive material

#2Recycling/520 rpm 32 m/s 550 rpm Medium abrasive material

#3Rock feed/600 rpm 38 m/s 630 rpm Non abrasive mat.Crusher speed Selector switch is located at control panel. Position of the switch 1-2-3Speeds can be changed in monitoring device setup menu.

Note! Power of the crusher is highest in speed 3.

The material flow under the feedergrizzles can be directed to the mainconveyor.The chute is directed to the side conveyor.The material flow is screened and directed either to the side conveyor(passing) or to the main conveyor.

FEED CONTROLThe feeder can be stopped and restarted again during the crushing process. The starting and stopping buttons of the feeder are located in the control box on the service platform. If the machine has radio control (optional), the feeder can be started and stopped with radio control. Stop and restart the feeder as follows: -Stop the feeder during the crushing process by pressing the "feeder stop" button. -Restart the feeder after it has stopped completely by pressing the "feeder start" button. NOTE! The feeder starts automatically when the process is started and stops always when the process is stopped.

-The feeder always starts at minimum speed regardless of the speed setting in order to maximize the capacity. After a while the speed changes to the set value.

-In order to control the capacity, the feeder speed can be adjusted from the "capacity" switch. The switch is located in the control box on the service platform.

-Feeder will stop when crusher pressure has exceeded the crusher light over load value. Feeder will restart automatically when pressure is below alarm limit. -Increase the capacity, i.e. the speed of the feeder by turning the "capacity" switch until the desired feeder speed has been reached.

NOTE! Feeder's too high feeding capacity can cause falling of rocks over the flanks of hopper.NOTE! Radio control will prevent feeder controls from the control box on the service platform.

The best capacity can be reached when feeder remains running as much as possible

Feeder automatic control

Operation switch is located at the control panel. Function is off at 0-Position and the feeder speed can be controlled from capacity switch.( radio or operator platform)

Function is activated at 1-position. Automatic control is based on four different values of controlsystem. These values are: feeder min speed, feeder max speed, crusher load value acceptable, crusher light over load.

Feeder min speed: FMINFeeder max speed: FMAXCrusher load value acceptable: CLOKCrusher light over load: CLLD

Feeder speed remains at max speed until crusher load value acceptable (CLOK) value is achieved.Feeder speed will reduce until the crusher light over load (CLLD) value is achieved, after that feederstops. Feeder will restart automatically when pressure level is below light over load value. Pressure valves are editable via monitoring display system setup menu.

MINIMUM SETTINGThe hardness of the feed material will effect the min setting. Ref. NP1213 instruction manual for setting ranges. Minimum setting

Rock recycling50mmAsphalt30mm Maximum setting

All material100mm

Different example curves for feeder speed with automaticfeeder speed controlExample 1Example 2Example 3

CLEARING OF THE JAMMED MAINCONVEYOR

Note! Never try to clear the blockage with the excavator.

If the conveyor stops, follow these instructions:* Stop the process immediately* The machine is equipped with the override panel. The panel is used to control Crusher, feeder, main conveyor, discharge conveyor and magnetic separator. The buttons are located in the separate override control panel. Selected equipment can be started or stopped manually by using override control.* The engine RPM must be adjusted manually from drive control box. (Suitable engine speed for clearing the blockage is 1500 rpm)*Connect the override control box.

Clear the jammed conveyor manually as well as possible. When the most of material is removed the conveyor can be started from override control panel. Main conveyor directional valve can be used to reverse conveyor. Valve locates in hydraulic valve section.

NOTE! The safety devices and alarm controls are switched off when using this control method. Use separate control only in exceptional situations or when servicing the machine. Always make sure when starting any of the devices that no personnel is endangered. NOTE! Do NOT use this method if the rock is too big to pass under the magnetic separator!NOTE! Override control panel is used to clear the blockage or to keep the unit operational in case of plc-control failure.

Main conveyor directional valve canbe used to reverse conveyor.

Valve locates in hydraulic valvesection. (Valve position shown in thepicture in reverse direction).Main conveyor

REMOVAL OF THE STEEL

Always stop the machine (feeder, crusher, conveyors and engine) before removing metal from it. Ensure that it can not be started during removing metal from it.Use the hook to remove iron bars and wires. Be very careful not to hurt yourself. Never use hook when the machine is running.

INTERLOCKSSome functions of the machine are interlocked with each other to prevent damages and injuries. When the interlock has stopped something, find out the reason, fix it and restart.Here is the list of the interlocks and action when they occur: The engine gets too hot The engine stops in 1 minute. Process stops automatically. The engine oil pressure gets too low The engine stops. The oil level in the hydraulic tank gets too low The engine stops. The oil in the hydraulic tank gets too hot The feeder stops immediately. The crusher pressure too high The feeder stops. It starts automatically again when the crusher pressure is ok. The conveyor pressure too high The feeder stops. Feeder do not start automatically. If conveyor pressure draw is constant the process will be shut off. Crusher is openProcess does not start. Check

RECYCLING

In recycling applications the metal objects should be removed from the feed before entering the crusher.

Maximum allowed diameter of the steel 16 mm. The maximum allowed length of the steel in the feed 1,0 m.

The most efficient way is to prepare the feed material and remove all the metal from it before loading it to the LT1213.

The optional magnetic separator can be used for the removal of small metal objects.

OPTIONAL EQUIPMENT HYDRAULIC OUTPUTThe hydraulic output can be set on and off by turning the "Hydraulic output" switch to position START or STOP.

NOTE!The crushing process must be stopped when using the hydraulic output function for main conveyor folding. If the hoses of the main conveyor folding are left on their place, the hydraulic power take off switch must be in off position during processing.

INTERMEDIATE CABLE FOR SECONDARY UNITUnit is equipped with 6-pin socket allowing information transfer between primary and secondary unit. Socket X140 has three different functions:Intermediate cable is optional. (Order no: 923909)

Pins 1&2: When connected LT1213 gets information that secondary unit is connected.

Pins 3&4: Feeder on/off information (secondary feed/emergency functions can be connected to this). Normally open contact required.

Pins 5&6: For secondary unit's level sensor. Function similar as the level detector in LT1213 (feeder runs 10 sec. with minimum speed if "high cavity level" noticed. Speed is set automatically back or feeder is stopped if alarm won't disappear during the 10sec period). Normally closed contact required.

1. Engine rpm UP-Down/ feeder ON-OFF.2. Battery.3. Selector switch 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 feed gate open/close9. Key- switch.Instruction for Radio Control (optional)Power outlet adapter for 24 VDC

SELECTING THE RADIO CONTROL

The control panel has a selector switch. Radio control ON/OFF. In the ON position the radio control mode is selected. Note: Feeder can be controlled with the radio controller only when radio control mode is selected.

STARTING THE RADIO REMOTE CONTROL

The radio transmitter can be switched on by turning the key-switch located on the right side of the radio. (The key can be removed in the position 0.)

Turn the key-switch clockwise to position 1. The radio transmitter will indicate the turning of the key switch by peeping twice. By turning the key-switch to the start-position after the indication the radio can be activated.

NOTE! The radio transmitter has an automatic battery saving function and the radio transmitter will switch off automatically if the functions of the radio have not been used for 10 minutes. The radio will have to be switched on again if radio control is needed. (10 minutes automatic battery saving mode can be eliminated by disconnecting the jumper #J2 from radio transmitter).

THE VOLTAGE LEVEL OF THE BATTERY

1. Indication of Voltage Level The led indicator 6 indicates the voltage level by blinking. The radio does not function if the voltage level is too low. The aim is to use the battery full capacity for longer battery lifetime. 2. Voltage Level Alarm The transmitter gives an acoustical signal when the transmitter battery capacity is nearly exhausted.

OPERATING WITH RADIOSelect tracking mode or crushing mode with the switch # 7.Tracking Mode:Switch 1: Engine rpm up/down Levers 5 & 8: Track controlsSwitch 3 does not have a function in tracking mode.

Crushing Mode:Switch 1: Feeder ON/OFF Switch 3: Feeder speed adjustmentLevers 5: Feed gate open/close Remote STOP FunctionThe unit can be stopped rapidly with the remote stop function.NOTE! The remote stop function requires that the radio transmitter is in active state. Remote stop function is not possible when the radio is not active or when the battery in the radio transmitter is flat.

Discharge chute impact platePlate is designed to reduce the wear of theconveyor belt. Impact plate is designed to beused with hard rock & asphalt application.

Impact plate can be used in recycling applicationif the steel in the feed material is precut enough short.

Impact plate is mounted to discharge chute. Impactplate can be lifted to/from its place with the impactcrusher hoist.

FINAL DRIVEChange final driver oil after 150 operating hours. After that every 1500 hours.Oil amount is 4.5l (1.2 gal). Oil quality is ISO VG220FUEL LEVELThe fuel level can be checked from the fuel gaugein the control panel. The fuel tank capacity 600l (160 gal).

FILLING VOLUMES LOKOTRACK LT1213

Hydraulics520 l/ 140 gal

Final driver4,5 l/ 1,2 gal

Fuel tank600 l/ 160 gal

Feeder vib. Unit4 l/ 1,07 gal Volvo CaterpillarTWD 1231 3196

Engine oil 38 l/ 10 gal28,5 l/ 7,6 galWater 55 l/ 14 gal36,0 l/ 9,6 galDIESEL ENGINE

Front frameRear frameFrame hingeFrame cross beamRotor shaftRotorHammerHammer locking systemBreaker plateBreaker plate linerBreaker plate rodsBreaker platereturn springBreaker plateadjustment systemSide linersFeed plate

SettingMeasuring the Setting1. Stop the engine

2. Open the inspection door of the crusher

3. Rotate the Rotor to position as show in the drawing

4. Measure setting between the hammer and the lowest breaker plate liner. (measurement from the center of the hammer).

Changing the Setting1. Stop process2. Stop engine. Measuring the setting (ref. Page 58)3. Start engine4. Activate manual valves.5. Remove protection plate #16. Remove the spring tension with setting assistant #2.7. Turn the adjustment nut #3 to desired direction: -cw: open setting -ccw: close setting 8. Release spring tension with setting assistant #2.9. Stop the engine10. Check setting.11. Close inspection door12. Mount protection plate #1 on its place123

Wear parts of the crusherSide wear plateDischarge chute impact plateBreaker plate linerHammer

Crushing by impactThree crushing actions in a HSI

1. Rotor against Rock (Ec= 1/2 JW : 60% of the crushing effect)

2. Rock against the breaker plates (Ec= 1/2 MV : 30% of the crushing effect)

3. Rock on Rock(Attrition: 10% of the crushing effect)

How to set a NP

Manganese: manganese steel contains 1.0 to 1.3% of C, 1 to 2.5% of Crand 12 to 14% of Mn. This is equivalent to the FMU 86 of Magotteaux.

Martensitic: Martensitic steel contains 0.22 to 0.32% of C, 10 to 13% of Cr.This is equivalent to the FMU 22 of Magotteaux.

Chromium: Chromium iron steel contains 3.0 to 3.6% of C, 22 to 28% of Crand 1.4 to 2.2% of Mo. This is equivalent to the FMU 46 of Magotteaux.Hammer chemical composition

-Easy servicing -Simple and quick locking by wedges-Rotor and hammers have machining surface to improve the crushing resistance

Side or vertical changing of hammersNOTE: Use double nut on hammer locking wedge bolts it will save the threads

Hydraulic assistance for breaker plate

Complete shaft line of NP

21345Changing of the screen cloth1. Remove the wedges, point 1.2. Remove the plate, point 2. Fasten a chain block from item 4 and route it under the deck and hook it to grizzly bars. Dont stand under the deck.3. Open the bolt in the point 3, (2 bolts).4. Loosen the cotter bolts in point 5.5. Open the bolt in point 6, (2 bolts).6. Lower the deck down with the lifting tackle.7. Remove the old screen deck.8. Install a new screen cloth and continue in reverse working order.6

Oil drain portThe oil is changed for the first time at 200 running hoursand then every 1000 hours orat least ones a year.

The oil level is checked while theLT1213 is in level.

The recommended oil volume is4 l.

Oil type is ISO VG150 (factory fill,ref. Instruction manual)

The breather must be in operationalposition whenever the device isin use.

Replace the breather every 1000 hor when breather is dirty.Vibrating Machinery V150MaintenanceOil fill portOil level