Safety overview

  • Walk around the machine and ensure there is ample room to fold out

  • Ensure any parts removed for transport are refitted, and any transport brackets etc removed.

  • Explain the need for the Customer to read and understand the operation manual

  • List the location of every e/stop including the engine kill button on the remote control

  • Point out and explain the safety warning stickers

  • Explain each and every grid and the nip point it is covering and why they should not be removed

  • Explain why you should never enter the crushing chamber until all safety procedures are in place (Demonstrate)

  • Explain the use of the battery isolator

  • Explain the danger of high pressure oil

  • Explain and demonstrate lockout procedure

  • Explain the tracking operation and requirement for banks man

Pre-start

  • Explain to the customer the reasons to do a pre-start every time and that they should have their own pre-check sheet to follow

  • Ensure all guards are fitted

  • That no damage has been done during transport / shipping damage

  • Identify wear components

  • Show maintenance schedules

  • Check that there are no loose parts or leaks

  • Check all lubricants and oils are at specified levels

  • Explain to the customer the benefit to keeping a log book with the machine so they can record:

  • Hours run

  • Location

  • Feed material

  • Discharge material

  • Damage

  • Closed side setting

  • Condition of wear parts (skirts etc.)

  • Maintenance issues

  • Running records (engine load)

  • Running records (temperatures)

  • Point out to the customer all emergency stops around the machine

  • Identify to the customer the hydraulic components and their purpose around the plant

  • Identify to the customer the daily oil level checks

  • Diesel level and filler

  • Engine oil level and type used

  • Engine coolant level and type used

  • Hydraulic oil level and type used

  • Feeder gearbox oil level and type used

  • Urea level and where to fill

  • Greasing points around the machine

  • Track gearbox level and type used (not expected to be a daily check)

Navigating around the screens

  • Demonstrate and explain how to navigate around the screens

  • Demonstrate and explain the alarm fault codes and warning lights - what to expect, how to find the history

  • Demonstrate and explain the engine, screen etc.

  • Demonstrate and explain the set-up screen

Maintenance

  • Explain the importance of having a structured maintenance procedure and the benefits

  • Point out the position for locking off the machine and how and when to lock out and tag out

  • Show the customer the detailed maintenance schedule in the operations manual, for daily checks through to 2000 hours

  • Point out to the customer the locations of all maintenance related components

  • Engine oil, fuel filters and separators – location of dipstick

  • Hydraulic filters, return r filters and suction filters and how to change

  • Lube oil filters, levels, fill point

  • Hydraulic cone panel filters

  • Tank breathers

  • Drain points

  • Explain to the customer how to tension and track / align Product and Feeder belts using adjusters and return rollers.

  • Explain to the customer how to check the drive coupling.

  • Explain to the customer how to tension the tracks.

  • Point out and explain the components of the cone lube oil system including the lube tank, heat exchanger, countershaft and main lube feed points the flow meter, cooling fan, coolant taps on the engine and what they are likely to see on screen when running .

  • Explain to the customer how raise and lower the cone and how they adjust the closed side setting

  • Point out the ECM and the importance of this being disconnected when welding.

  • Explain and demonstrate the cone Hydraulic panel and what they would expect to see

  • Demonstrate re-charge pressure

  • Explain the wedge ring pressure – ( Dumpy jack circuit ) and what they are likely to see, recharge etc.

  • Explain the wedge lock circuit and what they are likely to see when raising and lowering the cone and whilst crushing

  • Explain the importance of calibrating the cone zero every day.

  • Explain how to carry out a liner change, Use supporting material if necessary.

  • Explain the tramp system on the cone

  • Explain how to test the metal detector.

  • Explain the importance of checking charge pressure every 250 hours.

  • Explain and demonstrate if necessary how to carry an out of round check.

  • On an RS Model demonstrate how to lower the screen assembly, change meshes and re-tension and raise back into a working position.

Selecting a site position

  • Explain the need to prepare a firm / stable and level base

  • Failure to do so will cause uneven and premature wear of parts, etc.

Tracking into position

  • Explain and demonstrate how to select tracking, how to track and manoeuvre slow and fast with the remote control and/or umbilical

Folding out

  • Demonstrate how to raise and lower the Belt feeder and pre-screen.

  • On an RS Models how to fold out the individual components.

Setting up

  • Explain and demonstrate how to set the feed box level sensor.

Starting and running the machine

  • Explain and demonstrate how to start the machine in manual and auto mode, explaining the sequence, the engine rpm, speeds and pressure on screen that would be expected.

  • Demonstrate and explain belt feeder control.

  • Explain the feeder inhibits function (the feed box level sensor), demonstrate this in operation.

  • Demonstrate and explain the metal detector. Highlight the importance of the metal detector being calibrated.

  • Demonstrate and explain the dust suppression system.

Shutting down the machine

  • Demonstrate and explain shutting down the machine, in manual, in auto, again what to look for and what to listen for.

Applications

  • Explain the things they are likely to see with different materials

  • Wet sticky material (clay)

  • High Fines content, (compacts)

  • Explain the need to Choke feeding

  • Explain the need to keep the feed in central and a steady Flow

Summary

  • Ensure the customer is happy with the procedure of how to fold down and prep for transport

  • Show the customer how to use the spare parts manual

  • Show the customer the contents of the operations manual and explain his need to read and understand

  • Explain the tool box contents

Additional comments and sign off

  • Were there any quality issues or unseen circumstances which affected your ability to commission the machine at the customer’s site?

  • Handover carried out by:

  • Person inducted

  • Person
  • Add signature

  • Date Handover carried out

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