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Summary of Contents for ALLU D Series
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ALLU Screener Crusher INSTRUCTION MANUAL D SERIES Type Serial number www.allu.net ALLU Finland Oy Jokimäentie 1, 16320 Pennala, Finland Tel:+358 (0)3 882 140, Fax:+358 (0)3 882 1440, E-mail:info@allu.net Courtesy of Machine.Market...
User responsibilities and general safety instructions ........... 15 Intended use and operating environment ............. 16 2.5.1 Intended use ..................... 16 2.5.2 Operation range ....................16 ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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Extensive maintenance ..................40 Replacement of wear parts ................... 42 4.3.1 Replacement of blades (DN, DS, and DH models with XHD drums) ..... 42 ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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Connecting the Screener crusher with the base machine’s hydraulic system .. 84 5.3.2 Single-motor buckets ..................85 5.3.3 Two-motor buckets ..................86 Noise level ......................88 ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
Read this manual carefully, and follow the instructions meticulously. If something seems unclear, ask your employer or your nearest ALLU representative for clarification. Each part of this manual contains information that is important for your safety. These instructions are also used in user training. Compliance with these instructions helps to keep maintenance costs and downtime to a minimum and the machine’s reliability and...
Machinery Directive. Store the EC-conformity declaration appropriately, and ensure that it is also passed on to any new owner of the machine. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
Because the product undergoes continuous improvement and development work, some changes might have been made to it that are not reflected in this manual. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
If you have any questions on the product or this manual, please contact your local ALLU representative. 1.6.1 The screener crusher models covered by this manual DSB 2-12 DH 3-12 DHB 2-12 DN 2-09 DNS 2-09 DS 3-12 DSB 2-17...
N OT E A note contains instructions or describes pertinent regulations. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
Read and observe Maintain a safe Use safety Use a respirator the instructions distance goggles for use Wear a safety Use hearing Wear protective helmet protection clothing ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
2.1.2 Safety markings on the Screener crusher The following warning markings must be displayed on the ALLU screener crusher. Any damaged or loose warning labels must be replaced. DAN GER RISK OF BEING CRUSHED OR THROWN Anyone under five metres from...
Screener crusher or base machine. A protective structure must be installed for open-top base machines to protect the user from falling and flying objects. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
If, under exceptional circumstances, another person has to enter the danger zones, the user must be made aware of this, so that he or she can take extra care when operating the Screener crusher. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
Exposure to high-pressure oil spray causes a risk of death or serious injury. Seek medical assistance immediately if any hydraulic oil enters your eyes or high-pressure spray penetrates your skin. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
Minimise the environmental damage by using solid material such as sand or peat to absorb the leaking lubricant. Dispose of the contaminated sand or other material in an appropriate manner. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
The Screener crusher must never be serviced, inspected, repaired, or checked while the engine of the base machine is running. The Screener crusher is to be operated only from the cabin of the base machine. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
The Screener crusher is to be operated only outdoors and in indoor spaces suitable for work with such machines. The Screener crusher’s intended operating temperature range is -25 °C to 60 °C. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
Screener crusher, the base machine, or the environment. 2.5.4 Repairs and changes ALLU Screener crushers are to be repaired and equipped with only genuine ALLU spare parts and accessories. It is forbidden to make any changes to the Screener crusher without written permission from the manufacturer.
The weight of the Screener crusher (without accessories and an adapter) is stated on the machine plate and in the table of technical data in this manual. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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Note the risk of falling when loosening the straps used to secure the Screener crusher for transport. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
A Screener crusher coming loose and falling causes a risk of death or serious injury! ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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Use stretch sleeves [1] under each mounting pin. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
3.2.2 Diagrams of adapters Excavator adapter, direct pin mounting. Wheel loader adapter, quick connection (similar to Volvo). Wheel loader adapter, Z link connection. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
If the viscosity differs from the recommended values, the service life of the motor becomes shorter. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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The power control valve begins to control the engine’s pressure difference when this value exceeds 280 bar and the hydraulic flow when it exceeds the model-specific maximum value. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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[3] via a drain line [1]. The drained oil can either be filtered via a separate filter [2] or directed to the return filter of the base machine (see the diagram in section 5.3.3). ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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[2]. 3.2.4.5 Hoses and connections Connections: Screener crusher Operating ports Drain port Pressure port model All models G1" female G3/8" female G1/4" female thread thread thread ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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CAU T I ON Minimise the risk of hydraulic oil entering the environment by having basins and material for absorbing any leaks available while making connections! ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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Exposure to high-pressure oil spray from a pressurised connection causes a risk of death or serious injury. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
Instruction manual Spare-parts list Warranty registration form and warranty terms Fill in the warranty registration form and send it to your ALLU representative. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
Tip the Screener crusher into various positions, to ensure that it cannot hit the boom of the base machine and that the hydraulic hoses are not going to get stretched or crimped. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
0° position is not possible). 4 5 ° The best operation angle depends on the material being processed. Various angles should be tested when work is commenced. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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The drums should be stopped before the bucket is completely empty, to keep stones from being thrown and to improve the overall capacity (material usually passes through more slowly when the Screener crusher is nearly empty). ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
Screener crusher. Never use the Screener crusher as a support when moving the base machine, as this may damage the Screener crusher. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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Screener crusher. Be sure to keep large stones from entering the bucket, to avoid excessive wear. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
Daily / every 8 hrs Weekly inspection and 4.1.2 Weekly / every 40 hrs lubrication of bearings Extensive maintenance Annually / every 500 hrs Replacement of wear parts When necessary ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
If any damage or faults are observed in the inspected machine components, these must be rectified before work begins. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
In addition to those of the eight-hour inspection, the following checks are performed: 1. Use a spanner to ensure that all the adapter bolts [1] have been tightened properly. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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Recommended bearing lubricants: Operating temperature NLGI grade Below 0 °C 0–25 °C Over 25 °C Use lithium-complex-based lubricants for bearings. The ALLU first-installation lubricant is Rocol Sapphire 1. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
[B] exceeds 2 mm (see section 4.1.2). 2. Check the condition of the bearing grease tubes and connectors. Repair any broken tubes/hoses and joints. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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Teboil Universal CLS (NLGI grade 00 centralised system lubricant). Load amounts for the lubricant: Model Load amount / 1 chain housing DN/DNS 4 kg DS/DH/DSB/DHB 5 kg ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
Screener crusher. - A cotter press compatible with an impact drill is available as an accessory (SDS Max head). ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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Remove the blade. The blade is removed by pushing it upward through a slot in the side plate. Push a new blade into its place. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
4.3.2 Replacement of counter blades (DN, DS, and DH models with XHD and X drums) Number Item Quantity Note Hexagonal screw M16 × 70, 10.9 200 Nm Base plate M16 Locking nut M16 Counter blade Counter blade lock plate ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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3. Remove the counter blades. 4. Check the condition of the counter- blade-holders, repairing them as necessary. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
Counter blade lock plate, left-handed Counter blade lock plate, right-handed Counter blade Removal and installation of the top counter blade is performed as described below for the bottom counter blade. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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Drop the front edge of the counter blade in front of the teeth, and push the blade into place by tilting it. Then push the counter blade under the teeth. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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Use hard threadlocker for the horizontal bolts. 6. Tighten all the bolts and locking nuts. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
(TS16 TS32 or TS25 TS50) are described below. 1. Remove the locking plates [1], screen combs [2] and spacing elements [3] from the Screener crusher. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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Fix them in place temporarily with one or two bolts, to hold them in position while the combs are being installed. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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(see the previous picture [3]) directs the screen combs into the right slots in the correct number. Check that the clearances are even along the entire bucket. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
Bearing unit Hexagonal screw M16 × 80 Lock plate NL16 Fender washer, 45 × 4 and 55 × 4 55 × 4 in the middle Locking nut M16 ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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3. Remove the chain wheels and bearing 8–11 units [8–11] from the drums, following the instructions in section 4.3.8. 4. Detach parts 5–7 from the drums. 5. Slide the blades off the shaft. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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Position the blades and the drums carefully in the correct places. Positioning blades in the wrong way could cause the blades of adjacent drums to hit each other. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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Positioning of the blades in drums TS16 and TS32: ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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Positioning of the blades in drums TS25 and TS50: Direction of the drum when installed. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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Positioning of the blades in drum TS35: Direction of the drum when installed. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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The arrangement of the chain’s links forces adjacent drums into the positions shown in the picture. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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7. Install the locking plates [1]. Push the locking plate upwards, to prevent a large gap between the plate [1] and the screen combs [2]. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
In the picture, the drums have been removed, but it is possible to replace the bearing-protection fender without taking the drums out. 1. Loosen the mounting bolts. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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3. Mount the bearing-protection fender. Support it carefully, to prevent it from falling over. 4. Fix the bearing-protection fender’s mounting bolts in their places. Use hard threadlocker for the bolts. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
Note that lubricant has been added to the chain housings, and some of it may leak out when the covers are removed. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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2. Open the chain locks, and remove the chains. 3. Remove the grease tube connectors from the bearing unit. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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7. Remove the drum. Use an appropriate hoisting device to which the drum can be secured to prevent it from falling! ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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Silicone should be applied to the frame and back plate surfaces that come in contact with each other. 12. Fix the back plate locking bolts in place. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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The arrangement of the chain’s links forces adjacent drums into the positions shown in the picture. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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20. Attach the covers. The covers should be sealed in place with a silicone adhesive. Clean the surfaces before applying silicone. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
4.3.8 Removal and installation of bearings and chain wheels 1. Remove the chain wheel’s lock ring. 2. Loosen the chain wheel with an extractor tool. 3. Remove the wedge. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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7. Install a new end sleeve and sealing plate at the end of the drum. The sleeve is secured with, for example, sealant to prevent the end sleeve from rotating. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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8. Install a new O-ring for the bearing unit. 9. Mount the bearing units on the drum shaft. Make sure not to damage the seal in the bearing unit cap. 10. Install the wedge. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
4.3.9 Maintenance of the bearing unit A worn bearing unit may be replaced or, alternatively, can be serviced, if the frame is intact, by replacement of the bearing and the seal. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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1. Loosen the set screw and its locking nut. 2. Loosen the bearing unit’s cap by turning it. 3. Remove the radial shaft seal from the cap. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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4. Remove the bearing from its housing. 5. Remove the sealing plate. 6. Mount a new sealing plate in place. Note the correct mounting direction, parallel to the bearing! ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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8. Place a new radial shaft seal on the bearing unit’s cap. Make sure to install the seal the right way round. 9. Place the cap in its place loosely. Do not tighten it yet! ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
Minimise the risk of hydraulic oil entering the environment by having basins and material for absorbing any leaks available while connecting the hydraulic system and performing inspections! ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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280 bar, be equal to that value. If the pressure remains considerably lower, the problem may lie in the power control valve (DPV) or hydraulic motor. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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If leakage occurs in only one rotation direction, one of the eliminator’s non-return valves has become stuck. Remove and clean the valves (see the spare-parts list) or contact your ALLU representative.
Detach all internal hydraulic hoses and grease tubes. Dispose of the metal waste, oily tubes, and oil waste in an appropriate manner in accordance with locally applicable guidelines and regulations. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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The Screener crusher weights specified in the table do not include accessories or adapters. Weights, dimensions, and values are approximate. The manufacturer may change the technical specifications without notice. ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
5. Return filter (the drain line may be connected to the tank via either a separate filter or the base machine’s return filter) 6. Cooling system for hydraulic oil ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
5.3.2 Single-motor buckets Power limiting valve: Power limiting valve and drain-line eliminator (accessory): ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
Power limiting valve and drain-line safety valve (accessory): 5.3.3 Two-motor buckets Power limiting valve: ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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Power limiting valve and drain-line eliminator (accessory): Power limiting valve and drain-line safety valve (accessory): ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
4) Sound power level at the maximum sound pressure level 5) Addition for the impulse of the measured sound pressure level 6) Addition for the tonality of the measured sound pressure level ALLU D SERIES - ORIGINAL INSTRUCTION MANUAL - ALLU_6- M-DENG0615 Courtesy of Machine.Market...
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