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METBERG T3000 Operation Manual

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Summary of Contents for METBERG T3000

  • Page 2: Table Of Contents

    CONTENTS Page No. Section 1.0 General Information. 1.1 Copyright 1.2 Foreword / Reservation of rights 1.3 Terms and Descriptions Used in this Manual 1.4 Warranty 1.5 Specification Alterations 1.6 Machine Specification 1.7 Familiarisation 1.8 Optional Equipment 1.9 Correct Use of the Machine Section 2.0 Safety.
  • Page 3 Section 4.0 Standard Operation Procedures. 4.1 Safety Before and During Operation 4.2 Pre-Operation Checks 4.3 Initial Setup 4.4 Starting the Machine 4.5 Manual Tracking with Umbilical Handset 4.6 Normal Operation 4.7 Shutting Down the Machine Section 5.0 Maintenance. 5.1 Safety Before and During Maintenance 5.2 Regular Maintenance 5.3 Check Fuel Level and Top up 5.4 Adjusting Trommel Brush...
  • Page 4 6.3 Putting the Machine into Transport Position 6.3.1 Folding the Oversize Conveyor to Transport Position Section 7.0 Fault Finding. Section 8.0 Spare Parts. 8.1 Spare Parts Ordering Information...
  • Page 5 EU DECLARATION OF CONFORMITY 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.

  • Page 6: Section 1.0 General Information

    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...

  • Page 7: Specification Alterations

    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.

  • Page 8: Familiarisation

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

  • Page 9: Correct Use Of The Machine

    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).

  • Page 10: Section 2.0 Safety

    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.

  • Page 11: Hazard Warning Signs

    HAZARD WARNING SIGNS The following hazard signs may be used on your machine please ensure that you make yourself familiar with these and the corresponding level of hazard LOCK OUT EQUIPMENT BEFORE SERVICING. FALLING HAZARD - DO NOT CLIMB ON TO WORKING MACHINERY. BEWARE OF HYDRAULIC OIL LEAKS.
  • Page 12 EAR PROTECTION MUST BE WORN IN THIS AREA NIP POINT - KEEP HANDS CLEAR OF MOVING MACHINERY NIP & ENTANGLEMENT POINT. ONLY TRAINED PERSONNEL ARE PERMITTED TO OPERATE MACHINERY WITH THIS HAZARD SIGN. ALL LOOSE CLOTHING AND HAIR MUST BE TIED UP. ALL PROTECTIVE GUARDS MUST BE IN PLACE WITH ALL BOLTS PROVIDED AND ONLY REMOVED ONCE THE MACHINERY HAS BEEN STOPPED AND LOCKED OUT.

  • Page 13: Hazard Warning Signs On The Machine

    FALLING MATERIAL HAZARD. NO ONE IS PERMITTED TO STAND AROUND MACHINERY WHILST MATERIAL IS BEING LOADED. RISK OF SERIOUS INJURY OR DEATH. 1. ELECTRICAL HAZARD. RISK OF SERIOUS INJURY OR DEATH. 2. WORK ON THE ELECTRICAL SYSTEM MUST ONLY BE CARRIED OUT BY A QUALIFIED ELECTRICIAN.

  • Page 14: Hazard Warning Signs In This Manual

    SAFETY WARNINGS IN THIS MANUAL The following safety warnings are used throughout this manual to highlight areas of potential hazards. Ensure that you make yourself familiar with each sign and their corresponding level of hazard warning. CAUTION sign below indicates a minor or moderate hazard potential. In this situation care should be taken to avoid the risk otherwise injury to personnel may occur.

  • Page 15: Plant Hazards - Electrics

    Modification to any part of the electrical system on this machine can cause the machine to operate in an unsafe manner. No such modifications should be carried out without prior written permission from Metberg Ltd. Unauthorised modifications will invalidate the warranty conditions of the electrical system.

  • Page 16: Plant Hazards -Nip Points

    2.11 PLANT HAZARDS –MANOEUVRING ON SITE Make sure that personnel are kept clear when moving the machine on site. The machine must only be transported with the machine fully lowered. Avoid manoeuvring the machine over extremely uneven ground as damage may occur. Make sure that the machine is not manoeuvred on a gradient greater than 3 degrees.

  • Page 17: Safety Guards On The Machine

    Before removing any guard follow the ! DANGER “Shut Down” and “Lock Out” procedures. Replace all missing guards immediately 2.14 SAFETY GUARDS ON THE MACHINE. Safety guards are important features of the machine. Take time to familiarise yourself with their locations as shown below. (4).

  • Page 18: Lock Out" Procedure

    Ensure that the following “Lock Out” ! WARNING procedure is carried out before carrying out any work on the machine 2.16 “LOCK OUT” PROCEDURE Each and every time access is required onto or near the machine to carry out work of any type, regardless of how insignificant it may seem, ensure that a “Lock Out “...

  • Page 19: Emergency Shut Down Procedure

    2.17 EMERGENCY SHUT DOWN PROCEDURE In an emergency, only stop the machine by pressing an emergency stop button on the machine. When an emergency stop has been initiated, the ignition switch stays on. Do not attempt to restart the engine until it is safe to do so. (i).

  • Page 20: Safety Before And After Setup

    (xi). Test the machine to ensure that it is functioning properly. If problems occur during testing shut down and adopt the “Lock Out” procedure before attempting to rectify the problem. (xii). After testing, shut down the machine and check for loose or missing bolts, washers or nuts etc.

  • Page 21: Safety Before And During Transport

    (v). Repairs, maintenance or adjustments to the plant must never be performed while it is running. An exception to the rule is the belt adjustment. (vi). Guards or access doors should be replaced or closed before leaving the machine unattended, even for short periods of time. Onlookers or bystanders should be kept outside the 10-metre hazard zone during maintenance of equipment.

  • Page 22: Section 3.0 Initial Setup

    SECTION 3.0 INITIAL SETUP Setup of this equipment must be carried out by qualified and trained personnel CAUTION only. Never setup this equipment on your own. Before setting up the machine ensure ! WARNING that you have read and understand the safety instructions in section 2 of this manual.

  • Page 23: Machine Location Considerations

    Check all loose parts, small-parts boxes, and tools against the packing list to ensure all items shipped are present. Check in and around the machine for any loose items that may have been shipped inside the machine. MACHINE LOCATION CONSIDERATIONS Prior to setting up the machine, consideration should be given to a suitable layout to prevent oversize material or metal from entering the machine.

  • Page 24: Fold Out Oversize Conveyor

    (iii). Press the green button twice Press X 2 (iv). Wait for 10 seconds delay siren (v) The engine starts automatically 3.5.2 FOLD OUT OVERSIZE CONVEYOR Ensure all personnel are clear from the ! WARNING machine. Wear personal protective equipment. (i).

  • Page 25: Section 4.0 Standard Operation Procedures

    SECTION 4.0 STANDARD OPERATION PROCEDURES Only trained, experienced, and qualified personnel should attempt to operate this CAUTION equipment. SAFETY BEFORE AND DURING OPERATION (I). Read and understand all safety hazards and operating procedures before starting the machine. (ii). Study all safety and hazard warning signs on the machine. (iii).

  • Page 26: Initial Setup

    This section should be read and understood prior to starting the machine. If there are any doubts, consult your local dealer or Metberg service department. (i). Refer to the engine manufacturer’s manual for initial start up of the engine.

  • Page 27: Manual Tracking With Umbilical Handset

    (iv). Wait for 10 seconds delay siren (v). The engine starts automatically (vi). Using the throttle control increase throttle speed to 2100RPM MANUAL TRACKING WITH UMBILICAL HANDSET (i). Attached umbilical lead connector to plug in at side of control panel (ii).

  • Page 28: Normal Operation

    NORMAL OPERATION (i). Ensure all control levers are in the NEUTRAL (non-operational) position (ii) (iii) (ii) Push Fines/ Stockpile control valve to start the fines conveyor. (iii) Push Trommel control valve to start the trommel drum. (iv) Push Feeder control valve to start the feeder belt. The machine is now ready to receive material.

  • Page 29: Section 5.0 Maintenance

    SECTION 5.0 MAINTENANCE Maintenance should only be carried out CAUTION by authorised and qualified personnel. Never carry out maintenance or repair work alone. Before undertaking any maintenance, repairs or retooling work on the machine, ! WARNING switch off the machine and implement the lockout and tagout procedure.

  • Page 30: Regular Maintenance

    (xix). If required, only use lifting equipment, including slings and chains, that are in good working order, has been tested adequately and has the required lifting capacity for the job at hand. REGULAR MAINTENANCE It is important that a strict routine of regular servicing is undertaken from the start of operation of the machine.

  • Page 31: Adjusting Trommel Brush

    ADJUSTING TROMMEL BRUSH The brush is designed for cleaning and unclogging the screen mesh during charge material screening. If these operations are not necessary, the brush should be raised. When in use the trommel drum cleaning brushes should be checked for proper adjustment every day. The adjuster rods are located inside and outside the door on the brush side.
  • Page 32 It is essential that the tracks are correctly tensioned. Check track tension regularly. Moving the machine with incorrectly tensioned tracks can cause severe damage to the undercarriage components and may invalidate the warranty. It is important that the track is not tensioned too tightly as this puts excessive loads on the gearbox grease cylinder and idler bearings.

  • Page 33: Track Gearbox Oil Level

    Ensure that only qualified and trained personnel operate and maintain this equipment. Regularly check the control system and connections for any damage. Never adjust any components or settings without authorisation from Metberg Ltd. DAILY MAINTENANCE The purpose of daily maintenance is to discover minor irregularities on the machine before they develop into major problems.

  • Page 34: Weekly Maintenance

    Pipelines/Hoses/Leaks Check / replace Check hoses and wear areas for leaks Bolts & Pins Check / fasten / replace HYDRAULIC SYSTEM Hydraulic oil level Check / top up Hydraulic return line filter indicator Check Replace filters when indicated MOVING PARTS Material build up Remove Drums &...

  • Page 35: 1000 Hour Maintenance

    5.11 1000 HOUR MAINTENANCE (Machine Stopped) Object Remarks FIRST Carry out all jobs as per 10 hour / daily maintenance schedule Carry out all jobs as per 50 hour / weekly maintenance schedule Carry out all jobs as per 100 hour / weekly maintenance schedule Carry out all jobs as per 500 hour / weekly maintenance schedule...

  • Page 36: Weekly

    5.13.3 WEEKLY Object Remarks Hoses & clamps Inspect / Replace Fuel tank water & sediment Drain 5.13.4 EVERY 250 SERVICE HOURS Object Remarks Coolant system coolant sample Obtain Engine oil & filter change Change* *Due to the severe environment that the machine may operate in the engine oil and filter change should be every 250 hours of service.

  • Page 37: Every 4000 Service Hours

    Coolant system coolant Change 5.13.10 EVERY 4000 SERVICE HOURS Object Remarks Aftercooler core Clean / Test 5.13.11 EVERY 6000 SERVICE HOURS OR 3 YEARS Object Remarks Coolant system cooler extender 5.13.12 EVERY 12000 SERVICE HOURS OR 6 YEARS Object Remarks Coolant system coolant Change Warranty will not apply if bearings are not lubricated...
  • Page 38 Using a standard hand operated grease gun, they should be greased with 25g or 2 Pumps every 100 running hours. Do not mix greases. The blend can have a lower specification than an individual grease and can lead to premature bearing failure. Note.

  • Page 39: Hydraulic System

    (vii). Using clean oil, flush the tank out to remove any dirt. Clean and reuse the suction filters and replace on the suction pipes. (viii). Replace cover plate using a new gasket. (ix). Replace drain plug and tighten. (x). Refill the tank with clean hydraulic oil to a level halfway between minimum and maximum as marked on the level indicator.

  • Page 40: Belt Alignment

    5.16.3 BELT ALIGNMENT Oblique travel may cause fast deterioration of the belt. Some causes of oblique travel are shown below with suggested solutions. Reasons for oblique travel Remedies 1.Insufficient aligning of (i). Align all drums, carrying idlers and return idlers at right drums and Idlers, angles to the travelling direction of the belt.

  • Page 41: Section 6.0 Transportation

    SECTION 6.0 TRANSPORTATION This machine should only be CAUTION transported using an appropriate road worthy vehicle and trailer. SAFETY BEFORE AND DURING TRANSPORT (i). The preparations to move the machine by an articulated lorry should be supervised by a minimum of two persons. Ensure persons transporting the machine adhere to all safety signs and procedures.

  • Page 42: Safety Before And During Transportation

    (iii). Move the control valve lever to “track” position, to activate the tracks. (iv). Turn the dial to “On” on the handheld control unit in readiness to move the machine off the low loading trailer. (v). Press the forward or backward buttons to move the machine in the desired direction. (vi).

  • Page 43: Putting The Machine Into Transport Position

    PUTTING THE MACHINE INTO TRANSPORT POSITION Entanglement hazard. Ensure all ! WARNING personnel are clear of the conveyor Prior to transportation the machine must be put into the transport position. Observe all safety warnings Start the machine as Section 3.5.1 6.3.1 FOLDING THE OVERSIZE CONVEYOR TO TRANSPORT POSITION Ensure all personnel are clear from the ! WARNING...

  • Page 44: Section 7.0 Fault Finding

    SECTION 7.0 FAULT FINDING Before carry out maintenance or repairs on the machine ensure that you have ! WARNING read and understand the safety instructions in section 2 of this manual Sympton Possible Fault Remedy 1.No response from Overload tripped or fuse Replace fuses.

  • Page 45: Section 8.0 Spare Parts

    SECTION 8.0 SPARE PARTS SPARE PART ORDERING INFORMATION. To ensure that the correct parts are delivered without delay, Metberg will require the following information at the time of order. Your company name and delivery address. Your contact name and number.

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