Mobile single-shaft shredder TERMINATOR Model : Type : TERMINATOR 3400D / 3400SD / 5000D/ 5000SD / 6000D Serial number : 183 042 Year of construction : 2014 Copyright 2011 KOMPTECH Umwelttechnik GmbH. All rights reserved. Printed: 03/2011 Translation of the original instructions: ID 1104333 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
Contents Safety regulations (separate handbook) 1. Safety and dangers Technical specifications (separate handbook) 2. Preface 3. Product identification Operating manual 4. Setting up, commissioning, transport... 4 4.1. Check the machine upon delivery... 4 4.1.1. Delivery status... 4 4.1.2. Scope of supply... 4 4.2. Setting up the machine... 5 4.2.1. Unloading / uncoupling... 6 4.2.2. Ambient conditions for operation... 7 4.3. Preparations for operation... 7 4.3.1. Personnel training... 7 4.3.2. Dangers during commissioning... 8 4.3.3. Safety zones... 9 4.3.4. Operation... 10 4.3.5. Daily preparatory work... 10 4.4. Commissioning the machine... 11 4.4.1. Warm-up phases... 13 4.4.2. Control elements of the rear control panel... 14 4.4.3. Bring the machine into operating position... 15 4.5. Transport instructions... 20 4.5.1. Preparations for transport... 21 4.5.2. Bring the machine into transport position... 22 5. Operation... 23 5.1. Main control panel... 23 5.2. Operating elements of the main control panel... 24 5.3. Relocation... 33 5.3.1. Hook with hauling device (optional)... 33 Page 2 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
5.3.2. Hook with feed device (optional)... 34 5.3.3. Trailer with feed device (optional)... 35 5.4. Operating elements of mobile versions... 36 5.5. Wireless remote control... 38 5.6. Controls of the wireless remote control... 39 5.7. Operating elements of the wireless remote control for mobile versions... 44 5.7.1. Track (optional)... 44 5.7.2. Hook with hauling device (optional)... 45 5.7.3. Hook with feed device (optional)... 45 5.7.4. Trailer with feed device (optional)... 46 5.8. Service interval reminder... 46 5.9. Optimization of the shredding mode... 47 5.9.1. Optimizing the drum speed and the engine speed... 47 5.9.2. Optimizing operating procedures... 48 5.9.3. Selection of the shredding program... 49 5.9.4. Cycle times for program 9... 50 5.10. Switching off the machine... 51 5.11. Stopping the machine in cases of emergency... 52 Index... 53 Maintenance instructions (separate handbook) 6. Maintenance 7. Maintenance instructions 8. Faults, causes and remedies 9. Dismantling/disposal Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 3 of 54
4. Setting up, commissioning, transport This chapter describes the preparations required before and during transport, transferring the machine upon delivery, correct setting up as well as instructions for the commissioning of the machine itself. 4.1. Check the machine upon delivery. 4.1.1. Delivery status Check the machine as soon as it has been delivered to ensure the full scope of supply has been delivered and to verify possible transport damage: The product documentation will be delivered with the machine. The machine will undergo a final inspection before delivery and is fully functional. 4.1.2. Scope of supply The speciation of the machine you purchased may differ from the functional units and components described in the operating manual. Please take note of your sales contract in this respect. Page 4 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
4.2. Setting up the machine Danger of electrocution. Death and very severe injuries may occur. Make sure that no power supply line is in the swivel range of the discharge belt. Overturning and loss of stability of the machine. Death and very severe injuries may occur. Make sure that the high position of the center of gravity is taken into account for the setup of the machine. The machine dimensions are provided in the model photographs in the handbook "Technical specifications". Observe the local safety and accident prevention regulations when setting up the machine. Make sure that there is enough space available to set up and operate the machine. Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 5 of 54
Select a horizontal and solid surface to set up the machine. If the ground is slightly sloped, take appropriate measures to ensure that the machine is stable. Take appropriate measures to prevent the machine from sinking into soft ground. Make sure that all control panels are and remain easily accessible. Please remember not to block emergency escape routes! Only authorized persons using the compulsory protective equipment are permitted access to the danger areas. Observe all safety distances to other equipment and make sure that no other objects such as high-voltage power lines, other machines, etc. are within the machine's danger zone. 4.2.1. Unloading / uncoupling HOOK TRACK TRAILER The machine is equipped with lifting eyes. Use suitable lifting tools (lifting straps or chains) and lift the machine from the lowloading truck by means of a crane. Slowly drive the machine down the loading platform via the ramp by means of the wireless control unit. The machine tilts at the breakpoint between the loading platform and the ramp. Do not navigate while the machine tilts! Maximum ramp incline of 12 ( 20% )! Lock the connection pipes (lighting, brake), lower the supporting leg and uncouple the trailer. Page 6 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
4.2.2. Ambient conditions for operation Global use (mobile, outdoor). Optimum temperature range: from -10 C to +37 C (from 14 F to 99 F). 4.3. Preparations for operation 4.3.1. Personnel training No commissioning before factory-provided initial operation. Users are trained how to operate the machine during transfer. The training course has to include the following elements: Safety briefing Operating elements, machine functions Explanations about the use of the operating manual. Request to use the operating manual. Making, checking and changing basic settings Briefing about initial operation (hot startup) Maintenance instructions Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 7 of 54
4.3.2. Dangers during commissioning Operating manual Danger of burning and scalding. Death and very severe injuries may occur. Make sure that the hydraulic hoses are visually inspected and that the screw connections are checked before commissioning. Danger of electrocution. Death and very severe injuries may occur. Make sure that there is no power supply line in the vicinity of the machine when setting up the machine. Page 8 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
4.3.3. Safety zones Respective safety zones have to be maintained: Intrusion of unauthorized persons in the danger zone. Death and very severe injuries may occur. If unauthorized persons enter the danger zone, the operation has to be stopped immediately and unauthorized persons have to be taken away from the danger zone. 1 Access permitted to trained personnel observing the safety regulations. Unauthorized persons are not permitted to enter this area. 2 A Access to trained personnel only when: the machine is switched off and it is secured from unauthorized switch-on. Work area Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 9 of 54
4.3.4. Operation Operation stands for the application of the machine for the purpose of shredding specified materials (see handbook Technical specifications ). If the machine was preset correctly (drum speed, shredding program, engine speed, etc.), it is not necessary for the operating person to intervene. A change of the material or the occurrence of extraneous materials may require a setting adjustment. The respective functions are available during operation. Measures such as servicing or maintenance are not encompassed by the operation section of the machine and described in the handbook Maintenance Instructions. 4.3.5. Daily preparatory work Check the stability of the machine. Ensure the required machine condition. (Inspection of the safety equipment, inspection of the functionality of the control elements, etc.) Ensure the general readiness for operation of the engine and the machine. (Refill the fuel, check the coolant level and engine oil level, check the indication instruments.) Check all operating materials (hydraulic oil level, lubricant level of the central lubrication system, lubricating points, oil level in planetary gear sets and transfer boxes) Inspect the machine for damage and carry out required repairs immediately. Check cooling fins of the water cooling systems and the hydraulic oil cooling system for staining and clean these elements if required. Check the fuel pre-filter and drain it if required (in case of water in the inspection glass). Clean the engine compartment or keep it dust-free. Page 10 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
You can find a detailed description of the functions of your machine in the handbook Technical Specifications. 4.4. Commissioning the machine ACTIVATE THE BATTERY MAIN SWITCH Switch on the battery main switch (switch is parallel to the housing, see following image for details) to activate the power supply to the control panel. "switched on" RELEASE THE EMERGENCY-STOP BUTTON (11) All EMERGENCY-STOP SWITCHES must be released before the machine can start. IGNITION ON (55) Insert the ignition key into the ignition (55) of the main control panel and turn it from 0 to 1. Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 11 of 54
DISPLAY ON (20) The display (20) switches on when the ignition (55) is on. The display (20) will initially show the version number of the software. Then the display (20) changes to the main screen. WAIT FOR THE LAMP TEST (1) - (10) Wait for the lamp test. All control displays, (1) to (10), have to light up and go out. (Exception: load control (1) will not go out) START (55) Turn the ignition key to the START position. The machine starts. Take your hand off the key as soon as the engine starts. The key will turn to position 1. The repeat-start lock prevents the ignition from being restarted. First return the ignition key to 0 (ignition off) and repeat the aforementioned procedure to start the engine again. Page 12 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
4.4.1. Warm-up phases Non-compliance with the warm-up phase. A machine breakdown may occur. Comply with the warm-up phases of the respective ambient temperature, particularly with regard to low temperatures! Warm-up stage depending on the ambient temperature Engine oil types SAE 0W40 Engine oil types SAE 5W40-25 C -13 F -20 C -4 F -15 C 5 F -10 C 14 C 0 C 32 F 10 C 50 F 20 C 68 F 30 C 86 F 40 C 104 F You must warm up the machine before beginning work: begin with the lowest engine speed switch on the shredding unit after 10 minutes (in neutral gear without material) increase the engine speed after another 5 minutes You must warm up the machine before beginning work: begin with the lowest engine speed switch on the shredding unit after 5 minutes (in neutral gear without material) increase the engine speed after another 5 minutes Please inquire if the ambient temperature is outside the ranges mentioned above! Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 13 of 54
4.4.2. Control elements of the rear control panel The rear control panel must be used in order to bring the machine into operating position. It is located in the left rear sheet plate housing next to the discharge belt. You can find the control elements for the rear machine components on the bottom control panel. Close the rear hopper wall and run in the telescope walls. Open the rear hopper wall and extend the telescope walls. Steepen the discharge belt or shut it. Level or shut the discharge belt. Reverse the extraction belt (function is only available during maintenance). Moving forward the two conveyor belts (function is only available during maintenance). Page 14 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
Lower the transferring magnet (optionally) and bring it into operating position. Lift the transferring magnet (optionally) and bring it into operating position. 4.4.3. Bring the machine into operating position Unlock the transferring magnet (optionally) and slew it aside before you bring the discharge belt into operating position! Slew the transferring magnet back and lock it after opening the discharge belt. The machine has a maximum height of approximately 7.5m (25ft) during the opening process of the discharge belt. Make sure that there is enough space for this process! Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 15 of 54
1. Transport position with transferring magnet (optional) 2. Swung out transferring magnet Page 16 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
3. Fold out the discharge belt 4. Return and lower the transferring magnet Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 17 of 54
5. Fold up the side guiding rail (1) and lock it. Open the two lower conveyor belt doors (2). Illustration without optional transferring magnet Page 18 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
Open the side hopper walls first and then the rear hopper wall! The front hopper wall can be brought into position as required. Press the function buttons (38) and (40) on the main control panel to open the left and right-hand side hopper walls. Press the function button (II) on the rear control panel to open the rear hopper wall and to extend the telescope walls. Press the function button (28) on the main control panel to start the shredding unit and the conveyor belts. Now, the machine is ready for operation and can be applied according to its intended use. Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 19 of 54
4.5. Transport instructions Wrong machine use during transport. Death and very severe injuries may occur. The transport of people and loads on the machine is prohibited! Inappropriate transport preparations. Personal or machine damage may occur. Strictly comply with the following instructions for the transport preparation of the machine! Page 20 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
4.5.1. Preparations for transport Prepare the machine according to its mobile version for transport as follows: UNLOADING / COUPLING Hook Track Trailer The machine is equipped with lifting eyelets (provided that it is not transported by means of a hook lift). Use a suitable hoist (lifting straps or chains) and lift the machine by means of a crane onto the low-loading truck. Slowly drive the machine down the loading platform via the ramp by means of the wireless control unit. The machine tilts at the break-point between the loading platform and the ramp. Do not navigate while the machine tilts! Maximum ramp incline of 12 ( 20% )! Set the tow bar and saddle to the correct height, couple the trailer to the towing vehicle (the coupling has to click into place), connect the lead wires (lighting, brakes) and test everything to make sure that the equipment is functioning properly. Secure the machine (also applies to the hook and the track) to prevent tilting, shifting, etc. according to the respective standards (e.g. EN 12195-1 Load Restraint Equipment on Load Vehicles Safety Part 1: Calculation of Lashing Forces ). Comply with all regulations for the towing of trailers / hooks (maximum speed, permissible axle loads, permissible total weight etc.). Comply with all legal regulations for the transport of heavy goods on public roads and adhere to the general safety regulations. Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 21 of 54
4.5.2. Bring the machine into transport position Bring the machine into the specified transport position before transport. Also see section Bring the machine into transport position. Take the following measures in the following order: 1. Close all doors. 2. Pull in the telescope walls and close the rear hopper wall. 3. Close the left and right-hand hopper walls. 4. Fold and lock the side guiding rails. 5. Slew the transferring magnet (optional) aside and fold the discharge belt. 6. Return and lock the transferring magnet (optional). Page 22 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
5. Operation 5.1. Main control panel The main control panel is located to the front left-hand side of the engine compartment door in a lockable control panel. The main control panel contains all machine control elements, control displays, the display for operating notifications and an EMERGENCY-STOP BUTTON. 50 51 a 52 a 53 a 54 a 53 b 54 b Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 23 of 54
5.2. Operating elements of the main control panel If one or several control displays light up, they are also indicated with the respective symbol on the display (20) at the same time. CHARGE INDICATOR (1) The symbol for the charge indicator lights up when the battery is not charging. ENGINE OIL PRESSURE (2) The indicator for the engine oil pressure lights up when the engine oil pressure drops below the threshold value. The engine switches off. COOLANT TEMPERATURE (3) The indicator for the coolant temperature lights up when the coolant temperature is too high. The fan speed and the drum speed are regulated according to the coolant temperature. Controlling the fan speed according to the coolant temperature up to 80 C (176 F) 70% fan speed from 81 C (178 F) 70% fan speed with brief pauses (1.5 s) from 85 C (185 F) Increase in the fan speed by 6% for every 1 C increase from 90 C (194 F) 100% fan speed (in reverse operation always 100%) Controlling the drum speed according to the coolant temperature up to 94 C (201 F) Normal operation of the shredding unit (according to set speed) from 95 C (203 F) Reduction of the drum speed by 10% for every 1 C increase from 99 C (210 F) from 100 C (212 F) from 107 C (225 F) Breakdown of the sensor Drum sped constant at 50% of the maximum value Shredding unit is stopped Engine is stopped Shredding unit is stopped Page 24 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
COOLANT LEVEL (4) The indicator for the coolant level (4) lights up and the symbol shown on the left appears on the display when the coolant level of the engine drops below the threshold value for 10 seconds. The engine switches off. Inspect the machine to establish the reason for the loss of coolant. After establishing the reason for the loss, add sufficient coolant containing 50% antifreeze (also see separate maintenance manual)! AIR FILTER (5) The indicator for the air filter (5) lights up and the symbol shown on the left appears on the display when the air filter is unable to take in sufficient air (e.g. if it is soiled). Clean the air filter! Replace the air filter if the indicator lights up again! HYDRAULIC OIL LEVEL (6) The indicator for the hydraulic oil level (6) lights up and the symbol shown on the left appears on the display when the hydraulic oil level drops below the threshold value. The engine switches off. Inspect the machine to establish the reason for the loss! After establishing the reason for the loss, refill sufficient hydraulic oil! Use the oil level display on the hydraulic oil tank to orient yourself! HYDRAULIC OIL TEMPERATURE (7) The indicator for the hydraulic oil temperature (7) lights up and the symbol shown on the left appears on the display when the hydraulic oil temperature has reached 94 C (201 F). The drum speed is regulated according to the hydraulic oil temperature. Regulation of the drum speed according to the hydraulic oil temperature from 35 C (95 F) up to 90 C (194 F) from 91 C (196 F) from 95 C (203 F) from 96 C (205 F) If a sensor breaks down If several sensors break down Fan is switched on Normal operation of the shredding unit (according to set speed) Reduction of the drum speed by 10% for every 1 C increase Drum sped constant at 50% of the maximum value Shredding unit is stopped Drum speed maximum 50% of the maximum value Shredding unit is stopped Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 25 of 54
When the indicator of the hydraulic temperature lights up, the current temperature is shown when you press the information button twice. PLANETARY GEAR SET OIL LEVEL (8) The indicator for the planetary gear set oil level (8) lights up and the symbol shown on the left appears on the display (20) when the planetary gear set oil level drops below the threshold value. The engine switches off. Inspect the machine to establish the reason for the loss! After establishing the reason for the loss, refill sufficient gearbox oil! GEARBOX OIL TEMPERATURE (9) The indicator for the gearbox oil temperature (9) lights up and the symbol shown on the left appears on the display (20) when the gearbox oil temperature has reached 96 C (205 F). The cooling circulation and drum speed are regulated according to the gearbox oil temperature. Regulation of the drum speed according to the gearbox oil temperature from 105 C (221 F) The shredding unit is stopped if the temperature fails to drop after 15 minutes. NOTE (10) The indicator for general maintenance work (10) lights up and the symbol shown on the left appears on the display (20) when the EMERGENCY-STOP BUTTON (11) was pressed. EMERGENCY-STOP BUTTON (11) In an emergency situation or in case a person or the machine may be in danger, press the nearest EMERGENCY-STOP BUTTON (11) to immediately halt the machine and all its components. Clarify the situation and remedy the danger! Then turn the activated EMERGENCY-STOP BUTTON (11) to the left. This unlocks the switch and the switch will pop back out. The machine can now be started again. Page 26 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
DRUM SPEED (12) The current drum speed is indicated via the light-emitting diodes below the symbol for the drum speed (12). The more light-emitting diodes light up, the higher the drum speed. When the machine is switched off, the last drum speed is saved. The next time the machine starts, the drums operate at this speed. Changing the drum speed: Arrow key (13): Increase the drum speed Arrow key (14): Reduce the drum speed SELECTING THE SHREDDING PROGRAM (15) See selection of the shredding program. WIRELESS REMOTE CONTROL (18) Press the function button (18) to switch to wireless remote control operation. The remote control must be switched on before you can do so. Please also refer to the chapter Wireless remote control. When the green LED next to the function button (18) lights up, can you operate the machine via remote control. MAINTENANCE WORK (19) Press the function button (19) to switch to maintenance mode. See separate handbook Maintenance instructions. Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 27 of 54
DISPLAY (20) The display indicates error messages, warnings and operating modes. The display is activated as soon as the ignition is switched on (turn the ignition key to the right, to position 1 ). Current values are showed on the display (e.g. coolant temperature, engine speed, operating hours). The indicators (1) to (10) light up briefly during the light test. The display will briefly show the software version number and the EA-module number. The display will then switch to the main screen. INFO BUTTON (21) Press the info button (21) to read current values (e.g. hydraulic oil temperature, operating hours of the day) on the display (20). acknowledge operating messages (e.g. fuel capacity MIN ). enter and confirm new values (e.g. engine speed adjustment ). TANK CONTENTS (22) If the contents of the fuel tank drop below the threshold value, the tank symbol appears on the display and the red light warning light appears. Refill the machine as soon as possible! The current fuel content is indicated by the light-emitting diodes below the tank symbol (22). The fewer light-emitting diodes light up, the lower the fuel level in the tank. If you are unable to refill the tank immediately, acknowledge the display message via the info button (21). The display message will be displayed again the next time the engine is started. ENGINE SPEED (23) The current engine speed is indicated by the light-emitting diodes under the engine speed symbol (23) and also indicated on the display (20). If the machine is idling, the engine and drum speed are automatically reduced. If material is filled into the hopper, the engine speed increases to the previous speed setting (also see ECO-Mode, button 49). Changing the engine speed: Arrow key (24): Increase the engine speed Arrow key (25): Reduce the engine speed Page 28 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
STOPPING THE SHREDDING UNIT AND THE CONVEYOR BELTS (26) Press the function button (26) to stop the shredding unit and the conveyor belts. SHREDDING UNIT, CONVEYOR BELTS (27) The light-emitting diodes next to the symbol for the shredding unit and conveyor belts (27) indicate whether these are switched on or off. Red LED: switched off Green LED: switched on STARTING THE SHREDDING UNIT AND THE CONVEYOR BELTS (28) Press the function button (28) in order to start the shredding unit and the conveyor belts. REVERSING THE SHREDDING UNIT (29) Press the function button (29) to manually reverse the rotation direction of the shredding unit (available as button function in maintenance mode). In normal mode, the shredding unit must always be active; switch to forward. MANUAL CONTROL OF THE SHREDDNG UNIT (30) The light-emitting diodes next to the symbol for the shredding unit manual control (30) indicate whether it turns forward or backward. Yellow LED: backward Green LED: forward SHREDDING UNIT, FORWARD (31) Press the function button (31) to manually reverse the rotation direction of the shredding unit to forward (available as button function in maintenance mode). EXTRACTION BELT, REVERSE (32) Press the function button (32) to manually reverse the direction of the extraction belt (only available as button function). The function is used to relieve the machine. Do not use until the shredding process. Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 29 of 54
MANUAL CONVEYOR BELT CONTROL (33) The light-emitting diodes next to the symbol for conveyor belt manual control (33) indicate the direction of the belts. Yellow LED: extraction belt backward, discharge belt forward Green LED: both conveyor belts forward BOTH CONVEYOR BELTS FORWRD (34) Press the function button (34) to manually switch the direction of both conveyor belts to forward (available as button function in maintenance mode). LOWER FRONT HOPPER WALL (35) Decrease the angle of the front hopper wall. LIFT FRONT HOPPER WALL (36) Increase the angle of the front hopper wall. CLOSING THE LEFT HOPPER WALL (37) OPENING THE LEFT HOPPER WALL (38) CLOSING THE RIGHT HOPPER WALL (39) OPERNING THE RIGHT HOPPER WALL (40) Page 30 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
If the ball valve is not switched to the direction of flow (closed), the counter comb remains closed for the shredding mode and can also not be opened in maintenance mode! If the ball valve is switched to the direction of flow (open), the counter comb can be opened or closed by means of the function button (41 or 42). Lock counter comb safety device. To prevent inadvertent closing of the counter comb, the counter comb safety device must be locked. Press the red locking lever (A) to the right and then downward (see images). Counter comb not locked Counter comb locked Danger of crushing due to inadvertent closing of the counter comb. Severe injuries may occur. Lock the counter comb safety device as soon as the counter comb has opened completely. Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 31 of 54
REDUCING THE CUTTING SIZE (41) INCREASE THE CUTTING SIZE (42) PREPARING THE RELOCATION (47) See relocation. COMPLETING THE RELOCATION (48) See relocation. ECO MODE (49) When ECO mode is active, the engine speed automatically drops when the load is reduced to save fuel. We recommend leaving the ECO mode active! In the case of materials which are easy to crush or materials which incur small motor load fluctuations only, the ECO mode should be deactivated. MOISTENING EQUIPMENT (50) (OPTIONAL) Press the function button (50) to moistening the material during the shredding process. Page 32 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
5.3. Relocation 5.3.1. Hook with hauling device (optional) When towing the machine with a towing vehicle, the towing angle of 70 (maximum of 85 for a brief period only) must not be exceeded as this will result in increased wear on the tires and tow bar. PREPARING THE RELOCATION (47) Press the function button (47) or the function button on the remote control to extend the two reels. COMPLETING THE RELOCATION (48) Press the function button (48) or the function button on the remote control to retract the two reels. Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 33 of 54
5.3.2. Hook with feed device (optional) Operating manual Danger of crushing due to running-in tow wheels. Death and very severe injuries may occur. Keep a sufficient distance to the machine when the tow wheels are extended. Using the optional feed device, you can move the hook forward or backward without a tow vehicle. PREPARING THE RELOCATION (47) Press the function button (47) or the function button on the remote control to extend the back tow wheels and the front support wheels. When the function button (53 b) is pressed, a signal tone resounds and the machine moves forward as long as the button remains pressed (button mode). When the function button (54 b) is pressed, a signal tone resounds and the machine moves backwards as long as the button remains pressed (button mode). 20 seconds after you release the function button (53 b) Forward drive or the function button (54 b) Reverse drive, a signal tone resounds and the support and tow wheels are automatically retracted. Page 34 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
You can also use the hook with feed device with a towing vehicle to move the hook into the desired operating position. In this case, the hook may not be moved with the feed device shortly before as the tow wheels will only be retracted automatically after 20 seconds! Start the machine before towing! The engine must be running so that the brakes can be released. Comply with the maximum towing speed of 6km/h (3.8mp/h)! Always drive the towing vehicle to the hook! If you move the hook to the towing vehicle with the feed device, the towing wheels of the hook may retract automatically while the machine is being towed! COMPLETING THE RELOCATION (48) Press the function button (48) or the function button on the remote control to retract the back tow wheels and the front support wheels. 5.3.3. Trailer with feed device (optional) The machine can be moved with the feed device only as long as there is sufficient air in the pressure reservoir of the trailers to air the brake. In case of too high loss of pressure, a drawing vehicle with a suitable compressed air system has to be used to move the machine further or to refill the pressure reservoir. The trailer must be secured by means of a stop-block while the pressure reservoir is refilled. With the optional feed device, you can move the trailer forward and backward without a towing vehicle. Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 35 of 54
PREPARING THE RELOCATION (47) Press the function button (47) or the function button on the remote control to adjust the tow wheels to the wheels of the trailer. The drawing vehicle can now be attached. After removing the stop-block and releasing the brake valve, the feed device can be activated. When the function button (53 b) is pressed, a signal tone resounds and the machine moves forward as long as the button remains pressed (button mode). When the function button (54 b) is pressed, a signal tone resounds and the machine moves backwards as long as the button remains pressed (button mode). After relocation the brake valve must be locked and the trailer must be secured by means of the stop-block. A towing vehicle may be attached afterwards if required. COMPLETING THE RELOCATION (48) Press the function button (48) or the function button on the remote control to retract the towing wheels from the tires. 5.4. Operating elements of mobile versions The following functions are available for the main control panel according to the respective scope of delivery. MOVE THE MACHINE FORWARD (53 b) MOVE THE MACHINE BACKWARD (54 b) Page 36 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
TRACK LEFT FORWARD (51 a) Press the function button (51 a) to move the left-hand crawler forward. The machine moves forward in a right-hand bend. TRACK RIGHT FORWARD (52 a) Press the function button (52 a) to move the right-hand crawler forward. The machine moves forward in a left-hand bend. MOVING THE MACHINE FORWARD (51 a) + (52 a) Press the two function buttons (51 a) + (52 a) at the same time to drive the machine straight on. TRACK LEFT BACKWARD (53 a) Press the function button (53 a) to move the left-hand crawler backward. The machine moves in a right-hand bend. TRACK RIGHT BACKWARD (54 a) Press the function button (54 a) to move the right-hand crawler backward. The machine moves in a left-hand bend. MOVING THE MACHINE BACKWARD (53 a) + (54 a) Press the two function buttons (53 a) + (54 a) at the same time to drive the machine straight on. Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 37 of 54
5.5. Wireless remote control Operating the machine by means of the remote control constitutes an increased safety risk. Death and very severe injuries may occur. Adhere carefully to the safety instructions, and pay special attention that third persons stay a sufficient distance away from the machine! The wireless remote control is located in the engine compartment door, front left, in a lockable control cabinet directly next to the main control panel. You can control the most important machine functions by means of the remote control. Wireless remote control hook / hook with hauling device / hook with feed device / trailer / trailer with feed device Wireless remote control track Page 38 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
5.6. Controls of the wireless remote control The MACHINE STOP BUTTON on the wireless remote control can only be used if the wireless remote control is active and a wireless remote connection has been established. The functions of the wireless remote control are only active within the transmission range. If the transmission range is left, the red light of the machine lights up and the shredding unit and the conveyor belts are switched off, the engine turns to idling mode. As soon as the radio contact is established again, the red light of the machine goes out and the shredding unit can be restarted. The engine only increases to its previous speed after the drum-on button was pressed. If the MACHINE-STOP BUTTON of the wireless remote control is not unlocked, the machine engine switches off during the shifting process. Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 39 of 54
MACHINE-STOP BUTTON (A) ON THE WIRELESS REMOTE CONTROL Press the MACHINE-STOP BUTTON on the wireless remote control (A) to stop the engine. Turn the locked MACHINE-STOP BUTTON (A) to the right to start the machine again. This releases the MACHINE-STOP BUTTON (A), which will jump back into position. The machine can not be started again. SWITCHING ON THE WIRELESS REMOTE CONTROL (R) Press the function button (R) to activate the wireless remote control. DRUM FORWARD (B) Press the function button (B) to switch the rotation direction of the drum to forward (function only available in maintenance mode). SWITCHING ON AND OFF THE SHREDDING UNIT AND THE CONVEYOR BELTS (C) Press the function button (C) to switch on/off the shredding unit and the conveyor belts at the same time. The shredding unit switches off first. The conveyor belts continue to run until the machine is empty and stop after a delay. SHREDDING UNIT BACKWARD(D) Press the function button (D) to switch the rotation direction of the shredding unit to backward (function only available in maintenance mode). EXTEND THE TRAILING ARMS (E) EXTEND THE FORWARD DRIVE WHEELS (E) PRESS ON THE SUPPORTING WHEELS (E) See Wireless remote control for mobile versions. Page 40 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
REVERSING THE SHREDDING UNIT (F) Press the function button (F) to switch the rotation direction of the shredding unit to backward. The shredding unit will turn in reverse as long as the button remains pressed (button mode). RUN IN THE TRAILING ARMS (G) RUN IN THE FORWARD DRIVE WHEELS (G) SWIVEL OUT THE SUPPORTING WHEELS (G) See Wireless remote control for mobile versions. OPENING THE LEFT-HAND HOPPER WALL (H) Press the function button (H) to open the left-hand hopper wall. OPENING THE RIGHT-HAND HOPPER WALL (I) Press the function button (I) to open the right-hand hopper wall. UNFOLDING THE DISCHARGE BELT (J) Press the function button (J) to unfold the discharge belt and to bring it into operating position. Press the function button (J) to decrease the operating angle of the discharge belt. CLOSING THE LEFT-HAND HOPPER WALL (K) Press the function button (K) to close the left-hand hopper wall. Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 41 of 54
CLOSING THE RIGHT-HAND HOPPER WALL (L) Press the function button (L) to close the right-hand hopper wall. FOLDING UP THE DISCHARGE BELT (M) Press the function button (M) to increase the working angle of the discharge belt. Press the function button (M) to fold up the discharge belt and to bring it into transport position. REDUCE THE CUTTING SIZE (N) Press the function button (N) to reduce the cutting size between the drum and the counter comb. MOISTENING EQUIPMENT (O) Press the function button (O) to moistening the material during the shredding process (function only available if your machine has moistening equipment). INCREASE THE CUTTING SIZE (P) Press the function button (P) to reduce cutting size between the drum and the counter comb. Page 42 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
WIRELESS REMOTE CONTROL DISPLAY (Q) You can see the following operating modes on the wireless remote control display: DISPLAY Red, flashing point Rapidly flashing L (standing for LOW). The exterior segments rotate clockwise. No indication on the display OPERATING MODE Ready for operation Battery capacity runs out (capacity for only approx. 15 minutes of remote control operation) During the switching-off after pressing the MACHINE- STOP BUTTON (approx. 2 seconds). The machine was switched off by pressing the MACHINE-STOP BUTTON or the battery is flat. Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 43 of 54
5.7. Operating elements of the wireless remote control for mobile versions Different functions of operating elements for options. Personal or machine damage may occur. Please note that the function buttons of the wireless remote control have different functions for tracks, hooks with hauling devices and hooks with feed devices in operating mode than in maintenance mode. 5.7.1. Track (optional) LEFT-HAND TRACK FORWARD (B) Press the function button (B) to move the left-hand crawler forward. The machine moves forward in a right-hand bend (function only available in operating mode). RIGHT-HAND TRACK FORWARD (D) Press the function button (D) to move the right-hand crawler forward. The machine moves forward in a left-hand bend (function only available in operating mode). MOVING THE TRACK FORWARD (B) + (D) Press the two function buttons (B) + (D) at the same time to drive the machine forward in a straight line (function only available in operating mode). Page 44 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
LEFT-HAND TRACK BACKWARD (E) Press the function button (E) to move the left-hand crawler backward. The machine reverses in a right-hand bend (function only available in operating mode). RIGHT-HAND TRACK BACKWARD (G) Press the function button (G) to move the right-hand crawler backward. The machine reverses in a left-hand bend (function only available in operating mode). MOVING THE TRACK BACKWARD (E) + (G) Press the two function buttons (E) + (G) at the same time to reverse the machine in a straight line (function only available in operating mode). 5.7.2. Hook with hauling device (optional) If your machine has a HOOK with hauling device (optional), the towing wheels may be extended by means of the function button (E) and run in by means of the function button (G) (These functions are only available in operating mode). See also Section Relocation. 5.7.3. Hook with feed device (optional) If your machine has a HOOK with feed device (optional), you can press the function button (B) on the remote control to move the machine forward and the function button (D) to reverse it. The function button (E) is used to extend the back forward wheels and the front supporting wheel and the function button (G) is used to run in them (These functions are only available in operating mode). See also Section Relocation. Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 45 of 54
5.7.4. Trailer with feed device (optional) Operating manual If your machine has a TRAILER with feed device (optional), you can press the function button (B) to move the machine forward and the function button (D) to move it backward. The function button (E) is used for the pressing on and the function button (G) is used to swing the tow wheels (These functions are only available in operating mode). See also Section Relocation. 5.8. Service interval reminder You received a Service Log Book with your machine. You are required to perform the maintenance work described in this book (see separate maintenance manual ). 30 operating hours before the next maintenance is due, a first message will appear on the INFO display (20) reminding you to perform the maintenance work. Every time you start the machine within the next 50 operating hours, the message Note! Service interval! will be displayed again until you perform the maintenance work! Service work: Perform the service work according to the instructions contained in the accompanying handbook Maintenance manual and make a note of the work performed in the service log book. Page 46 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
5.9. Optimization of the shredding mode If you change the programs while the shredding unit rotates, the new program will only start after you stop and re-start the shredding unit. You can operate the machine using presetting (drum speed, shredding program, engine speed, activated ECO-mode, etc.). However, you can also directly intervene for optimization and change the settings during drive mode. 5.9.1. Optimizing the drum speed and the engine speed Arrow key (13): Increase the drum speed (12) Arrow key (14): Reduce the drum speed (12) Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 47 of 54
Arrow key (24): Increase the engine speed (23), e.g. when the machine runs at low revs due to the respective material or the material load slows down the drum speed too strongly. Arrow key (25): Reduce the engine speed (23), e.g. when the machine runs at high revs due to the respective material or an insufficient material load makes the shredding unit run too quickly. Deactivate the ECO-mode (49) if you do not wish automatic reduction of performance due to an insufficient material load. 5.9.2. Optimizing operating procedures In some operating situations, you can directly influence the operating mode of the machine and avoid failures in this way! Press the function button (29) in case of temporary stiffness or imminent blockage of the shredding unit. The rotating direction of the shredding unit will be switched to reverse. Press the function button (29) in case of temporary stiffness or imminent blockage of the extraction belt. Do not use until the shredding process. The extraction belt will be switched to reverse. Page 48 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
5.9.3. Selection of the shredding program The selection of the suitable shredding program (15) strongly depends on the material you wish to shred. The programs differ in terms of different lengths of cycle times for reserve and forward (drum rotation direction). You can operate the machine with the predefined programs 0 8 or the self-definable program 9. The selected program is indicated by the respective light-emitting diode. Select the desired program by means of the arrow keys (16) and (17). The program is activated when switching off- and on the shredding unit. CYCLE TIMES IN SECONDS Program Drum moves forwards Drum moves backwards 0 60 5 1 60 10 2 120 5 3 120 10 4 180 5 5 180 10 6 240 5 7 240 10 8 300 5 9 Minutes and seconds adjustable Seconds adjustable Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 49 of 54
5.9.4. Cycle times for program 9 Operating manual Press the function button (26) to stop the shredding unit and the conveyor belts. Press the function button (26) and one of the two arrow keys (13) or (14) at the same time to access the setting mode. Press the top arrow key (16) to move the cursor to the right to access the program selection. Press the bottom arrow key (17) to move the cursor to the right to access the program selection. Press the top arrow key (24) to increase the value. Press the bottom arrow key (25) to reduce the value. Press the info button (21) to confirm the selected program and to leave the setting mode of program 9. Page 50 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
5.10. Switching off the machine Conveyor belts or shredder units standing still due to a blockade. Severe injuries may occur as the machine may suddenly start when the blockade is removed. Note that stationary conveyor belts or a stationary shredder unit does not necessarily indicate that the machine is switched off. Wrong switching off of the machine. Machine damage may occur. Only use the ignition key and not the battery main switch to switch off the machine. The machine must be completely empty and the shredding unit must be stopped before the machine may be switched off. An idle run of the engine after the shredding process is necessary to prefent turbo troubles. SWITCHING OFF Turn the ignition key in the ignition lock (55) to 0. The engine is stopped. Remove the ignition key! Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 51 of 54
5.11. Stopping the machine in cases of emergency Emergency due to failure of the machine. Death and very severe injuries may occur. Press the nearest EMERGENCY-STOP BUTTON to stop the machine and its components immediately in cases of emergency or threatening personal or machine damage. The MACHINE STOP BUTTON on the wireless remote control can only be used if the wireless remote control is active and a wireless remote connection has been established. You will find one EMERGENCY-STOP BUTTON (11) on the top right-hand side of the operating panel, the MACHINE- STOP BUTTON (A) on the wireless remote control as well as 2 further EMERGENCY-STOP BUTTONS behind the machine on the left-hand or right-hand side next to the discharge belt. Page 52 of 54 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc
Index Battery main switch... 11 Commissioning... 4 Conveyor belts... 29, 30, 41, 42, 51 Counter comb... 31 Coupling... 21 Danger zone... 9 Dimensions... 5 Display... 12 Drum speed... 24, 25, 27, 47 ECO-Mode... 32, 48 Emergency-stop-button... 11, 26, 51, 52 Escape routes... 6 Fan speed... 24 Functions... 11 Gearbox oil temperatur... 26 Hook with feed device... 34 Hook with hauling device... 33 Hopper... 14, 19, 30, 41 Hydraulic oil temperature... 25 Hydraulik oil level... 25 Ignition... 11 Installation site... 6 Machine stop button... 40 Main control panel... 23 Maintenance work... 27 Motor speed... 28, 48 Operating elements... 23, 24, 39 Optimization shredding mode... 47 Optionen... 36, 44 Preparations for operation... 7 Preparatory work... 10 Relocation... 32, 33, 45, 46 Repeat-start lock... 12 Safety zones... 9 Scope of supply... 4 Screen basket... 42 Service interval... 46 Setting up... 4 Setting up the machine... 5 Shredding program... 49 Start... 12 Switching off the machine... 51 Techical specifications... 5 Technical Specifications... 11 Temperature range... 7 Trailer with feed device... 35 Transferring magnet... 15 Transmission range... 39 Transport... 4 Transport instructions... 20 Use conditions... 7 Wireless remote control... 27, 38 Betriebsanleitung_Bedienungsanleitung_Terminator_Diesel_4T_V2_en_PI4485_2_1255554.doc Page 53 of 54
Komptech Umwelttechnik GmbH Kühau 37 A-8130 Frohnleiten [t] +43 3126 59207-0 [t] +43 3126 59207-7777 [e] info@komptech.com Komptech GmbH Kühau 37 A-8130 Frohnleiten [t] +43 3126 505-0 [t] +43 3126 505-505 [e] info@komptech.com www.komptech.com