user manual PC1

user manual PC1 PC1-013 bis XX

Index

1. WARRANTIES AND LIABILITIES 4

2. DESCRIPTON OF MACHINE 5
2.1. GENERAL LAYOUT DRAWING 5

2.2. CHARGING AREA & VIBRATING CHUTE 6

2.3. CRUSHER 8

2.4. TRACK CHAINDRIVE 15

2.5. FRAME 16

2.6. MAIN CONVEYOR BELT 17

2.7. MAIN DRIVE – power pack 18

2.8. CLUTCH WITH PUMP DISTRIBUTOR GEAR 19

2.9. SIDE CONVEYOR BELT 20

2.10. SPRINKER UNIT 20

2.11. CHUTE 20

2.12. MAGNETIC SEPERATOR 21

2.13. ELECTRIC POWER UNIT 21

2.14. REMOTE CONTROL 24

3. SICHERHEITSFUNKTIONEN
3.1. NOT-AUS-Schaltkreis

3.2. WORKING HYDRAULICS DISCONNECTION 27

3.3. VIRATING CHUTE - DISCONNECTION 28

4. START UP PROCEDURES 28
4.1. START UP 28

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4.2. REGULAR STOP 29

5. DRIVING FUNCTION 29

6. TRANSPORTATION 30

7. SAFETY INSTRUCTIONS 31

8. GENERAL 33
8.1. LIST OF CONTACT ADRESSES 33

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1. WARRANTIES AND LIABILITIES

Warranties and liabilities will only be issued by Powercrusher Gmbh if operation and
maintenance is being carried out in according to the manuals and only original spare
parts are being used.

The warranty running time, agreed upon with conclusion of a contract, becomes only
valid with the sending back of a completely filled out warranty passport of
Powercrusher equipment. Further we recommend, to send also back a copy of the
starting up registration of the responsible CAT dealer to Powercrusher company.

Initially Powercrusher engineers and technical supervisors will train the customers
operators and engineers in operational and maintenance procedures and this have to
be signed on the handing over certificate. It is the responsibility of the customer to
ensue that the operators and engineers are familiar and understand how the crusher
works and once the plant is operational this level of competence on the plant is
maintained.

Guarantees & warrantees will only be accepted if immediate notice of faulty

components is sent in writing to Powercrusher Gmbh

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2. DESCRIPTON OF MACHINE

2.1. GENERAL LAYOUT DRAWING

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 2.2. CHARGING AREA & VIBRATING CHUTE
The main components of the charging are
the steel frame, the hydraulically operated
driving station and the hopper which is lined
with the wear resistant material. The drive
consists of a hydraulic motor, clutch,
gearbox and centrifugal weights. The
vibrating chute is mounted on compression
springs and rubber buffers. The chute is
excited by the drive and made to vibrate
which causes the material to move in the
direction of the crusher.

DRIVE OF VIBRATING CHUTE

The opposed totating centrifugal weights of the directional exciters generate linear
vibrating motions. The directional exciter is a single-stage reduction unit with 4 free
shaft ends on which two pair of centrifugal weights are mounted, each pair consists
of two segments - one segment is fixed to the shaft, the other segment may be
adjusted by stepwise turning. The directional exciter is driven by a hydraulic motor,
which is connected to the gearbox by a clutch.

By varying the hydraulic flow the speed of the hydraulic motor can be adjusted to the
material which should be crushed. The adjustment can be made
Durch Veränderung der Durchflussmenge am Hydraulikmotor kann die
Schwingfrequenz der Vibrorinne dem verwendeten Material angepasst werden. Die
Drehzahlverstellung kann an verschiedenen Plätzen (Fernbedienung und Schalter an
der Bedienerplattform) erfolgen

ATTENTION: A max. permissible speed of the hydraulic motor of ca. 1000 rpm is to
be kept absolutely. Higher frequencies of oscillation can entail framework tears or
also framework breaks. The standard attitudes with distribution may not be changed
by the operator without consultation with powercrusher constructrion. Particularly
after maintenance and/or repair work at the drive of vibrating chute we recommend
the examination of the operating speed of the vibrating chute.

The acitvation and deactivation of the vibro conveyor can be done from 3 different
positions.

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START-UP PRECEDURES OF VIBRATING CHUTE
Before beginning the start up procedures, check the following:
 The centrifugal weights must be able to rotate freely
 The connecting flanges of motor, clutch and gearbox must be correctly aligned
without deflection
 The oil level of the directional exciter must be checked
 mounting of ventilation filter
 the protection covers of centrifugal weights must be in place

CENTRIFUGAL WEIGHTS
The centrifugal weights are set firmly to the maximum. Due to the hydraulic
mechanism of the drive the driving speed of the motor may be regulated by the
hydraulic flow divider, and this is also true for the vibrating frequency.

SIZER
The sizer is bolted to the vibrating chute and serves for pre-screen, which means that
bigger material pieces slide along the sizer into the crusher and the finer material is
falling through the sizer into the folding chute, from where it is discharged to the side
conveyor or the main conveyor belt.

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 2.3. CRUSHER
The drive takes place via the diesel engine by means of a clutch with V-belts to the
flywheel of the rotor.

INTENDED USE OF CRUSHER

The powercrusher is equipped with a impact crusher of the series PC1. This impact
crusher is suitable for crushing of nature rock, reinforced concrete, building debris,
bitumen and such a thing.
The edge lenth of the raw material, which can be feed, dependents to the kind of raw
material and of the used type of hammer. With hard rock as raw material, the
maximal edge length is limited to 300mm. Detailed informations about use of different
hammers please see attachment "different hammer qualities". In case of doubts of
use, please contact Hartl Anlagenbau GmbH, to find the optimal solution for your
material.
Only so we can ensure a reasonable wear of the hammers and wear parts of
crusher.

ATTENTION: Take care that no big iron parts come into the crusher during
operation. The maximal diameter of metal parts is limited with 20mm.
Especially, when crushing reinforced concrete, select the bigger metal parts
from the feeding material. Any damage on the crusher, effected from crushing
iron parts, are out of warranty.

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DESCRIPTION OF FUNCTION OF CRUSHER
The major components are the crusher entrace, crusher cover, crusher rear wall,
side walls, crusher lower part, rotor assembly and the swingbeams (upper & lower)

upper swingbeam
distance plates,
shock absorber
covewr with
wearplates

crusher cover

rotor

lower rotor protection plate

swingbeam
hammer
The inner walls of the crushing chamber and the swing beams are lined with wear
plates, this is done to prolong the service life of the crusher. If necessary the wear
resistant plates can be replaced. The doors in the sidewalls of the crusher are used
for adjustment purposes and for crusher room control purposes.

ATTENTION: These doors can only be opened by using tools and must be
opened when the rotor is not running.

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Function mode: The material arrives over the crusher inlet into the crushing room.
There it is seized and broken by the rotating hammers. At the same time the material
is hurled and broken against the swing beams. The broken material is transported to
the main conveyor belt after passing the crusher outlet adjustment plate. the raw
material can be crushed to the desired grain size by adjusting the gap between rotor
and swing beams.

impact support
pressure springs

distance plates
threaded washer
threaded rod

The compression springs at both swing beams make possible the evade by large raw
material and prevent therby material fracture. The nuts for these springs may be
opened only by technical personnel, since they are pre stressed.

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ROTOR

The rotor is equipped with 4 (impact) hammers. They may be turned after they have
been worn out.
CAUTION: This is only permitted if sufficient material is available to be guided
(clamped)

SAFETY DEVICE: During service and repair work the crusher rotor must be locked
against turning with the locking rods through the openings in the side walls. Take
care when closing the crusher parts that nobody or nothing is crushed by accident.

SWING BEAM ADJUSTMENT

By varying the distance between swing beam and rotor the wished grain size of the
crushed material can be adjusted.
The following procedure must be followed when adjusting the swing beams.

1. Take off safety plate for the adjustment plates

2. Open the doors on the crusher side wall opposite the side
of the drive.
3. start the diesel engine and let it run on low speed
4. activate the working hydraulic
5. Check, that the crusher is not activated.
6. Activate hand lever for swing beam adjustment on the
lower hydraulic panel
7. Activate the hand levers at the crusher
housing and move the cylinder eye to
the adjusting lever.
8. Move the hydraulic cylinder (using the
hand levers) from the midway point.
Now the distance plates on the rear
side of the shim are easy to pull out. If
a smaller distance is required between
the rotor and the swing beam wear
plate take out the front distance plates.
If a bigger distance is required then take the distance plates from the back and
put them in the front. Make sure when changing the distance plates the plate
with the cham on both corners is always left at the back to prevent cracking or
bending of the distance plates. Make sure that the same amount of plates are
being used on the left side distance box as on the right side distance box.
9. The adjusting nut for fine adjustment will be used when for example only a
small way then the thickness of the adjustment plates is necessary. This nut
also will be used as adjustment, when all distance plates are used on one
side.

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 10. The distance between hammer and swing beam wear plate can be seen
through the inspection doors. The measurment between the top of the
hammer and the front surface of the wear plates is the shortest distance and
this distance is responsible for the final material size.
11. After adjusting the swing beams the cylinders must be set in neutral position,
the safety plates have to be mounted again and the side door must be shut.
12. Set handlever on the bottem hydraulic panel in neutral position.

DEVICE: The swind beam compression springs are there to prevent machine
parts from breaking (If a stone is to large or hard to be crushed the swing beam
will absorb some of the impact through the compression springs) - the swing
beams simply avoid bigger pieces. The adjusting nuts for these springs must not
be romoved by the customer as they have been pre-stressed.

WEAR PLATES OF CRUSHER

The walls of the crushing room and the swing beams are lined with screw able wear
plates. The service life of the crusher extends. If necessary the individual wear plates
can be replaced.

For checking of the crusher area, folding doors are inserted in the crusher side
panels.

ATTENTION: These doors are to be opened only by using from tool and should
opnly opened with stop of the machine.

The wear plates may become worn out up to max. the half their original strength. In
order to obtain an even wear, the identically constructed plates can be changed
among themselves. See in addition representation in spare part book.

OPENING OF CRUSHER HOUSING OR CRUSHER COVER

The crusher housing, or only the crusher cover alone is opened by 2 hydraulic
cylinders. Open the crusher is permitted only with stop of the machine. Before
opening the crusher housing or the crusher cover, the specific eye bolts must be
screwed off. The operation of the cylinders effected from the hydraulic panel function
crusher open. The opened housing or cover must become secured with the pertinent
locking pin. The housing and the cover are secured with an induction switch against
unexpected open. This switch release the crusher from the engine automatically.
ATTENTION: When opening the crusher regard that nothing will be jammed or
twisted.

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ADJUSTMENT PLATE CRUSHER OUTLET
At the lower surface of the impact mill is placed the quadruple adjustable discharge
plate with the square bar steel at the front edge of the impact mill. The square bar
steel can become worn out up to the upper edge of the screws. This mechanism
serves on the one hand for the protection of the conveyor belt within the release
range, as well as for wear reduction at the crusher rear wall and for the fine crushing
of the broken material.

The adjusting of the plate must be done manually by hand.

RECYCLING MATERIAL: 1-2 grids to the rotor (depending upon iron portion)
ASPHALT: 2-3 grids to the rotor
ROCK: 3-4 grids to the rotor
hammer

adjustment plate with

quadruple steel

HAMMERS
The rotor is equipped with 4 hammers. The hammers must be turned before reaching
the wear limit. The rotor should be damaged under no circumstances, since
otherwise unbalance develops. The rotor guard plate can become worn out up to the
upper edge of the screws.

Change of the hammers: The plant must be stand stoll. Open the housing upper
part and secure this position. Secure the rotor against turning. Remove the swing
beams as far from the rotor, that sufficient space for the new hammers develop. The
crushing room and particularly all guideways have to be cleaned. Remove the lock
plates of the hammers. Fix the hammer at the crane and pull him out laterally.
ATTENTION: Always pay attention to good seat of the lifting tackle, and lift out
the hammers at the centre of gravity. Before installing the hammers, all
guideways are to be controlled and cleaned from the dirt. After having mounted
the new hammers install the lock plates. Close the crusher and remove the
rotor safety device. Adjust the distance between hammer and swing beam.

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 rotor protection plate

wear limit of hammer

lock plate

LUBRICATION OF CRUSHER
The lubrication points of the crusher are on both sides of the rotor bearing. On the
driving side of the rotor there are 3 lubrication points, which lead by a pipe to the
bearing. The two outside lubrication points grease the labyrinth seals. The middle
lubrication point geases the bearing. On the other side 3 lubrication points are
directly at the bearing.

CRUSHER INLET COVER

Opening of the crusher inlet cover is exclusively permitted for the visual inspection of
the intake range and as a check of the wear plates. The crusher inlet cover can be
opened laterally, at the engine operation station, by hand levers with the help of 2
hydraulic cylinders.
ATTENTION: The crusher inlet cover may be opened only with stop of the rotor.

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 2.4. TRACK CHAINDRIVE

track wheel,
driving gear,
crawler chain hydraulic motor

track roller

guide wheel
unit

The manovering drive mechanism for the crusher consists of crawler chain, track
wheels. guide wheel unit, driving gear and a hydraulic motor.
The crawler chain's width (3 rib bottom plate element) ensures safe driving of the
plant. The drive mechanism can be operated with the remote control. Ther are two
speed steps.

slow speed: Each crawler unit can be activated by one push button at remote
control (forward and backwards). This step should be used for loading purpose or
where much force is needed.

fast speed: Both crawler unit are activated together by one switch of remote control.
This step should be used for all manouvering purposes.

The following procedure must be followed when activating the crawlers.

transport - loading:
1. set switch of loading mode at electric panel to position "1"
2. activate battery main swich
3. start engine and let it run warm
4. activate push button for working hydraulic at electric panel
5. activate hand transmitter of remote control

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 6. By pushing the buttons for low speed at the hand transmitter the plant can be
adjusted to the wished position. (The crawler is in motion as long as the button
is pressed)
7. After loading or moving the plant deactivate the hand transmitter (blue push
butten, shut off engine and disconnect battery main switch)

brakes chaindrive
The chaindrive is equipped with an automatic brake. If the chaindrive isn't used, by a
springtensioned valve the brake shoes are pressed on the drum of the drive. As soon
as the drives are used, the valve switches and the brake shoes come up.

ATTENTION: Steering the machine should take place in principle only with the
remote control and only in an emergency situation from the operating station. The
drive chain is to be retightened regularly at the laterally appropriate openings by
means of commercial grease gun and adapter piece.
1. Place machine on even soil
2. drive one chain length forwards
3. tension chain so for a long tome, until it does not sag any longer

no sagging

guide wheel unit track roller driving gear

2.5. FRAME
The frame has been designed to withstand the calculated load. The welding has all
been done by authorised welding specialists. The material used for the frame and
accessories is ST37-2. The frame eas sand blasted and sprayed with a primer. After
all the accessories have mounted everything is then sprayed with the Hartl colours
yellow RAL1028 and grey RAL 7016.

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 2.6. MAIN CONVEYOR BELT
The conveyor belt is made of a sectional steel frame. The driving drum (head drum)
has been mounted in front and the reversing drum (tail drum) is located in low height
between the track chains at the backside.

The conveyor belt is reinforced at the crusher outlet area by gliding plates which
support both belt and load as material leaves the crusher.

Each roller station consists of one support wheel and two inclined wheels. This forms
the through which allows good material transportation. There are also return idlers to
ensure smooth return movement.

For the lateral belt guidance additional guide pulleys have been mounted. The tail
pulley may be adjusted for belt guidance. The driving drum is designed with a
tensioning unit for manual adjustment of lateral guidance and tensing of the belt.

The drum is driven by a hydraulic motor and gearbox.

ATTENTION: Failure to connect or incorrect connection of

the leakage line coupling will result in damage to the motor
due to a pressure build up with no point of release. Strippers
have been mounted on the conveyor belt in order to keep
the drums and the belt free of contamination

SAFETY WARNING: The main conveyor belt is equiped with a safety rope which is
activated by a pull switch. Only the main conveyor belt will be stopped. When the
switch is activated it stops the conveyor from moving by closing the hydraulic fluid
needed. In order to restart the conveyor the emergency stop must be reset and the
hydraulics must be reactivated at the main electric control panel, only then may the
conveyor belt be started again at the operator's panel.

CAUTION: Maintenance and lubrication work on the conveyor belt must only be
carried out when the conveyor is not in motion. See warning and caution signs.

EXCEPTION: Only belt centering adjustments are allowed, but this must be carried
out a very low speed. CAT motor speed 1000rpm.

This must only be conducted by trained personel (ref. to maintenance rules)

Beware of loose clothing getting caught in the moving parts.

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 2.7. MAIN DRIVE – power pack
The engine is covered with a housing, which reduces the noise level. Under this
housing, the hydraulic oil tank as well as a big combination cooler for cooling the
complete plant, are mounted. The covers of this housing can be moved away to the
side or upward, to have an optimal access to all components of the driving station.

DIESEL ENGINE
Fabrikat CAT
type: CAT C9 – St. III
supply voltage 24V
operating speed 2000 U/min.
For further details regarding the CAT engine refer to the delivered CAT
documentation.

The engine serves all aggregates of the plant with the necessary quantities of
energy. The engine drives also the crusher via a electric switchable clutch.

cooler
Responsible for the cooling of load air, the drive of cooler
cooling agent cycle of the diesel engine as
well as for the hydraulic oil. Fresh air is
sucked in from the outside over the
radiator, flows through the engine
installation and arrives over louvers again in
the free.
The speed of the fan varies according to
engine revolutions. A hydraulic regulation
valve on the top of hydraulic oil tank
protects the hydraulic motor of overload.
NOTE: For cleaning purpose the different elements of the cooler can be clamped

fuel tank
The fuel tank is in the back beside the feed
hopper. Filling takes place via an electrical
pump or by means of manual filling at the
tank filling cap. In the upper area of the
tank, there is a optical glass, in order to
indicate, when the fuel tank gets full.
water tank diesel tank

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 2.8. CLUTCH WITH PUMP DISTRIBUTOR GEAR
This sub assembly consists of the pump distributor gear, the cluch and the clutch
control panel.

SAFETY RULES

The following rules have to be considered during operation of clutches. as well during
any assembly, maintenance and repair work, in order to avoid accidents and injuries.
1. During and maintenance and repair works on the clutch the machine main
switch must be off and secured against unintentional starting. The admissible
load limits as well as the maximum number of revolutions (rpm) must not be
exceeded. Before doing any disconnected by handlever.
2. Keep friction linings absolutely free from oil and grease, otherwise the torque
won't be sufficiently transfered, and the linings would have to be replaced.
During cleaning procedures on the machine take care that the clutch area in
particular the clutch itself, has to be kept free from oil and caustic cleansing
agents.
3. CAUTION: Risk of burns during repair and maintenance work on the clutch
heated during operation.
4. Improper detachment of the clutch may lead to injuries. Remember that the
clutch is held under spring tension. The clutch may fail when screws become
loose. the given starting torque must be adhered to in any case. Check weekly
if the bolts from the clutch are tightene!
5. Before starting make sure that all assembly auxiliaries have been removed
from the clutch all protection devices have been applied and / or mounted.
6. The admissible alignment parameters must not be exceeded. (ref. to
enclosure)
7. Beware of loose clothing getting caught during operating the clutch.

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 2.9. SIDE CONVEYOR BELT
Consisting of a sectional steel frame with roller stations. The rubber coated driving
drum (head drum ) bets driven by a hydraulic motor. By means of the stretching
device the belt may be centred. The chute is dimensioned to cooperage with the
width of the belt and hands over the material. The inner stripper is fixed to the
deflection pulley and is responsible for belt cleaning by reversing. For transport the
side belt unit is clamp able.

CAUTION: The rollers are not covered in order to allow for better working
conditions! Therefore it is recommended to be extremely cautions in this area!
Maintenance and lubrication and all other kinds of work are allowed only during
machine stoppage. (see warning and caution signs)

EXCEPTION: Adjustment of belt to run straight is only allowed (ref. to maintenance

rules). Adjustment to be carried out only by specialists. A stop pushbutton is placed
next to the side belt conveyor.

There are two stop push buttons at the side conveyor, by which the operating of the
side conveyor and the complete hydraulic operatings (exception: crusher) of the plant
can be stopped. To start the hydraulic again, press the hydraulic push buttom at the
controll panel.

For transport purposes the belt must be folded and secured

2.10. SPRINKER UNIT

To avoid high dust emissions a water spraying system has been installed on top of
the crusher inlet. This is also available as a conveyor belt spray system. The water
inlet for the crusher spraying system is located on top of the crusher entry cover.

The required pressure of the sprayer system operates at a min. of 2 bar and max. of
3,5 bar.
For asphalt crushing it is advised that these sprayers are used. The amount of water
used is dependent on the type of material being crushed, water operating pressure
and rate of crushing.

There are no fixed guidelines for the amount of water required other than owner
preference.

2.11. CHUTE
The chute receives the material from the sizer (rost) directing it to the crusher
(conveyor) discharging belt. There are hatches in the side wall for inspection
purposes . They may only be accessed when the vibrating feeder is not in motion.
Machines which have a lateral discharging belt mounted are equipped with a chute
but this will be disassembled when using the side conveyor belt.

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 2.12. MAGNETIC SEPERATOR
Attachment and adjustment of the magnet is realised by chains and shackles at the
required distance to the main conveyor belt. The detected iron is discharged and
dropped laterally.

CAUTION! Avoid using metallic instruments or tools and in the magnet area, as the
magnet attracs metallic parts quickly and intensely with high force. Mind electronic
elements, such as watches, mobile phones, pace-makers etc and others ! (see
warning signs)

2.13. ELECTRIC POWER UNIT

The plant is equipped with an operating electrical connection (supply voltage = 24V
of DC voltage). All control elements for the controlling of the plant (engine and
crusher control) are at the electrical box. At the exterior are the serving and control
elements. Inside the cabinet are all electrical function components. These steer the
electrohydraulical drive units. Further the receiver of the remote control as well as the
accumulator charging unit are built in the box.

10) CAT Messenger Display 4) increase engine speed

9) warning lamp 11) warning lamp

5) reduce engine speed

1) working hydraulics on 8) fuel pump

6) working lamp

7) water pump

2) working hydraulics off 3) switch for vibro

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OPERATOR - ELEMENTS AT ELECTROBOX
1) Push button to start working hydraulics: The complete hydraulic
systems is activated by pushing this button, i.e. the individual functions
can be switched now at the respective hydraulic valves. The activation
of the button is signaled by constant shining of the light inside the
button. Caution: Never turn on working hydraulics by an engine rpm
with 1200rpm.
2) push button to stop working hydraulics: By pressing this button the
operating hydraulics is switched off. NOTE: The same function as the
stop push button of operating hydraulics has the activation of a push
pull cable switch at the main discharge volume, or pressing an out -
tracer at the side conveyor belt.
3) switch for vibro, manual or automatic mode: manual mode: The
activation of the apron feeder takes place only by means of hand levers
of the hydraulic valve; automatic mode: the activation of the apron
feeder takes place through pressing of the vibro push button at the
remote control. The hand lever of the hydraulic valve must be however
switched.; Note: Starting of the vibrating chute is only possible after
switching on of the crusher.
4) Push button to increase rpm`s of engine: By short pressing of this
button the number of revolutions of the diesel engine increases over
approx. 50 rpm. Longer pressing of the button increases the number of
revolutions faster. The announcement of the current number of
revolutions takes place in the CAT - indicator display.
5) Push button to reduce rpm´s of engine: By short pressing of this
button the number of revolutions of the diesel engine becomes over
approx.. 50 U/min. lowered. Longer pressing of the button degrades the
number of revolutions faster. The announcement of the current number
of revolutions takes place in the CAT - indicator display
6) Working lamp on / off: The spotlights at the crusher can be activated
by this switch.
7) waterpump: Activates and deactivates the pump for sprinkler system.
8) fuelpump: Turns on and off the fuelpump to fill the dieseltank

ANNOUNCEMENT ELEMENTS AT ELECTROBOX

9) Warning lamp: Signals a proplem with the CAT engine
10) CAT-Messenger Display
11) Warning lamp: pressure vibro off: Signals an overload of the main
conveyor belt. As soon as the belt load falls down, the vibrating chute
restarts automatically

GENERAL GUIDELINES ELECTRICAL SYSTEM

We would like to point out that manipulations at the electrical connection system can
lead to endangerments of the operator personnel. Further these can have also the
loss from warranty claims to the consequence.

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ATTENTION: Maintenance and inspection work in the electric system may be done
only by expert personnel.

NOTE: Due to the high dust missions during the crushing the electrical box should
remain always locked during the operation. Note also that by penetration of humidity
with opened electrobox malfunctionings can occur.

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 2.14. REMOTE CONTROL
The plant is equipped with a remote control unit. The receiver as well as the charger
for the batteries are mounted inside of the electrobox. For activating the remote
control, the blue push button must be activated. A flashing green light on the
transmitter signals "ready for operation" This remote control offers the following
functions.

On the Transmitter you have this functions.

1. left crawler: slow speed forward / backwards
2. right crawler: slow speed forward / backward
3. both crawlers: fast forward / backward
4. vibro on / off
5. vibro rpm increase / decrease
6. working hydraulics off
7. crusher cover open / close
8. horn

6) working hydrauliks 2) right crawler

8) horn
1) left crawler

7) crusher cover 4) vibro on /off

open /close
5) vibro
faster / slower
3) fast speed for crawler

The driving functions are on ly active as long as the button is pressed.

The function vibro on/off can only be activated, when the switch at the electrobox is
set on position automatic.

DEVICE: Never change the batteries of the hand transmitter, when the transmitter is
activated. A damage to the fuse inside of the transmitter can be caused by this.

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user manual PC1 PC1-013 bis xx Seite 25 von 33
3. safety features
The plant is equipped with different protection circuits. These make on the one hand
an immediate stopping of the plant for the operator personnel possible. On the other
hand the plant is protected against damage by overloadings.

3.1. emergency stop

The plant is equipped with several characterized emergency stop switches. The
switches are at the following places:

- At the electrical - box.

- At the hydraulic valves for the drives.
- At the machine operating station of vibrating chute.
- At the main frame near the side conveyor belt.

The complete plant is turned off by activation of each switch immediately (diesel
engine switches off). A restart is only possible after unblocking of the activated
switch.

NOTE: We would like to point out that manipulations at these safety elements can lead to
endangerments of the operator personnel.

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 3.2. WORKING HYDRAULICS DISCONNECTION
The main discharge conveyor belt is equipped with 2 push pull cable switches. By
pulling the red rope (on both sides of the volume) the operating hydraulics can be
switched off. A new activation is possible only after unblocking of the push pull cable
switch as well as a recent activation of operating hydraulics at the electrical operating
station.
push pull cable switches

The side conveyor belt is equipped with 2 switch-off tracers. The activation tracers
entails a switching of operating hydraulics off. A new activation is possible only after
unblocking of the out tracer and a recent activation of operating hydraulics at the
electrical operating station.

In the hydraulic tank a level - switch is installed. If the level of the hydraulic oil should
fall below a certain value, a disconnection of operating hydraulics takes place. A
restart of operating hydraulics is only possible if the hydraulic oil level has against the
correct value.

NOTE: We point out that manipulations at these safety members can lead to endangerments of
the operator personnel or also to machine damages. Appropriate damage to the plant is
excluded from the warranty claims.

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 3.3. VIRATING CHUTE - DISCONNECTION
The plant is equipped with a temperature sensor in the hydraulic oil circuit. If the
temperature should reach the adjusted limit value, an automatic disconnection of the
vibrating chute takes place. A restart of the vibrating chute is only possible after
cooling of the hydraulic oil.

A pressure sensor in the hydraulic system of the main discharge conveyor

suoervises the volume load. If the adjusted limit value should be achieved, the
vibrating chute switches off automatically. As soon as the pressure level achieves
again a low value, automatic switching on of the vibrating chute takes place.

NOTE: Manipulations at these safety members can lead to machine damages.

START UP PROCEDURES
Before starting, it must be checked if.
1. any material has been left in crusher - if so, the crusher has to be emptied
first.
2. there is sufficient el. capacity in the battery.
3. there is sufficient fuel in the fuel tank
4. there is sufficient hydraulic oil in the reservoir
5. there is sufficient motor oil in the CAT-motor
6. there is sufficient water (and anti freeze liquid by low temperatures) in the
water cooling system (-30°C)
7. the main ball valves between hydraulic reservoir and the hydraulic pumps has
been opened
8. all elements have been installed properly
9. all covers of the plant are closed
10. all safety devices are installed and all safety regulations are kept by the
operators
11. rotor locking bars have been dismounted after service and repairwork

3.4. START UP
1. Set key operated switch at battery (battery box) to starting position
2. Turn ignition key at motor control panel, motor gets running!
3. Let motor get warm up to reach working temperature (ref. to CAT
documentation)
4. Set gas to reach approx. 1250 rpm.
5. Check if the crusher room is empty

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 6. Switch on working hydraulics. All functions should be deactivated (conveyors,
vibro,)
7. Engage the crusher drive by pressing "ENGAGE" on the clutch control panel.
This is best by 1050rpm from the diesel engine. Press the button at least 5sec.
8. Wait till the Engage was successful
9. Set working rotations to approx. 1800rpm but not higher then max. 2000rpm
10. Switch on additional functions eg conveyor belts (at the switch box) Starting
vibrating chute direcly by hand lever or remote control is only possible when
the crusher is running, to insure to have enough power before the first material
can reach the mill. To start the vibrating chute at the operator panel the
remote control unit must first be deactivated.
11. Start material feeding at the charging area.

3.5. REGULAR STOP

1. Empty the machine completely, of all material
2. Reduce number of rotations of CAT motor to 800rpm
3. Disengage the clutch by pressing the red push button.
4. Set work hydraulic to position "off"
5. Let the CAT motor run for further 10 min to cool down
6. Set ignition key on operator panel to "OFF" position
7. Set key operated switch at battery box to "OFF" position

4. DRIVING FUNCTION
Drive function while loading has to be done carefully at a CAT-motor speed of 700-
800 rpm. Other drive function should be done at a CAT-motor speed up to 1800-2000
rpm.

The Powercrusher PC 1 I is able to rotate 360 ° on the same point and it also has
excellent hill climbing abilities (approx. 20 incline) these qualities allow for its all-
terrain use. The machine’s maximum speed is 1,2km/h.

The powercrusher is equipped with a two steps speed gear drive. At low speed each
side of the crawler can be activated as a single function. At high speed both crawlers
(left and right side) are activated at the same time. This function is only for longer
drive periods.

The different speed functions can be activated by remote control.

In case of no function of remote control, the driving function of the plant can be done
manually via levers at the hydraulic valves. (See chapter “track chaindrive”) In this
case only low speed of crawlers is possible.

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5. TRANSPORTATION
The powercrusher PC1 is with his low weight and short overall length easy to
transport without special permission / permits.

The sideconveyor is to fold and to lock.

The ladder of the walkway is to disassemble

Thevibro is to lock with the suspension points.

For Transportation purpose the PC1 drives onto the truck with the conveyor belt
ahead of it. Secure the magnet against shaking.

Dimensions, total weight see transport sketch attached.

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6. SAFETY INSTRUCTIONS
1. It is absolutely necessary to follow the attached signs and labels on the
machine and to observe the respective information. Its the opportunity of the
owner to ad up warning and caution signs and labels as stipulated by the local
laws and recommended regulations of the government.
2. Only trained users is allowed to operate the machine.
3. The working and service instruction have to be observed accurately
4. Before starting take care that all protective covers (caps) are closed
5. During operation consider all points listed below
a. safe distance are kept
b. the operator is always aware of his surroundings
c. nobody is staying in dropping area of the magnetic adsorbed parts
d. the upper and lateral crusher covers are not opened and the complete
set of chains is added as an safety curtain
e. no work is carried out on the diesel engine
f. noise protection is used in accordance with the local regulations
6. Make sure that nobody is staying in the clamping area (squeezing!), when the
conveyors are folded up for transportation or when the magnet is swivelled.
7. It is the responsibility of the customer to take care and proove that all listed
regulations and safety instructions will be kept by the people working on the
machine
8. Operators are fully aware of where all emergency stop push buttons are
situated on the machine (one left , one on right side on top left at the operator
platform, one between the hand levers for driving function directly at the
motor housing and one directly on the electric operator panel.
9. Before operating the track drive, the operator must ensure there are no
persons or objects in the direction the machine is travelling. Only once this
has been checked may the operator commence with moving the machine.
10. Some areas the plant have no side protection plates on the conveyors, the
reason for this is for ease of maintenance and ease of use. These areas must
be marked with warning signs.
11. If the plant is operated in cold climates, all snow and ice must be removed
from the gang way ( walking platform) and the ladder before the plant is
operated

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 During the operation it’s not allowed:
 to stay on the crusher cover
 to stay on the vibrating chute or on the sizer
 to reach into the vibrating chute to pick up iron parts and others
 to stay near the dropping area of conveyor belts
 to stay near the dropping area of magnetic separator
 to open the crusher cover and the crusher door
 to remove safety and protective covers as chain curtains rubber shields and
other

*Attention*: The operator must wear protective glasses and ear protectors and a
hard hat when standing on the plattform of the crusher at all times. All other personel
working near the vibrating feeder and the crusher must wear hard hats at all times

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7. GENERAL
ALL INFORMATION OF THIS PUBLICATION ARE BASED ON THE LATEST
PRODUCT DEVELOPMENT INFORMATION, WHICH WAS AVAILABLE AT TIME
OF THE GRANT TO PRINT, POWERCRUSHER RESERVES ALL RIGHTS TO PUT
ON CHANGES AT ANY TIME AND WITHOUT ADVANCE NOTICE, WITHOUT
UNDERTAKING ANY OBLIGATION NOT ANY PART OF THIS PUBLICATION HAS
TO BE REPRODUCED WITHOUT WRITTEN GRANT OF POWERCRUSHER.

Startup technicians are available for repair and service if required. List of work and
time shedule for service work that has to be done in time, see service manual
attached. Information for spare parts and wearing parts are listed at the spare parts
list attached. For quotation of spare parts please contact our service and
maintenance department.

7.1. LIST OF CONTACT ADRESSES

AUSTRIA:
HARTL ANLAGENBAU GmbH
Gollensdorf 24
A-4300 St. Valentin

Tel: +43 (0)7238 / 29350

Fax: +43 (0)7238 / 29350-40

Mail: warranty dept [email protected] Davison Eva

Mail: service dept: [email protected] Kastner Wolfgang

Mail: Spare part dept: [email protected] Hauri Marcel

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