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 the purpose of the guard on the crusher inlet and why it should be down when the crusher is in operation

  • 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


  • 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


  • 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

  • Tank breathers

  • Drain points

  • Explain the importance of replacing the charge pressure filter every 250 hours.

  • Explain the importance of keeping drive belts tight (constant high drive ) and how to check and tighten

  • Explain the operation of the underpan feeder (if fitted) and the importance of keeping it clean.

  • Explain to the customer the importance of keeping all wear parts inside the chamber tight and highlight the tendency of these wear parts to come loose.

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

  • Explain to the customer how to tension the tracks.

  • Explain and if necessary demonstrate how to change pre-screen screen meshes.

  • Explain the difference between full and half size bars and the different types available and their benefits.

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

  • Explain and demonstrate if necessary how to change and turn Blowbars using the lifting beam. Stressing the importance of the rotor locking pin

  • On a RS model explain and demonstrate how to lower the screener, change meshes, and lift 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.

  • Fold out access ladders and secure.

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

Setting up

  • Explain and demonstrate how to set the apron settings

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 feeder control and how to use this with the remote control.

  • Explain the feeder inhibits function and what they are likely to see.

  • Demonstrate and explain how to adjust magnet speed.

  • 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.


  • Explain the benefit of Trialling different feeder and rotor speeds and apron settings

  • Even wear on Blowbars (longer life)

  • Reduced wear sometimes when running slower

  • Improvement on shape / Quality

  • More and even through put

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

  • Wet sticky material (clay)

  • Asphalt

  • High Fines content

  • Explain the need to Choke feeding

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


  • 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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