Lt105 Instruction Manual

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140529
Instruction manual Nordberg LT105
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This instruction manual is valid for diesel engine driven Nordberg LT105 manufactured by
Nordberg. Nordberg LT105 is a portable jaw crusher unit, which is intented to be used in
recycling crushing applications in crushing plants.
Because of the continuous development of the product, the manufacturer reserves a right to alter
the technical specifications written in this manual, without any advance information.
This is the first edition published in April 1999 in Tampere, Finland.
Manufacturer:
Nordberg-Lokomo
PL 306
33101 Tampere
Finland
Puh +358-204 80 142
Fax +358-204 80 143
4/99 140529
Instruction Manual Nordberg LT105
/RNRWUDFN
1. PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3. MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 MAIN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4 CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.5 FEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.6 MAIN CONVEYOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.7 SIDE CONVEYOR (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.8 MAGNETIC SEPARATOR (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.9 HYDRAULIC VALVE LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
4. CONTROL PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

4.1 MAIN CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
4.2.1 CABLE CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
4.3 REMOTE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
4.4 OVER RIDE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
5. STARTING AND STOPPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 BEFORE STARTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 STARTING THE DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3 STOPPING THE DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4 ADJUSTING ENGINE RPM SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.5 EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
6. TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
6.1 MOVING ON SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
6.2 SELECTING THE DRIVING SPEED RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
6.3 DRIVING THE LT105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
6.4 TRANSPORT FROM SITE TO SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

6.5 DRIVING ONTO/OFF LOW LOADER/TRAILER . . . . . . . . . . . . . . . . . . . . . . . . 4-6
7. CRUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
7.1 CRUSHING LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
7.2 FEEDING ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
7.3 DISCHARGE ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
7.4 CRUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
7.5 CRUSHING PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
7.6 FEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
7.7 MINIMUM SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
7.8 CLEARING OF THE BLOCKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
4/99 140529
Nordberg LT105 Instruction Manual
7.9 REMOVAL OF THE STEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

7.10 INTERLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
7.11 RECYCLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
7.12 OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
8. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
8.1 PERIODICAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
8.2 RUNNING-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
8.3 HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
8.4 FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
8.5 FUEL LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
8.6 CRUSHER SPACER REMOVAL/ ASSEMBLY WITH HYDRAULIC SETTING

DEVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
8.7 FILLING VOLUMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
8.8 TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
8.9 LUBRICANT RECOMMENDATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
8.10 CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
8.11 FEEDER/SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

8.12 TRACK GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
8.13 GREASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
9. SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

9.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
9.2 BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
9.3 OTHER ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
9.4 WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
10. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
ADDITIONAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

GUARDS AND PROTECTION DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
DISPOSAL OF WASTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
FIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
STORAGE OF THE MACHINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
DISPOSAL OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Appendix
A Symbols
B Additional information
C Noise levels
D Recycling
E Transport drawing
140529 4/99
Preface
35()$&(
This instruction manual is intended to assist This instruction manual must be read and used
owners and users of Nordberg products in the by each person who works with the
proper use of the equipment. equipment, typically:
It includes important references to safe, — operations, including installation, startup,
proper and economical operation of the operation, application engineering,
equipment. Following these instructions will materi als handling, site labo ur,
help to avoid possible danger, reduce repair environmental engineering and safety
costs and breakdowns and to increase the departments.
reliability and life of the equipment. — maintenance, including inspection and
repair.
This manual must be completed by those — transport, materials handling and rigging.
instructions necessary because of existing
national mandatory rules relating to accident
prevention and environmental protection. Note that this instruction manual contains
information and instructions on several
A copy of this manual must be kept at the alternative and optional equipment. Normally
equipment’s location and made available to the machines have only some of them. Before
the operators as required. maintaining and servicing, find out which
In addition to this manual and accident alternative and optional equipment your
prevention regulations mandatory in the machine has.
country of use and at the equipment’s place of See separate instruction manuals for more
operation, generally recognized rules for safe detailed instructions when servicing the main
and professional operation must be observed. components.
There may be optional equipment which have
separate instruction manuals. Those manuals
must be read and used by each person who
works with the equipment.
1/95 1-00-B 1-1

Safety
6$)(7<
WARNING SYMBOLS not intended to replace safety codes, insurance

The following symbols for particularly requirements, federal, state and local laws,
important instructions are being used in the rules and regulations.
instruction manual:
SAFETY of the operator and maintenance
Reference personnel is of prime concern. These
paragraphs are presented as a helpful guide to
construction equipment personnel and shows
some of the daily work problems which they
may encounter.
It is the responsibility of the operator to know
what specific requirements, precautions and
Refers to economical operation of the work area hazards exist and to discuss them
equipment. with his supervisor. A common understanding
should be reached by all personnel to assure
safe performance in operating the equipment.
Attention
The operator is the key to safe job performance
and should study these safety tips to be aware
of basic safety precautions to help prevent
serious injury and damage to property.
STOP ACCIDENTS BEFORE THEY STOP
YOU!
Particular attention must be given to prevent
possible incorrect or dangerous operating In order to alert you, the user, and those
situations from occurring. entrusted as operators and maintenance
personnel, dangerous or hazardous operations
are shown in this instruction manual with
WARNING notes.
Danger
Particular attention must be given to prevent

accidents or damage to personnel and/or
property.
PERSONNEL SAFETY
This portion of the instruction manual is
intended to illustrate only basic safety The safest machine must still be operated with
procedures. Additional precautions may be care and with knowledge of its performance
necessary for the safe operation of a Crusher. capabilities. The most comprehensive safety
The information contained in this manual is program must still be followed.
12/97 2-01-B 2-1

Safety
Remember that on any job, YOU are the key READ THE MANUAL furnished with your
to safety. Good safety practices not only equipment to learn its operating and
protect the men around you, they are your own maintenance characteristics, capacities and
best protection. Study this manual and any limitations. Learn the location and function of
manufacturer’s operator’s manuals covering ALL controls, indicators, warning devices and
your specific equipment. Read all warning and caution instructions.
caution instructions. Practice safe operation.
DO YOU HAVE KNOWLEDGE OF
INSIST THAT YOUR FELLOW WORKERS WORKING AREAS?
DO, TOO. BE ALERT TO POSSIBLE Learn − beforehand as much about your
HAZARDS BE FORE THEY CAUS E working area as possible:
TROUBLE, AND REMEMBER . . . SAFETY
IS UP TO YOU!!! Be a good housekeeper . . . keep the floor
clean, free of oil, grease, rags, cables, chains,
DO YOU KNOW YOUR EMPLOYER’S buckets, rocks and other hazards. Keep loose
SAFETY PROGRAM? parts in a tool box. Use only non-flammable
Company safety records show that the greatest solutions for cleaning.
percentage of accidents are caused by
d isr egard of simp le safety rules. Know the weight limitations for any floors on
Know-observe!-the overall program . . . and which you will operate.
consul t your sup erv isor fo r sp ecific Know the clearances in the work area. A little
instructions when starting a job. time spent checking side and overhead
ARE YOU DRESSED PROPERLY FOR clearances, including power lines, can save a
THE JOB? lot of trouble later.
You may need any number of special items - Be careful of dust, smoke or fog, which may
safety hat, safety shoes, safety glasses, obscure your vision.
goggles, heavy gloves, ear protective devices,
etc., - for your own protection. Find out what ARE YOU PREPARED FOR
items are required and wear them! EMERGENCIES?
Plan ahead - stay alert - operate sensibly - and
Loose clothing can catch in moving parts. you will avoid both having and causing
Keep sleeves buttoned, jackets belted and personal injury and accidental equipment
wear your special safety equipment. Keep damage. If a careless moment does cause an
warm without restricting your movement. emergency - react quickly with the tools and
Wrist watches and rings can be dangerous. skills at hand. Know the location of and how
Keep your pockets free of objects which may to use a fire extinguisher and a first aid kit.
fall out.
Know where to get prompt assistance.
DO YOU UNDERS TAND YO UR
MACHINERY? An emergency calls for fast action.
DON’T STOP YOUR SAFETY PROGRAM
WITH THESE GENERAL RULES. BE
EQUALLY CONSCIOUS THAT SPECIFIC
WORKING CONDITIONS AND YOUR
PARTI CUL AR E QUIPMENT - CAN
REQUIRE ADDITIONAL PRECAUTIONS.
BEFORE STARTING CHECK
Equipment not properly prepared for
operation is unsafe equipment. Run a careful
check at the beginning of your shift. If you find
2-2 2-01-B 12/97

Safety
something that needs attention, THINK improper readings are observed.

TWICE before deciding to "let it go this time".
Even minor mechanical defects can lead to 5 TEST all controls for proper
personal injury and accidents. functioning.
1 DO NOT allow unauthorized personnel 6 LISTEN for and report any unusual
to operate the Crusher! noises.
2 MAKE SURE all guards and other 7 RE-CHECK alarms or other warning
protective devices are in place, secured and safety devices.
and not damaged. 8 DO NOT stand on the Crusher while
3 CHECK fluid systems: Are they at the the Crusher is running.
correct level and completely leak free? 9 DO NOT lean or place your hands on
4 CHECK every drain cock, valve and or against the tension spring while the
fitting to sure it is in place and secure Crusher is in operation.
5 Loss of pressure from low fluid levels 10 DO NOT take a chance with a defective
may lead to serious hydraulic failures. machine. REPORT IT TO YOUR
SUPERVISOR.
6 CRUSHER SEIZURE from lack of oil
or grease is a problem that may cause REPORT A DEFECTIVE MACHINE
accidents. Inspect your machine daily . . . check for loose,
worn or damaged parts. Report or correct any
7 NEVER tamper with safety devices. unsafe conditions immediately . . . and do not
operate the machine until they have been
8 CHECK the Crusher thoroughly for corrected.
visual defects, such as leaks, worn hoses
or loose parts. Even a minor defect can become serious . . .
report any machine defects to your supervisor.
9 INSPECT your machine according to
the operator’s manual and your STOPPING SAFELY
supervisor’s instructions. Be sure Crusher is stopped before . . . cleaning,
servicing, lubricating . . . checking belt tension
10 BEFORE STARTING walk completely . . . removing housing covers . . . working on
around your machine. Make sure there the hydraulic system . . . making repairs . . . or
is no one next to under or on the attempting to clear a plugged cavity. MAKE
machine. Warn any personnel nearby NO CHECKS, ADJUSTMENTS OR
that you are starting up. RE PAIRS OF ANY KIND WHILE
REPORT ANY DEFECTS TO YOUR CRUSHER IS IN OPERATION.
SUPERVISOR TIPS FOR SAFE MAINTENANCE
START UP SAFELY Perform maintenance with care.
1 CHECK equipment for warning tags. READ AND UNDERSTAND
2 FOLLOW the recommended starting 1 Instruction manual furnished with the
procedure as outlined in Section 5 Crusher, especially Section 5,
OPERATION. OPERATION.
3 AFTER Crusher has been started, check 2 Instructions for inspection and
all gauges and instruments to be sure maintenance located in Section 5
that everything is operating properly. OPERATION and 7 PERIODICAL
MAINTENANCE.
4 SHUT DOWN immediately if any
12/97 2-01-B 2-3

Safety
3 Warning and caution plates provided on the 8 WEAR SAFETY GLASSES AND
machine. PROTECTIVE CLOTHING when
using high pressure air.
4 Warning and caution notes in the
instruction manual. 9 WEAR GOGGLES AND
PROTECTIVE CLOTHING when
5 Lubrication guides for periodic handling molten metals; zinc, babbitt,
servicing in Section 6, LUBRICATION. lead, etc.
WARNING TAGS 10 WEAR EAR PROTECTIVE DEVICES
Before working inside a Crusher, be sure to tag when required or REDUCE exposure
and lockout the electrical controls so no one time as required.
else will start it.
ALCOHOLIC BEVERAGES AND
Attach warning tags to prevent accidents: MEDICATION
1 If Crusher is unsafe for operation. 1 DO NOT use alcoholic beverages
before coming to work or while on the
2 If controls are being serviced. job.
3 If machine is being repaired. 2 BEWARE of medicines, tranquilizers
or other drugs which can make you
LOCKOUT ELECTRICAL SERVICE sleepy or less alert.
1 Always lockout all electrical controls
before performing any type of WORK AREA
maintenance work on the Crusher. 1 PROMOTE GOOD HOUSEKEEPING,
keep the floor clean and dry, free of
2 Provide each maintenance man with debris and tools. Oily and wet floors,
his own personal padlock and ONE key. steps and hand rails are slippery. In
CLOTHING - SAFE PRACTICE winter watch out for ice and snow. Wet
1 KEEP HANDS AND CLOTHING spots, especially near electrical
AWAY FROM MOVING PARTS. Do equipment, are dangerous.
not take chances by wearing loose 2 DO NOT let material lay and build up
sleeves, floppy ties, watches and rings. on or around the Crusher.
2 WEAR EYE PROTECTION when 3 STORE dangerous fluids in a suitable
handling fuel, cleaning fluid, oil or place - away from unauthorized
brake fluid. THESE MATERIALS CAN personnel. ALLOW NO SMOKING IN
DAMAGE YOUR EYES. THE AREA!
3 WEAR A RESPIRATOR when 4 NEVER start a diesel or gasoline engine
required. within an enclosed area unless there is
4 WEAR SAFETY GLASSES when adequate ventilation. Exhaust fumes can
drilling, grinding or hammering metal. kill!
5 KEEP YOUR POCKETS FREE of EQUIPMENT

objects which can fall out and into 1 Use the proper tools; handle tools and
machinery. heavy parts sensibly.
6 WEAR HARD HAT AND SAFETY 2 Keep all tools and equipment free of
SHOES, when required. dirt, oil and grease. Do not drop or toss
them.
7 WEAR GLOVES to protect your
hands when changing cables. 3 Use hoisting equipment for heavy lifting.
2-4 2-01-B 12/97

Safety
Save your back. what type of fire. Check regularly - at

least monthly - to be sure it is in the
4 Lower parts, do not drop them. working area.
5 To prevent slipping, wipe hand levers PRESSURIZED SYSTEMS -
and knobs clean of oil or grease. HYDRAULIC OR AIR
6 Do not use sheaves with cracked rims 1 Relieve ALL pressure before opening
or spokes. or removing any hydraulic or air
pressure lines, valves, fittings, etc.
7 Check for missing, cracked or frayed
V-belts. 2 Check for worn hoses or damaged lines.
8 Check for broken, defective or missing 3 High pressure oil can be dangerous.
parts and replace them. Keep equipment USE QUALITY PARTS
clean and free of dirt and oil so you can A replacement part for any item should always
spot loose or defective parts. be of comparable SIZE, TYP E AND
9 When using cables to move a load, be QUALITY - as the part being discarded.
sure cables are of adequate size and REPORT NECESSARY REPAIRS
replace any worn, badly frayed, broken If your daily check uncovers any item that
or kinked ones. Check end connections need attention - repair, replacement or
for wear. adjustment - REPORT IT NOW!
FIRE HAZARDS The most minor defect could result in more
1 DO NOT smoke while refueling - or serious trouble - IF THE MACHINE IS
when handling fuel containers. OPERATED.
2 SHUT OFF engine when refueling - Only perform the work you’re authorized to
and use extra caution if engine is hot. do. Do not attempt repairs you do not
3 WHEN pouring fuel into the tank, understand.
ground the funnel or spout against the Only work on equipment you thoroughly
filler neck to avoid static electric spark. understand - a pressure-loaded part, if
4 DO NOT use gasoline or diesel fuel carelessly released could injure anyone in its
for cleaning parts. Good commercial, path.
non-flammable solvents are preferred. Remember you are entrusted with the
5 DO NOT smoke while using cleaning operation and maintenance of a highly
solvents. valuable piece of equipment TREAT IT AS
SUCH!
6 DO NOT let greasy, oily rags
accumulate in poorly ventilated area.
Store oily rags and other combustible
material in a safe place.
7 NEVER use an open flame to check
fuel, battery electrolyte or coolant levels
. . . or to look for hydraulic leaks
anywhere on the equipment.
Use a flashlight!
8 KNOW where fire extinguishers are
kept - and how they operate - and for
12/97 2-01-B 2-5

Safety
5(0(0%(5
6$)(7<,68372<28
PLANT SAFETY
The safety procedures mentioned here do not
eliminate all safety hazards found in the area
of crushing plants. However, they do highlight
some of the procedures which have been found
through long experience to improve safety
conditions around Crushers and crushing
plants. Nordberg will welcome inquiries
regarding other suggested safety procedures
for use around their Crushers and related
equipment.
DRIVE GUARDS
Proper safety precautions start with the initial
installation of the Crusher. Crushers are driven someone working below. Do not fasten the
either by V-belts or by direct couplings to operator’s platform to the Crusher.
motors. THE BELT DRIVE OR COUPLING
SHOULD HAVE A PROTECTIVE GUARD ELECTRICAL LOCKOUT
THE ELECTRICAL POWER SOURCE FOR
AROUND IT.
THE CRUSHING EQUIPMENT SHOULD
Crusher-sheaves in particular are designed for BE LOCKED OUT WHENEVER ANYONE
maximum rim speeds. If these speeds are IS WORKING ON IT. Each maintenance man
exceeded it is possible that the sheave could who normally works on a Crusher should be
explode and cause severe injury or even death. provided with his own personal padlock with
only one key. When he works on any assembly
Since the speed of the Crusher is quite of the Crusher, he should use this padlock to
important for proper operation, most V-belt lock out the electrical controls for the Crusher.
drive guards usually have a small opening It is most important that only one key be
immediately opposite the center of the crusher provided for the lock and that key must be in
drive shaft so that a tachometer can be inserted the pocket of the person who is working on the
to occasionally check the speed of the Crusher. If more than one person works on the
eccentric shaft. This opening should be Crusher, each should have his own lock and
covered with an access door or hatch. key at separate lockout stations for the controls
OPERATOR’S PLATFORM of the Crusher. Accidental start-up of crushing
Since periodic inspection and maintenance equipment with men in the immediate area can
must be performed on each Crusher, IT IS be responsible for many accidents on what was
IMPORTANT THAT SOME TYPE OF supposedly a "clear" machine.
PLATFORM BE ERECTED AT A LEVEL CRANES
CONVENIENT FOR THE MAINTENANCE Crushers, like any other type of mechanical
MEN WHO MUST INSPECT AND WORK equipment, require norm al peri odic
ON THE CRUSHER. A good operator’s maintenance if the operator is to get the most
platform constructed of "solid" floor plate for his money from the use of the machine.
should have hand railings, toe plates and wire One of the most flagrant Crusher safety
mesh or expanded metal between the platform violations is the use of inadequate and unsafe
and the top of the hand railing to prevent tools lifting equipment. Although a Crusher is not a
from dropping off the platform and hitting finely tuned piece of equipment, such as an
2-6 2-01-B 12/97

Safety
automobile engine, the internal parts of a quickly vaporize the hydraulic fluid as it
Cr usher should be assembled and reaches the atmosphere. This vaporized fluid
disassembled with crane facilities that have the can quickly become a mass of flames, resulting
capability of gently and slowly lifting and in severe burns for personnel in the immediate
lowering the various parts that make up a area. ALL MAINTENANCE PERSONNEL
Cr usher. WHEN USING A CRANE, WHO NORMALLY USE TORCH
ALWAYS OP ERATE WITHIN THE CUTTING EQUIPMENT SHOULD BE
RATED CAPACITY OF THE CRANE. THE ADVISED IF THERE ARE HYDRAULIC
SAFE RATED CAPACITY INCLUDES COMPONENTS IN THE IMMEDIATE
WEIGHT OF HOOK, BLOCK AND ANY AREA IN WHICH THEY ARE WORKING.
MATERIALS HANDLING DEVICES Then adequate precautions be made to avoid
SUCH AS CABLES, SLINGS, SPREADER contact with these components. Rubber lined
BARS, ETC. SUBTRACT THE WEIGHT OF hoses are not immune to the torch cutting
ALL THESE TO FIND THE TRUE WEIGHT equipment which is used in normal plant
OF THE LOAD THAT CAN BE HANDLED maintenance procedures.
SAFELY. Chain falls should be considered
only as a last resort to assemble and CONVEYOR BELTS
disassemble a Crusher. When it comes to DO NOT USE CONVEYOR BELTS AS
safety, the best should be used. WALKWAYS. Conveyor belts leading to and
from the Crusher should be provided with
MOBILE CRANES walkways alongside the conveyor. Always
WHEN USING A MOBI LE CRANE, provide hand rails along the conveyor belt
ALWAYS OP ERATE WITHIN THE walkway as an added safety precaution.
RATED CAPACITY OF THE MACHINE
TO AVOID BUCKLING THE BOOM OR PORTABLE PLANTS
TIPPING. Safe ratings are based on operating If the crushing plant consists of portable
the crane on firm, level ground; outriggers equipment, that is, crushing and screening
should be properly extended and/or lowered equipment mounted on trailers, trailer footing
whenever possible. Avoid fast swings, hoists or cribbing is extremely important for safe
or sudden braking; these can cause overloads. operation. Check your footing. Your machine
Do not handle large, heavy loads in strong should be on a solid and level a footing as
winds. possible. Use heavy timber mats as needed.
Trailers must be raised so that trailer wheels
When moving your crane, check bridges do not touch the ground. Place screw jacks at
before crossing, make sure they will support each corner of the trailer or as near the corner
the weight of the machine. Check clearances as possible. All four jacks must be an equal
under bridges for overhead electrical lines or distance from each end. Adjust each jack until
any overhead obstruction. the unsupported portion of the trailer beams
stop vibrating or until vibrations are reduced
Check your hitcher, be sure he’s clear before to a minimum. NEVER leave your trailer in a
starting lift. Make certain he securely attaches low spot where rains may wash out your
the load. footing.
TORCH CUTTING EQUIPMENT PERIODICALLY RECHECK TRAILER
One of the most frequently used tools around FOOTING FOR STABILITY
the Crusher is the cutting torch. Crushers
which ar e equi pped wi th hydraulic When moving your trailer, check bridges
components should have these components before crossing, make sure they will support
depressurized and adequately covered with the weight of the machine. Check clearances
flame-proof material so that sparks, weld under bridges, for overhead lines or any
spatter, etc., cannot reach these areas. overhead obstruction. NEVER TRAVEL
Ruptured high pressure hydraulic lines will WITH NEAR-CAPACITY LOADS, CHECK
12/97 2-01-B 2-7

Safety
L OCAL LAWS, ESPECIALLY ON cavity by hand.

WEIGHT LIMITATIONS. When traveling on
the highway make sure all headlights, GENERAL MAINTENANCE WORK
clearance lights and tail lights are on. Use A certain amount of work must be done in the
proper traffic warning flags and signs. immediate area of the Crusher during the
normal course of operations on a day-to-day
CRUSHING PLANT "NOISE" basis. The following are some of the do’s and
Crushing equipment by its very nature is noisy don’ts to be followed as part of normal crusher
and the auxiliary equipment found in and operating procedures.
around crushing equipment such as chutes,
transfer stations, screens, etc., can at times be 1 DO NOT perform maintenance on
n oi si er than th e Crush er it self. EAR moving machinery. This includes such
P ROTECTI VE DEVICES MAY BE items as adding lubricating oil or
REQUIRED IF NOISE LEVELS ARE greasing parts of the Crusher while it is
HIGHER THAN THOSE ALLOWED BY in operation.
L AW. If ear pro tectiv e devi ces are 2 DO NOT put hands or feet on the
undesireable, consideration should be given to tension springs which project from the
reducing the amount of noise exposure that an rear of the Crusher while the Crusher is
operator or maintenance man may be in operation.
subjected to. In other words, shorter working
hours. 3 DO check the manufacturer’s
recommendations for periodic
Although alteration of the machinery to maintenance procedures. These
change its noise characteristics may be maintenance procedures are designed to
economically impossible, many operators not only avoid damage to the equipment
have found that the installation of a relatively but also avoid harm to the operator as
inexpensive operator’s station can improve well.
noise conditions. The operator can see the
equipment in operation and still be protected 4 DO avoid spillage around the Crusher.
from the noise through the installation of Crushers seem to attract odd size pieces
aco ust ical ti le do ub le wind ows, air of rock, gravel, etc. Plant operators
conditioning equipment, etc. These working should make it a habit to keep the area
conditions will normally result in a more immediately adjacent to the Crusher free
efficient operation and reduce potential from this type of spillage which could
injuries from noise. cause unsuspecting personnel to trip and
fall.
Many plant operators are finding that an
operator’s tower erected at an elevation above 5 NEVER look into the crushing cavity
most of the equipment provides both safety while the Crusher is in operation
features for the operator and increased without protection from possible flying
efficiency in plant operation. material.
CLEARING A CRUSHER
There are many unforseen events such as
power failures, sudden surge of materials, etc.,
which can cause a Crusher to become plugged
with material and stall. UNPLUGGING THE
CRUS HE R CAN BECOME A VERY
SERIOUS POTENTIAL SOURCE OF
ACCIDENTS. In many instances, the only
way in which the Crusher can be restarted is to
literally dig the material out of the crushing
2-8 2-01-B 12/97

Main components Nordberg LT105
0$,1&20321(176
3.1 MAIN ASSEMBLY
1. Diesel engine
2. Tracks
3. Crusher
4. Feeder
5. Main conveyor
6. Side conveyor (optional)
7. Magnetic separator (optional)
2/99 3-38-B 3-1

Nordberg LT105 Main components
3.2 DIESEL ENGINE 3.8 MAGNETIC SEPARATOR

(OPTIONAL)
The operating power of the LT105 is
generated from the Volvo or Cat diesel engine. The optional magnetic separator is installed
It runs the hydraulic pumps. above the main conveyor. It separates
magnetic objects from the crushed material
and transfers those to the separate pile beside
3.3 TRACKS the machine.
The LT105 moves with the tracks. The tracks

ensure safe and fast movements of the
machine even in the rough terrain.
3.4 CRUSHER
The Nordberg C105B jaw crusher is the heart

of the LT105. The crusher crushes the feed
material into smaller pieces.
3.5 FEEDER
The feeder ensures even and continuous

material flow into the crusher. The feed
material smaller than the opening of the feeder
grizzly goes through the grizzlies passing the
crusher. This increases the capacity and
prevents material packing in the crusher .
3.6 MAIN CONVEYOR
The main conveyor transfers the crushed

material from the crusher to the stock pile or
to the next process.
3.7 SIDE CONVEYOR (OPTIONAL)
The optional side conveyor transfers the

material that has passed the crusher through
feeder grizzlies to the stock pile beside the
machine.
3-2 3-38-B 2/99

Main components Nordberg LT105
3.9 HYDRAULIC VALVE LOCATION
1 Throttle valve 16 Disch. conv.

2 Dir. valve 17 Vibr. feeder
3 Throttle valve 18 Track right
4 Chek valve 19 Track left
5 LS-check valve 20 Magn. separator
6 Dir. valve 21 Hydr. outlet
7 Pres. switch (170/180 bar) 22 Main conveyor
8 Accumulator (130 bar) 23 Pres. gauge, LS-pressure
9 Shut-off valve 24 Socket for feeder side walls
10 Relief valve (195 bar) 25 Safety switch for conveyor
11 Gauge valve 26 Socket for over ride panel
12 Pres. gauge 27 Pilot valve, LS-pressure
13 Check valve 28 Pilot valve, fast speed
14 Disch. conv. lenght 29 Switch, with hydraulic
15 Disch. conv. turn setting adjustment
2/99 3-38-B 3-3

Control panels Nordberg LT105
&21752/3$1(/6
4.1 MAIN CONTROL PANEL 8. Radio control 0/1

9. Lubricating unit
1. Emergency stop 10. Engine preheater manu/clock
2. Process 0/1 11. Magnetic separator 0/1
3. Key switch / start 12. Hydraulic output 0/1
4. Working lights0/1 13. Signal horn
5. Drive /0 slow /1 crawl /2 fast
6. Discharge conveyor 0/1
7. Level switch 0/1
SIGNAL LIGHTS
A. Charging
B. Coolant temperature
C. Oil pressure
D. Hydr. oil temperature
E. Hydr. oil level
F. Hydr. oil filter
G. Glowing
2/99 4-38-B 4-1

Nordberg LT105 Control panels
4.2.1 CABLE CONTROL UNIT 4.2.2 SIDE WALL AND CONVEYOR

CONTROLS
1. Track, left-hand
2. Track, right-hand 1. Side conveyor up/down, left side wall
3. Speed up/down
4. Emergency stop 2. Side conveyor in/out, right side wall
up/down
3. Rear side wall up/down
4. Emergency stop
4-2 4-38-B 2/99

Control panels Nordberg LT105
4.3 REMOTE CONTROL
1. Emergency stop
2. Capacity
3. Feeder stop
4. Feeder start
5. Setting (optional)
2/99 4-38-B 4-3

Nordberg LT105 Control panels
4.4 OVER RIDE CONTROLS
Over ride controls can be used to temporary

overrun the usually logic driven function,
e.g. to clear a blockage. The feeder, crusher,
etc. can be used separately without starting
the process.
4-4 4-38-B 2/99

Starting and stopping Nordberg LT105
67$57,1*$1'67233,1*
5.1 BEFORE STARTING
Check the condition of the machine.

Lift the exhaust pipe up (figure 5.1.1).
Turn the light pole up (figure 5.1.2), if
necessary.
Figure 5.1.1 Lift the exhaust pipe up
Figure 5.1.2 Turn the light pole up
1/98 5-38-B 5-1

Nordberg LT105 Starting and stopping
Check the crusher V-belt tensions. The belt 5.2 STARTING THE DIESEL ENGINE
deflection is 22 mm (4/5") and the force is 50
N (figure 5.1.3). Start the diesel engine as follows:
1. Turn the main switch on.
Ensure that the machine is operated only in 2. Turn the key switch to "ON" position.
safe manner and when in good mechanical 3. Make sure that the safety and emergency
condition. Ensure that the machine is standing circuit is operational.
properly and will not overturn. 4. Make sure that the temperature and level
The operation of the machine must only be of the coolant water in the diesel
allowed, when all necessary protective and engine are normal.
safety devices, e.g. guards, emergency stop 5. Wait the self moutoring period. (10s.)
devices, silencers, aspirators etc. are in place When charging voltage & oil pressure
and in operating condition. light are on.
6. Turn the key switch to start position and
Before starting the machine, ensure that there wait untill the diesel motor starts.
are no persons in the area whose safety may be NOTE: 20 sec glowing delay.
endangered! Walk around the machine and
ensure that there is nobody on, by or below the
machine. Warn everybody in the vicinity NOTE! Hold the key switch at start position
before starting. untill diesel engine starts.
Figure 5.1.3 Check crusher V-belt tensions
5-2 5-38-B 1/98

Starting and stopping Nordberg LT105
5.3 STOPPING THE DIESEL ENGINE
Stop the diesel engine by turning the key

switch to "OFF" position.
NOTE! Before stopping the diesel engine,
make sure that the engine runs idle for few
minutes.
5.4 ADJUSTING ENGINE RPM SPEED
The automatic control of the machine

monitors and adjusts the diesel engine RPM
during the start and when controlling the
process. During this time, the user cannot
adjust the RPM speed. When the process is not
running, the RPM speed of the diesel engine
can be controlled with the RPM control switch
located in the drive control box. If the machine
has radio control (optional), the RPM speed of
the diesel engine can be adjusted with radio
control the same way as with the drive control
box.
Figure 5.5.1 Location of the "Emergency stop" -buttons.
1/98 5-38-B 5-3

Nordberg LT105 Starting and stopping
5.5 EMERGENCY STOP
In case of emergency press "emergency

stop"-button to stop the machine. The buttons
are shown in the drawing 5.5.1.
There is three emergency push buttons what
will cause emergency stop function. The main
hydraulic valve position switch will cause,
emergency stop function.
Ensure that the suction valves of the hydraulic
tank are open (figure 5.5.2)
Figure 5.5.2. Ensure that the suction valves of the hydraulic tank are open.
5-4 5-38-B 1/98

Transport Nordberg LT105
75$163257
6.1 MOVING ON SITE 6.2 SELECTING THE DRIVING SPEED

RANGE
Pay special attention to transport and moving
of the unit because of its dimensions and It is possible to use three different speed
weight. ranges; fast, slow and crawl. Select the speed
range with the "Drive speed"-switch located
Normally the LT105 can be moved on the site in the main control panel.
in its working position by driving on tracks.
Before driving make sure that
— driving route is plane enough.
— differences in altitude and road
inclination do not prevent driving.
Whilst tracking the machine, the maximum

inclination allowed is 5 degrees sideways and
15 degrees lengthways.
Make sure that the load bearing capacity of the
ground is at least 15,000 kg/m2(3072 lbf/sq f).
Start engine as instructed in chapter 5.2.
3/98 6-38-B 6-1

Nordberg LT105 Transport
6.3 DRIVING THE LT105
Drive the LT105 with the drive controls in the

drive control box. If the machine has radio
control (optional), the driving is also possible
with radio control, the same way as with the
drive control box.
Plug the drive control cable into one of the
cable connecting sockets (figure 6.3.1).
STOP
The Lokotrack can now be moved in either
direction using drive control levers in the
remote control unit (figure 6.3.2). - +
Always check the surroundings of Lokotrack

before moving it.
Figure 6.3.2 The LT 105 can now be moved
in either direction using drive control levers
in the remote control unit
Figure 6.3.1 Plug the drive control cable into

one of the connecting sockets
Figure 6.3.3 The LT105 can be moved in either direction using drive controls
6-2 6-38-B 3/98

NOTE! Make sure that there is nobody in the If no crushing is required, stop the engine as
area before driving. Avoid sudden and instructed in chapter 5.3.
unpredictable moves while driving.
If you start crushing, see section 5.2.
Driving speed can be regulated by adjusting
the engine speed between min - max rpm, Some hints to make turning the LT105
using the throttle. easier:
NOTE ! During longer moves (over 100 m / — LT105 turns easier on hard than soft
328 f) LT105 must be driven feeder end first. ground.
That is to keep the track chain tight and to — If the LT105 can not be turned when
prevent the chain from jumping over drive driving uphill, drive a short way
pulley teeth. downhill turning the unit at the same
time.
NOTE! During longer mo ves observe — If unit is equiped with three speed
hydraulic oil temperature continuously. Oil ranges the best turning with slow &
temperature should not exceed 90°C(194°F). krowl speeds
If the oil is too hot, it may damage the seals.
3/98 6-38-B 6-3

6.4 TRANSPORT FROM SITE TO SITE
When the LT105 is transported on public road,

take care that it has the necessary permissions
from authorities for special transport. Check
the local regulations, as they vary in each
country.
EQUIPMENT NEEDED
— Low loader, min capacity 40 t.
MEASURES BEFORE TRANSPORT
1. Turn down additional side walls of the

feeder. (ref 7.4)
2. Turn the side conveyor up. (ref 7.4)
6-4 6-38-B 3/98

3. Turn down the exhaust pipe. Ensure that

rain water does not get into the silencer.
4. Place light pole into the transport position.

5. See 7.3.1 if needed
NOTE! Side conveyor extension shut off val-
ve must be in closed position during transpor-
tation.
3/98 6-38-B 6-5

6.5 DRIVING ONTO/OFF LOW The LT105 may be driven onto the trailer
LOADER/TRAILER forwards or backwards depending on trailer
type.
Drive LT105 onto and off loader/trailer very
carefully.
Fix suitable ramp against the trailer so that the
maximum inclination does not exceed 1 in 4
when driving the LT105 up onto the trailer.
Weight of the Base unit 35400 kg/78000 lbs
Total weight of LT105 with options KG LBS
Side conveyor H 5-5 600 1320
Bracket for magn. separator 300 660
Magnetic separator 1100 2420
Feed hopper (9m3) 570 1255
Feed hopper ext. 110 240
Hydr. setting adjustm. 100 220
Recycling plate 85 187
Long conveyor H10-15 1765 3890
Dust cover 140 310
Hammer & Pedestal 1500 3300

Notice: The units actual weight can be calculated by adding the weight of the options to unit
base weight. (Note: Weights are directive. There can be some differences due to manufacturing
tolerances.)
6-6 6-38-B 3/98

Crushing Nordberg LT105
&586+,1*
7.1 CRUSHING LOCATION
The LT105 should be located near the material The location where the crusher is to be placed
pile to make loading easy and fast. Shape the must be even. The machine must not sway.
feed material pile with the wheel loader or The surface below the crusher must be leveled
excavator so that it is in small area and high off. Spread some fine material on the ground,
enough for easy loading (figure 7.1.1). then rub it smooth (figure 7.1.3). After that
make it solid by driving the LT105 forward
The location of the discharge pile must be and back on location (figure 7.1.4).
chosen so that it doesn’t cause any danger to
workers or passers-by. Ensure that there is
enough space for the discharge pile, discharge
machinery (wheel loader or excavator) and
lorry (figure 7.1.2).
Figure 7.1.1 Shape the material pile first Figure 7.1.2 General arrangement of the site.
Figure 7.1.3 Spread some fine material on the Figure 7.1.4 Make the ground solid by driving
ground, then rub it smooth. the LT105 forward and back on location.
3/98 7-28-B 7-1

Nordberg LT105 Crushing
Whilst crushing the LT105 must be level. The For service purposes it is good to have a hole
maximum inclination allowed is 1 degree under the LT105 (figures 7.1.7).
sideways and 2 degrees lengthways (figures
7.1.5 and 7.1.6).
max. 1°
Figure 7.1.5 During crushing the maximum Figure 7.1.6 During crushing the maximum
inclination allowed is 1 degree sideways. inclination allowed is 2 degrees lengthways.
h
Figure 7.1.7 Make a hole under the LT105 for
service purposes.
7-2 7-28-B 3/98

7.2 FEEDING ARRANGEMENT
LOADING EQUIPMENT
The LT105 can be loaded with an excavator
or wheel loader.
LOADING WITH EXCAVATOR

Loading can be done from side or behind.
Find the suitable loading position so that move
the excavator bucket to the loading position.
Then drive the LT105 under it to the suitable
position.
The excavator operator must have visual
communication to the top of the feeder (figure
Figure 7.2.1 The excavator operator must
7.2.1).
have visual communication to the top of the
Load the material in the feeder rear end on the feeder.
solid bottom (figure 7.2.2).
If there is metal in the feed material, a man
should stand beside the feeder and remove the
metal pieces before they enter the crusher.
LOADING WITH WHEEL LOADER

Loading can be done only from behind.
Maximum bucket width is 3200 mm.
If needed, make a loading ramp from the
material to reach the feeder better.
Drive the LT105 as near the pile as possible to
make loading fast and easy.
Figure 7.2.2 Load the material in the feeder
NOTICE:Feed er has two ap plications rear end on the solid bottom
stapilizing the feed and separating the fine
material before jaw crusher. Over filled feeder
will not separate the fine material and that will
reduce capasity.
3/98 7-28-B 7-3

7.3 DISCHARGE ARRANGEMENT
ALTERNATIVES
— Wheel loader
— Stack conveyor
— Additional process
— Lokotrack (secondary) h
Check the height and volume of the discharge

pile. Never let pile rise to the conveyor. The
distance between the pile and conveyor must
be always at least 200 mm (9") (figure 7.2.1).
When discharging with the wheel loader, be
careful not to damage the conveyor. Discharge Figure 7.3.1 The distance (h) between the pile
from the side, do not push the material under and conveyor must be always at least 200 mm
the LT105. (9").
The material coming from vibrating chute can
be directed to the main conveyor or side
conveyor with the control plate.
7-4 7-28-B 3/98

7 .3 .1 EXTENDET DISCHARGE
CONVEYOR
TRANSPORT TO CRUSHING CRUSHING TO TRANSPORT
— Turn hydraulic output switch/on — Turn hydraulic output switch/on
— Remove transport locking — Remove crushing position. Lockink
Lift slightly conveyor to allow easy pin at their places
locking pin removed Lift slightly conveyor to allow easy
— Turn the conveyor drivehead to locking pin removed
crushing position — Lower the conveyor drivehead to
— Mount locking pins at their places. transport position
Head of the pin must be inside the — Mount transport lockings at their
conveyor frame places
— Reset trip wire switchies. — Switch hydraulic output switch OFF
Adjust tighness if needed
— Secure side rubber position at the
both joint
— Switch hydraulic output switch OFF
NOTE! Drive the LT105 extremely carefully to low bed due to reduced ground clearance at
coveyor end.
Figure 7.3.2 Transport to crushing
Figure 7.3.3 Crushing to transport
3/98 7-28-B 7-5

7.4 CRUSHING
Remove the transport locking of the side

conveyor (optional). Turn the side conveyor
down with the controls located in the drive
control box (figure 7.4.1).
Figure 7.4.1 Turn the side conveyor down by connecting driver control to plug located
in hydraulic module
7-6 7-28-B 3/98

Turn the side walls of the feed hopper up and Turn the rear wall of the feed hopper up. Lock
lock them with the wedges and chains (figure it first with lower wedge. Then fasten the
7.4.2). Fasten the first wedge of the right hand upper wedges and lock them with bolts (figure
side from the service platform and the left 7.4.3).
hand side standing on the tracks. Don’t go
under the wall. Remove the transport locking of the feeder
figure 7.4.4).
Figure 7.4.2 Turn the side walls of the feed hopper up
Figure 7.4.3 Turn the rear wall of the feed Figure 7.4.4 Remove the transport locking of
hopper up the feeder.
3/98 7-28-B 7-7

Turn the light pole up (figure 7.4.5).

Ensure that the crusher is operated only in safe
manner and when in good mechanical
condition. Ensure that the crusher is standing
properly and will not overturn.
The operation of the crusher must only be
allowed, when all necessary protective and
safety devices, e.g. guards, emergency stop
devices, silencers, aspirators etc. are in place
and in operating condition.
Before starting the crusher, ensure that there
are no persons in the area whose safety may be
endangered! Walk around the machine and
ensure that there is nobody on, by or below the
machine. Warn everybody in the vicinity
before starting.
Figure 7.4.5 Turn the light pole up
7-8 7-28-B 3/98

Starting the crusher — Turn on the light if necessary.

Before starting always ensure that the crusher
cavity is empty. If there is material on the Stop the crushing process by pressing the
cavity. Clear the cavity as instructed in shapter "Process stop" button.
7.8.
NOTE! When stopping the crushing process,
When the crushing has started, the RPM speed the automatic control takes care of stopping
of the diesel engine cannot be adjusted by the the equipment, delays, watching for any
operator before the crushing process is troubles and adjusting the diesel engine RPM
stopped again. speed. The stopping of the crushing process
takes about one minute.
Start the crushing process as follows:
When the crushing process is running, the side
1. Select the optional equipment to be started: conveyor (optional) can be stoppped by
— If you want to use the side conveyor turning the "side conveyor" switch to position
(optional) in the crushing process, 0 and restarted by turning the switch to
lower the conveyor and lenghten it to position 1.
operating position and turn the "side
conveyor" -switch to position 1. The magnetic separator can be stopped by
NOTE! If the switch is in position 0, turning the "magnetic separator" switch to
the side conveyor cannot be turned position 0 if desired. It can be restarted by
on during the crushing process. turning the switch to position 1 despite of the
— If you want to start the magnetic state of the crushing process.
separator (optional) when starting the
crushing process, turn the "magnetic The stacker conveyor cannot be stopped or
separator" -switch to position 1. started by turning the "stacker conveyor"
NOTE! If the switch is in position 0, switch.
the magnetic separator will not Load some material on the feed hopper when
engage when starting the crushing the vibrating chute is running. See further
process. instructions in chapter 7.6 "Feed control".
— If you want to use the stacker
conveyor (optional) during the When loading with wheel loader, the feed
crushing process, turn the "stacker hopper must be almost empty before loading
conveyor" -switch to position 1. more material in the hopper. When loading
NOTE! If the switch is in position 0, with excavator you can load more buckets at
the stacker conveyor cannot be the time.
turned on during the crushing process.
See the crusher instruction manual for details
2. Start the crushing process with the in crushing and removal of blockages.
selected options by turning the In case of emergency press "Emergency
"process start" switch. stop"-button to stop the LT105 (Figure 7.4.6).
NOTE! When starting the process, the After having pressed the "Emergency
automatic control takes care of starting the stop"-button, the key switch must be turned to
devices, delays, watching for any troubles and "0" before it is possible to restart the machine.
adjusting the diesel engine RPM speed. The
Don’t try to crush oversized feed, that is too
starting of the crushing process takes about
large for the cavity. Having to reposition rock
one minute after the process switch has been
wastes time, reduces capacity, and imposes
turned.
unnecessary loads on the crusher.
— Connect the water supply (if needed).
Clay, wood and any non-stone-based material
3/98 7-28-B 7-9

must be prevented from entering the crusher.

These could cause blockage in the crusher
cavity and overloading which may damage the
crusher.
Note ! Uncrushable material must be
prevented from entering the crusher. This may
overload and damage the crusher. Make sure
no explosives enter the crusher.
Figure 7.4.6 "Emergency stop" - buttons
NOTE! Side conveyor must not switched on

if in transportation position
7-10 7-28-B 3/98

7.5 CRUSHING PARAMETERS
SETTING
See the crusher instruction manual for further
instructions.
DIRECTION TO THE SIDE CONVEYOR
The material flow under the feeder grizzles
can be directed to the main conveyor 3
(fig.7.5.1), to the optional side conveyor
(fig.7.5.2) or to the optional screen deck
(fig.7.5.3). Turn the lever to change the flow
direction. When using center position, lock the
lever with a bolt.
Figure 7.5.3 The material flow is screened and
directed either to the side conveyor (passing)
or to the main conveyor.
Figure 7.5.1 The chute is directed to the main

conveyor
Figure 7.5.2 The chute is directed to the side

conveyor
3/98 7-28-B 7-11

7.6 FEED CONTROL
The feeder can be stopped and restarted again Increase the capacity, i.e. the speed of the
during the crushing process. The starting and feeder by turning the "capacity" regulator
stopping buttons of the feeder are located in slowly clockwise until the desired feeder
the control box on the service platform. If the speed has been reached.
machine has radio control (optional), the Decrease the capacity, i.e. the feeder speed by
feeder can be started and stopped with radio turning the regulator counterclockwise.
control.
NOTE! When the process is running, the
Stop and restart the feeder as follows: automatic control takes care of stopping and
1. Stop the feeder during the crushing restarting the feeder if the crusher speed
process by pressing the "feeder stop" decreases or the level indicator (optional) of
button. the crusher gives an alarm.
2. Restart the feeder after it has stopped NOTE! Feeder’s too big feeding capacity can
completely by pressing the "feeder cause falling of rocks over the flanks of
start" button. hoppers.
NOTE! The feeder starts automatically when

the process is started and stops always when
the process is stopped.
The feeder always starts at full speed
regardless of the speed setting in order to
maximize the capacity. After a while the speed
changes to the set value.
In order to control the capacity, the feeder
speed can be adjusted the "capacity" regulator.
The regulator is located in the control box on
the service platform.
7-12 7-28-B 3/98

7.7 MINIMUM SETTING
The hardness of the crushed material will

effect to min setting. Ref. C-Jaw instruction
manual for setting ranges.
FEED MATERIAL
Feed sizes depending on the material:
Concrete 0...550 mm (22").
Concrete with rebars 0...550 mm(22"), the
maximum length of the rebars 500 mm(20")
and max. diameter is 20 mm(3/4").
Construction rubble (mixed, including fines)
0...550 mm(22").
Bricks 0...550 mm(22").
Rock 0...550 mm(22").
Asphalt 0...550 mm(22") (only if the Figure 7.7.1 Measuring the material
temperature is below +10° C(50° F) and the dimensions.
bitumen content is low).
Slag 0...550 mm(22").
Th e fi gu re 7.7.1 shows the material
dimensions.
3/98 7-28-B 7-13

7.8 CLEARING OF THE BLOCKAGE 7.9 REMOVAL OF THE STEEL
Note! Never try to clear the blockage with the Always stop the machine (feeder, crusher,
excavator. conveyors and engine) before removing
metal from it. Ensure that it can not be started
If the crusher stops, follow these instructions: during removing metal from it.
— Stop the process immediately Use the hook to remove iron bars and wires.
— The machine is equipped with the over run Be very careful not to hurt yourself. Never use
panels that can be used to overrun hook when the machine is running.
interlocks and use separately the crusher,
feeder, main conveyor and magnetic
separator without starting the whole
process. The buttons are located in the
separate overrun controlbox. The device
will run when the swich is turned on down
and stop immediately when the switch
turned off.
— The engine rpm. must be adjusted
manually to max. From cable control unit.
— Feeder speed can not be adjusted, It runs
at max speed.
— Connect the overrun controlbox.
— Make sure the main conveyor is running.
— Clear the blockage by swinging the
crusher pitman to both directions until it
turns over on reverse direction.
NOTE! The safety devices and alarm controls

are switched off when using this control
method, not counting the safety wires of the
conveyors. Use separate control only in
exceptional situations or when servicing the
machine. Always make sure when starting any
of th e devices that no personnel are
endangered.
NOTE! Do NOT use this method if the rock
is too big to pass under the magnetic separator!
NOTE! Over ride panel is ment to clear the
blockage and too keep the unit operational at
plc-control failure
7-14 7-28-B 3/98

7.10 INTERLOCKS
Some functions of the machine are interlocked

with each other to prevent damages and
injuries. When the interlock has stopped
something, find out the reason, fix it and
restart.
Here is the list of the interlocks and action
when they occur:
The engine gets too hot
— The engine stops in 1 minute.
— Process stops automatically.
The engine oil pressure gets too low

— The engine stops.
The oil level in the hydraulic tank gets too

low
— The engine stops.
The oil in the hydraulic tank gets too hot

— The feeder stops immediately.
The material rises to the level indicator

— The feeder stops. It starts
automatically again when the
material level is lowered.
The crusher runs too slowly

— The feeder stops. It starts
automatically again when the crusher
runs at full speed.
NOTE! If the oil is cold, the crusher speed can

not rise enough to permit the feeder start. In
this case wait and let oil get warmer.
3/98 7-28-B 7-15

7.11 RECYCLING position START or STOP.
In recycling applications the metal objects NOTE! The crushing process must be
should be removed from the feed before stopped when using the hydraulic output. The
entering the crusher. hydraulic output switch must be in STOP
position before restarting the side conveyor
A man should stand beside the feeder and and the feeder.
collect the metal pieces. Be very careful when
touching the feed material. The feeder must INTERMEDIATE CABLE FOR
be stopped when removing large objects. SECONDARY UNIT
Never go to the feeder. Unit is equipped with 6-pin socket allowing
The most efficient way is to prepare the feed information transfer between primary and
material and remove all the metal from it secondary unit. Socket X140 has three
before loading it to the LT105. different functions:
The optional magnetic separator can be used Intermediate cable is optional. (Order no:
for the removal of small metal objects. 923909)
Figure 7.11.1 Removal of metal objects in recycling application.
7.12 OPTIONAL EQUIPMENT Pins 1&2: When connected LT105 gets

information that secondary unit is connected.
LEVEL INDICATOR
Pins 3&4: Feeder on/off information
The purpose of the level indicator is to control (secondary feed/emergency functions can be
the feed material level in the crusher. The connected to this). Normally open contact
indicator stops the feeder and gives light required.
signal when the material level is too high. The
indicator resets automatically. Pins 5&6: For secondary unit’s level sensor.
Function similar as the level detector in
Keep the level indicator clean to ensure LT105(feeder runs 10 sec. with mininum
proper function. speed if "high cavity level" noticed. Speed is
set automaticly back or feeder is stopped if
HYDRAULIC OUTPUT alarm won’t disappear during the 10sec
The hydraulic output can be set on and off by period). Normally closed contact required.
turning the "Hydraulic output" switch to
7-16 7-28-B 3/98

Maintenance Nordberg LT105
0$,17(1$1&(
8.1 PERIODICAL MAINTENANCE
Carry out periodical maintenance according to given operating hours rather than given period.
Note: Grease lubrification specification NLGI EP 2.
Every 12 months
Every 6 months
When needed
Monthly
Weekly
Daily
DIESEL ENGINE
Change engine oil every 200 operating

X
hours.
Change oil filter every 200 operating

X
hours.
Drain water from fuel. X
Change the primary fuel filter every

X
1000 operating hours.
Change fine fuel filter every 1000

X
operating hours.
Check the service indicator of the air

filter. Change the cartridge if
X
necessary. Change the safety cartridge
every third time.
See the engine operating manual for

X
other maintenance.
JAW CRUSHER
Check V-belt tension. X
Check the tightness of the jaw bolts

daily during the first 40 operating hours X X
after jaw installation. Then weekly.
Check the tightness of cheek plate

X
bolts.
3/98 8-13-B 8-1

Nordberg LT105 Maintenance
Every 12 months
Every 6 months
When needed
Monthly
Weekly
Daily
Check the side guide plates and the
X
protection rubber of the toggle plate.
Lubricate crusher drive jack shaft

X
10g/40h/bearing
Check wear on the jaw plates. X
Check the sound, temperature (max.

75°C/ 167°F) and grease flow in the X
eccentric bearings.
Lubricate eccentric shaft bearings. X
Check wear on the cheek plates. X
Check toggle plate for aligment,

X
straightness and cracks.
Check toggle seats, clean as

X
necessary.
Check the tightness of the mounting

bolts of the labyrinth covers and the
frame bearings.
Check the tightness of the frame tie

X
rods.
Check the mounting of the flywheel. X
Check the tightness of the frame

X
mounting bolts on the side plates.
Check the bearings on the eccentric

X
shaft.
Check for any wear on the contact

X
surfaces of the pitman and front frame.
8-2 8-13-B 3/98

Every 12 months
Every 6 months
When needed
Monthly
Weekly
Daily
Check for any wear on the contact
surfaces between the side plates and X
cheek plates.
MECHANICAL SETTING ADJUSTMENT
Lubricate the cap nuts of the setting

X
adjustment device.
Check the rubber covers. X
AUTOMATIC LUBRICATING DEVICE
Check operation and grease amount

X
(add grease if necessary).
VIBRATORS
Lubrification 10g/200h/bearing X
FEEDER
Clean vibration unit from outside. X
Check tightness of vibration unit joints. X
Check the wires/hoses. X
CONVEYORS
Lubricate the bearings of head and tail

X
pulleys. 5g/40h/per bearing
Check the belt tension. X
HYDRAULICS
Check the oil level. X
Check the oil temperature (max 90 °C /

X
194°F).
3/98 8-13-B 8-3

Every 12 months
Every 6 months
When needed
Monthly
Weekly
Daily
Check the fixing bolts of all
X
components.
Check pipes and hoses. X
Change hydraulic oil every 2000

X
operating hours.
Clean the hydraulic tank every 2000

X
operating hours.
Check the breather of the hydraulic

X
tank.
FINAL DRIVE
Check oil level. X
Change oil X
BATTERY
Check fluid level. X
Check the cleanliness of the battery

X
terminals.
TRACKS
Check tension of track chains. X
Check tightness of track bolts. X
MAGNETIC SEPARATOR
Lubricate the bearings. 3g/40h/Bear. X
Check the belt tension. X
8-4 8-13-B 3/98

8.2 RUNNING-IN
See the crusher instruction manual for further — Teboil Tebo Hydraulic Oil 32 S
details.
In su mmer time e.g. in hot climate
conditions, when the ambient temperature
8.3 HYDRAULICS exceeds +35°C(95°F), the use of a special
hydraulic oil of ISO VG 68 class is
Basic requirements for the hydraulic oil
recommended. The max. allowable operating
quality:
temperature with this oil type is about
— viscosity index should be min. 150 +90°C(194°F) and min. allowable
— min. viscosity 16 cSt at operating starting temperature is about -10°C
temperature (14°F).
— max. viscosity 1000 cSt at starting
temperature Attached some examples of oil brands
meeting these requirements:
Unless otherwise mentioned, the factory fill — BP Energol SHF 68
oil is a special hydraulic oil of ISO VG 46 — Mobil DTE 16
cl ass. Th e m ax . all owab le o perat ing — Teboil Tebo Hydraulic Oil 68
temperature with this oil type is about +80°C
(176°F) and m in. al lowabl e start ing
temperature is about -20°C(-4°F), which Oil amount is 400 litres (105.7 gal) .
makes it suitable for use all year round in 8.3.1 HYDRAULIC ADJUSTMENTS
most operating conditions.
All components are set to operate at optimal
Attached some examples of oil brands speed. If adjustments is needed it is allowed
meeting these requirements: only for Nordberg authorizet person.
— BP Energol SHF 46 Factory set speeds:
— Esso Univis N 46
— Shell Tellus Oil T 46 Crusher 300 rpm
— Teboil Tebo Hydraulic Oil 46 Main conveyor 1,7-2,0 m/s
— Mobil DTE 15 (5,6-6.6 f/s)
Side conveyor 2,4-2,6 m/s
(7,7-8,5 f/s)
In winter time e.g. in cold climate conditions, Magnet conveyor 1,5-1,7 m/s
when the operating temperature of the oil stays (4,9-5,6 f/s)
below +60°C (140°F), the use of a special
hydraulic oil of ISO VG 3 2 class is
recommended. The max. allowable operating
temperature with this oil type is about +65°C
(149°F) and m in. al lowabl e start ing
temperature is about -30°C (86°F).
Attached some examples of oil brands
meeting these requirements:
— BP Energol SHF 32
— Esso Univis N 32
— Mobil DTE 13
— Shell Tellus Oil T 32
3/98 8-13-B 8-5

8.4 FINAL DRIVE 8.5 FUEL LEVEL
Change final drive oil after first 150 operating The fuel level can be checked from the fuel
hours. After that every 1500 operating hours. gauge in the control panel (figure 8.5.1). Fuel
Oil amount is 4.5l (1.2 gal). Oil quality is ISO tank capasity 600l (160gal).
VG 220.
Figure 8.5.1 Checking the fuel level
8-6 8-13-B 3/98

8.6 CRUSHER SPACER REMOVAL/

ASSEMBLY WITH HYDRAULIC
SETTING DEVICE(OPTIONAL).
NOTE! Open crusher setting as open as

possible before removal/assembly with
hydraulic setting device.
— Turn the operating-switch from

0-position to service position.
— Open the service valve.
— Lock the adjustin wedge see C105B
/5.11.
— Open wedges by turning switch from
service position to +-position(switch
will return to service position).
— Pitman moves forward automaticly.
— Remove/assemble the spacer on it’s
place.
— Pressurize the wedge equipment by
turning switch to 0-position.
— Pitman moves backward.
— Close the service valve.
3/98 8-13-B 8-7

8.7 FILLING VOLUMES
Oil amounts in litres and gallons.
LOKOTRACK
LT105
Hydraulics 520 l / 140 gal
Final drive 4,5 l / 1,2 gal
Fuel tank 600 l / 160 gal
DIESEL ENGINE
VOLVO CATERPILLAR
TD 100G TWD 1031 VE 3306

Engine oil 25 l / 6,6 gal 27 l / 7,2 gal 24 l / 6,3 gal
Water 40 l / 10,5 gal 45 l / 12 gal 40 l / 10,5 gal
8-8 8-13-B 3/98

8.8 Tracks
Tension
— Check track chains are properly Frame
tensioned (figure 8.8.1). Adjust as Check the welded structure for cracks or weld
necessary. See the correct chain failures, and carry out any necessary repairs as
deflection in the drawing 8.8.1. soon as possible.
Measure in the middle of main pulley
and idler. To tension tracks pump Track shoe bolt torque
more grease into regulating cylinder — With lubricant:
with a grease gun. Correspondingly, 304-358 Nm / 220-259 lbs/Ft
the tracks are loosened by letting
grease flow out through the opened
grease nipple and moving the — Without lubricant:
Lokotrack if needed. 365-430 Nm / 264-311 lbs/Ft
— Check track shoes for damage.
FIGURE 8.8.1 Check track chains are properly tensioned. The correct deflection (X) is 35 mm
3/98 8-13-B 8-9

8.9 LUBRICANT RECOMMENDATION — FINA

— Giran L 220
This section contains information and — FUCHS
instructions on several alternative and — Renolin AWD 220
optional equipment. Normally Lokotracks — KLÜBER
have only some of them. Before maintaining — Lamora 220
and servicing, find out which alternative and — KUWAIT
optional equipment your Lokotrack has. — Q8 Goya 220, El Greco 220
— MOBIL
— Mobilgear 630, SHC 220
8.10 CRUSHER — PANOLIN
— EP Gear Synth 220
See further instruction in your crusher manual. — TEXACO
— Syngear 220
— TOTAL
— Varter EP 220
8.11 FEEDER/SCREEN
See further instruction in your feeder/screen 8.13 GREASE

manual.
The grease must be NLGI EP 2 Type. Grease
containing Molybdenum additives in NOT
8.12 TRACK GEAR recommented.
— Oil designation to DIN 51517, part 3:

CLP 220.
— ISO viscosity to DIN 51519: ISO -
VG 220.
— Kinematic viscosity at 40°C(104°F):
Min. 198 mm2/s (cSt). Max. 242
mm2/s (cSt).
— FZG test A /8,3/90 to DIN 51354, p.
2: Min. breakdown load stage 12.
Recommended brands are e.g.:

— AGIP
— Blasia 220
— ARAL
— Degol BG 220
— AVIA
— Gear RSX 220
— BP
— Enersyn HTX 220
— CASTROL
— Alphasyn T 220, Aplha ZN 220
— DEA
— Trion EP 220, Intor HCLP 220
— ELF
— Reductelf SP 220, Elf Epona Z 220
8-10 8-13-B 3/98

Service instructions Nordberg LT105
6(59,&(,16758&7,216
9.1 GENERAL
Only skilled and experienced mechanics must Do not check for leaks with a bare hand, use
be allowed to service the plant. suitable cleaning cloth.
In any work related to the operation, Never adjust any hydraulic valve beyond the
adaptation to manufacture, conversion or pressure recommended by the manufacturer.
adjustment of the Lokotrack and its safety
equipmen t, as wel l as to inspection, Always ensure adequate ventilation when
maintenance and repair, observe starting and running the engine in a confined area.
stopping procedures in accordance with the
Instruction Manual and any indications Remember that some solvent qualities may
relating to maintenance work! cause skin irritation and may be extremely
inflammable. Avoid breathing of solvent
Secure extensively, as far as necessary, the fumes.
area of maintenance works!
Service facilities must be kept clean. Oil and
In case the Lokotrack is completely switched water can make floors slippery and highly
off during maintenance and repair works, it dangerous. Avoid severely soiled clothing,
must be safeguarded against unexpected they can be a fire hazard.
switchin g-o n. Lo ck -up main starting
equipment, draw off keys and affix a hazard Keep the Lokotrack and equipment free from
pictorial at the main switch. oil spillage and dust. A clean machine reduces
the fire risk and simplifies visual checks for
Smoking and any open flame is prohibited in components requiring attention.
the immediate area of the machine when
refuelling or servicing the fuel system. Be careful when using pressure cleaning
equi pment. Even low pressures and
In case of fire: temperatures can damage wire insulation.
— Move the Lokotrack away from the Check wiring for signs of abrasion damage or
dangerous area chaffing. This can cause short circuits and fire.
— Stop the engine
— Turn off the main switch Check hydraulic hoses for abrasion damage or
— Start fire fighting and give the alarm if chaffing.
necessary.
Never weld or gr ind containers of
Diesel fuel is flammable - do not use as inflammable liquids.
cleaning fluid. Use solvents of accepted
quality only. Always have a fire extinguisher on hand when
carrying out welding or grinding operations.
Always stop the engine during maintenance
unless it is mentioned in the instruction Noti fy the location and use of fire
manual to keep the engine running. extinguishers.
4/99 9-07-B 9-1

Nordberg LT105 Service instructions
9.2 BATTERY MAINTENANCE Batteries must always be maintained as far as

possible at full charge. If the charge is allowed
Fluid level check to remain low, the plates will become
sulphated reducing the capacity and efficiency
The fluid level in the batteries must be checked of the whole battery.
every 100 operating hours (figure 10.2.1). The
level should be approximately 10 mm(1/4") Remember that a half-charged battery will
above the plates. Add clean distilled water as freeze at a temperature of -25°C(-13°F) and a
required. Monitoring the fluid consumption flat one at only -10°C(14°F).
will give an indication of the charge of the
battery, but a separate test of the specific Never use an open flame when checking the
gravity of the acid will confirm the state of acid level of a battery. The gases given off by
charge. If the fluid consumption is high it is the chemical reaction during the recharging
possible for the alternator charging rate to be process are highly inflammable.
too high.
The liquid used in lead-acid batteries is dilute
sulphuric acid. This acid is corrosive and will
cause severe burns to exposed skin and will
damage clothing. Be very careful when
handling a battery.
Cleaning batteries, terminals and cables
Batteries and terminals must be cleaned at

least once per year. The terminals and the
cable ends should be cleaned with the special
tools which will restore the contact area to the
right form and size. After cleaning, the
FIGURE 9.2.1Check battery fluid level every terminals and cable ends should be liberally
100 operating hours. Add clean distilled water covered with petroleum jelly to protect against
in the accumulator as required oxidation. Check also the fastening of: battery
earth cables to the main frame, engine starter
cables, and electrical connections for the
alternator. Clean and tighten as necessary.
Battery check Keep battery cases clean and dry.
The level of charge in the battery must be
checked regularly using a Hydrometer. Do not
make this check immediately after adding any
distilled water to the battery; the water and
acid will be more evenly mixed after some
charging has taken place. The specific gravity
of a fully charged battery is approximately
1.28, and if only half-charged the reading will
be about 1.2. These values relate to a battery
temperature around +20°C(68°F).
9-2 9-07-B 4/99

Service instructions Nordberg LT105
9.3 OTHER ELECTRICAL EQUIPMENT
Charging circuit
Starter circuit
— Check and tighten connections regularly.
Normally the starter circuit requires little
— The alternator requires only periodic attention, but all components should be kept
attention. clean and electrical connections tight. The
batteries are an essential part of the electrical
It is important to strictly follow the system and are required to be kept fully
instructions for protecting the alternator: charged, clean and topped up properly to
maintain the acid level. Battery cables must
— Do not remove battery cables or any other also be checked for tightness and kept clean
connections in the charging circuit while and greased.
the engine is running.
— Never start the engine if any wire in the

charging circuit is disconnected or loose. 9.4 WELDING
— Whenever the batteries are charged using If any welding is to be done on the machine,
an external source, the earth lead to the care must be taken to protect sensitive
frame must be disconnected from the electrical equipment.
battery. When reconnecting batteries,
using jumper leads or a charger, be sure to — Stop the engine.
identify the correct polarities.
— Turn the main switch OFF.
— Always disconnect the batteries when
servicing the electrical equipment of the — Disconnect the earth lead to the batteries.
Lokotrack.
— Fasten the earth cable of the welding
— Do not cause a short circuit in any part of apparatus as close to the part to be welded,
the system, nor take a test reading with an as possible and make sure that no welding
instrument with low internal resistance. current is able to pass through any bearings
or electrical equipment.
If auxiliary batteries are used to assist engine
start, make sure that:
— batteries have the same voltage
— the correct poles are connected
4/99 9-07-B 9-3

Troubleshooting Nordberg LT105
7528%/(6+227,1*
Engine won’t start

Invalid start Start by the instructions
Emergency stop button depressed Reset (ref. emergency stop relay

indicators)
(To be able to see the indicators the

electrical cabinet must be open)
Check the E-stop relay indicator and release

the e-stop buttons
Out of fuel Add fuel
Hydraulic oil level too low Add oil

Locate/replace
Fuse blown Change fuse
Hydraulic valves closed Open valves (Ref: Emergency

stop relay indicators)
Engine coolant water level too low Add water
Engine stops
Emergency stop button has been pushed Check
Out of fuel Add fuel
Engine too hot (1 minute delay) Find out reason
Engine coolant water level too low (1 minute delay) Add water
Engine oil pressure too low Find out reason
4/99 10-09-B 10-1

Nordberg LT105 Troubleshooting
Hydraulic oil level too low Add oil
Main conveyor won’t start

Emergency wires pulled Check
Main conveyor stops

Emergency wires pulled Check
Too high pressure Check
Belt loose Tighten
Crusher won’t start

Belts broken Change belts
Conveyor not started Check
Crusher stops
Belts broken Change belts
Faulty speed control sensor Check
Crusher jammed Speed too low
Feeder won’t start

Crusher cavity full and the
level switch (option) gives alarm Empty cavity
Crusher speed too low Check crusher speed and reason
10-2 10-09-B 4/99

Troubleshooting Nordberg LT105
Feeder stops
Crusher cavity full and the level
switch (option) gives alarm Empty cavity
Crusher speed too low (overload) Empty cavity
Magnetic separator won’t start or stops

Side conveyor won’t start

Plug not attached Attach the plug
Side conveyor stops

Plug not attached Attach the plug
When driving the machine won’t move

Wrong way of driving Drive by the instructions
When driving the machine won’t turn

You are driving too fast Slow down
(fast->normal->slow)
depending of the terrain
4/99 10-09-B 10-3

Appendix A Lokotrack
6<0%2/,'(17,),&$7,216
1. General symbols
1. Starting 2. Stopping 3. Connecting 4. Disconnecting
5. Increases 6. Decreases 7. Stepless adjustable 8. Warning

movement
9. Warning: 10. Warning: 11. Grease 12. Oil

pressurized electric danger lubrication point lubrication point
13. Running hours 14. Lifting point 15. Noise signal 16. Level
17. Belt conveyor 18. Feeding 20. Check 21. Max. temperature
7/96 appenda A-1

Lokotrack Appendix A
2. Electric symbols
1. Remote control 2. Battery charging indicator
3. Lights
1. Working lights 2. Driving lights
4. Engine
1. Engine emergency2. Stopping of engine 3. Engine running 4. Combustion

stop speed engine
5. Starting of engine
A-2 appenda 7/96

1. Fuel volume 2. Fuel pressure 3. Fuel filter 4. Fuel shut-off
5. Fuel refill
5. Fuel
1. Oil level 2. Oil refill 3. Oil pressure 4. Oil temperature
5. Oil filter
6. Engine oil
7. Cooler system
7/96 appenda A-3

Lokotrack Appendix A
8. Transmission oil
1. Coolant refill 2. Coolant level 3. Coolant pres 4. Coolant

indicator temperature
9. Hydraulic oil
1. Oil refill 2. Oil level indicator 3. Oil pressure 4. Oil temperature
5. Oil filter 6. Testing point: oil pressure

10. Air
11. Symbols not included in the ISO standard
A-4 appenda 7/96

1. Hydraulic oil refil 2. Hydraulic oil level 3. Hydraulic 4. Hydraulic

oil pressure oil temperature
5. Hydraulic oil filter 6. ressure

P testing 7. Shut-off valve
1. Air intake 2. Air pressure 3. Air filter
1. Tensioning of power 2. Tightening of 3.emove

R / install 4. Check / tighten
transmission belt nuts and bolts transport locking concave bolts
7/96 appenda A-5

Nordberg LT105
$'',7,21$/,1)250$7,21
GUARDS AND PROTECTION DEVICES
— Belt drives are guarded.

— The feed opening to the crusher is guarded.
— Conveyor head and tail drum nip points are guarded.
— Conveyors are equipped with emergency stop cables and safety switches or valves.
— Emergency stop buttons are provided on the remote control box and service platform and in
the electrical centre and cabin.
EMERGENCY STOP
If a dangerous situation occurs, pull the nearest emergency stop cable or push an emergency stop
button. After pulling an emergency stop cable, the trip switch will remain engaged and a signal
light will show. To reset, push the button in the switch. To reset an emergency stop button, pull
the red button to its outer position. Before restarting the machine ensure the area is clear around
the unit and that no one will be endangered by your action. Start the machine according to the
instruction manual.
DISPOSAL OF WASTE
Waste materials, such as oil, battery acids and cleaning fluids etc. must be removed carefully
using suitable containers to prevent any hazard to people, animals or environment. The hazardous
material must be removed to a suitable waste collection plant for disposal or recycling.
FIRE
The Manufacturer has not provided this machine with a fire extinguisher, and recommends that
the user equips the machine with an extinguisher of a type approved by his local authorities.
Inflammable materials used in the construction and use of this machine include: diesel and
lubricating oils, conveyor belting and skirts, electrical cables and fittings, etc.
STORAGE OF THE MACHINES
The machine must be stored in a dry and covered area.
DISPOSAL OF THE MACHINE
Whenever a machine is taken out of use, being dismantled or disposed of, all hazardous materials,
such as oils, battery acids, fuels etc. must be carefully removed first to eliminate any danger to
life and the environment. The hazardous materials must be removed to a suitable waste collection
plant for disposal or recycling. Dispose of the machine so that there is no danger to life or the
environment.
1/99 12-00-B B-1

Lokotrack
12,6(/(9(/6
Noise levels in excess of 85 dBA around the Lokotrack while running are shown in the diagram
below. Ear protection must be worn in this area.
12/94 12-01-I C-1

Recycling
5(&<&/,1*
If the machine is used for recycling, pay attention to the following:
1. Preprocessing of the feed material
Break the feed material small enough and cut the metal bars to 0.5 - 1 metres long depending
on the machine. Too long bars may damage the conveyor belt.
2. Feeding the material
Remove the metal objects from the feed, if possible. At least remove the loose metal. The
metal objects larger than the crusher setting must not enter the crusher. When removing the
metal objects be very careful. Never go to the feeder when the machine is running. Observe
the feed material. Never let the uncrushable objects enter the crusher.
3. Removal of the blocking
Be very careful when clearing the blocking. Stop the machine and use safety valve or switch
during clearing.
8/95

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1RUGEHUJ/7

3. MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

4. CONTROL PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

5. STARTING AND STOPPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

6.4 TRANSPORT FROM SITE TO SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

7.9 REMOVAL OF THE STEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

8.6 CRUSHER SPACER REMOVAL/ ASSEMBLY WITH HYDRAULIC SETTING

8.11 FEEDER/SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

9. SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

ADDITIONAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1/95 1-00-B 1-1

WARNING SYMBOLS not intended to replace safety codes, insurance

Particular attention must be given to prevent

12/97 2-01-B 2-1

2-2 2-01-B 12/97

something that needs attention, THINK improper readings are observed.

12/97 2-01-B 2-3

5 KEEP YOUR POCKETS FREE of EQUIPMENT

2-4 2-01-B 12/97

Save your back. what type of fire. Check regularly - at

12/97 2-01-B 2-5

2-6 2-01-B 12/97

12/97 2-01-B 2-7

L OCAL LAWS, ESPECIALLY ON cavity by hand.

2-8 2-01-B 12/97

3.1 MAIN ASSEMBLY

2/99 3-38-B 3-1

3.2 DIESEL ENGINE 3.8 MAGNETIC SEPARATOR

The LT105 moves with the tracks. The tracks

The Nordberg C105B jaw crusher is the heart

The feeder ensures even and continuous

3.6 MAIN CONVEYOR

The main conveyor transfers the crushed

3.7 SIDE CONVEYOR (OPTIONAL)

The optional side conveyor transfers the

3-2 3-38-B 2/99

3.9 HYDRAULIC VALVE LOCATION

1 Throttle valve 16 Disch. conv.

2/99 3-38-B 3-3

4.1 MAIN CONTROL PANEL 8. Radio control 0/1

2/99 4-38-B 4-1

4.2.1 CABLE CONTROL UNIT 4.2.2 SIDE WALL AND CONVEYOR

4-2 4-38-B 2/99

4.3 REMOTE CONTROL

2/99 4-38-B 4-3

4.4 OVER RIDE CONTROLS

Over ride controls can be used to temporary

4-4 4-38-B 2/99

5.1 BEFORE STARTING

Check the condition of the machine.

Figure 5.1.1 Lift the exhaust pipe up

Figure 5.1.2 Turn the light pole up

1/98 5-38-B 5-1

Figure 5.1.3 Check crusher V-belt tensions

5-2 5-38-B 1/98

5.3 STOPPING THE DIESEL ENGINE

Stop the diesel engine by turning the key

5.4 ADJUSTING ENGINE RPM SPEED

1RUGEHUJ/7