Premiertrak 400 - R400 (T4) Operations Manual Revision 1.0 (En)

Premiertrak 400/R400 (T4)
Operations Manual
SUBJECT TO CHANGE WITHOUT PRIOR NOTICE

Original Instructions
Copyright TEREX GB Ltd
Issue Date: 30-Nov-2012

Language: English (en)
Revision No.: Rev 1.0
Terex Powerscreen,
200 Coalisland Road,
Dungannon, Co. Tyrone,
N. Ireland, BT71 4DR
+44 (0) 28 87 718 500
+44 (0) 28 87 747 231
Email: sales@powerscreen.com
www.powerscreen.com
Record of Revisions
Record of Revisions
Revision
Number Reason for Change Date
1.0 Introduction of the new manual layout and pre-screen 30-Nov-2012
option.
Operations Manual Revision 1.0 30-11-2012

Premiertrak 400/R400 Page 1
Record of Revisions
Intentionally Left Blank
30-11-2012 Revision 1.0 Operations Manual

Page 2 Premiertrak 400/R400
Table of Content
Table of Content
1 Introduction................................................................................................. 1-2
1.1 Notes to the Operations Manual.....................................................................1-2
(1) Units...........................................................................................................1-2
(2) Optional Equipment....................................................................................1-2
1.2 Safety Information...........................................................................................1-3
(1) Safety Warning Symbol..............................................................................1-3
(2) ANSI Hazard Classification System...........................................................1-3
(3) California Proposition 65 Warnings............................................................1-3
1.3 Intended Use...................................................................................................1-4
1.4 Prohibited Use.................................................................................................1-4
1.5 Declaration of Conformity................................................................................1-4
1.6 Copyright.........................................................................................................1-4
2 Safety........................................................................................................... 2-2
2.1 General Safety................................................................................................2-2
(3) Description of Safety Symbols....................................................................2-3
2.2 Positions of Safety Signs on the Machine.......................................................2-8
2.3 Personal Safety.............................................................................................2-22
(1) Personal Protective Equipment................................................................2-22
2.4 Work Area Safety..........................................................................................2-23
(1) General Work Area Guidelines.................................................................2-23
(2) Safety Warnings and Labels.....................................................................2-23
(a) Modifications........................................................................................2-23
(3) Transportation Safety...............................................................................2-23
(4) Operation Safety.......................................................................................2-24
(5) Hydraulic and Pneumatic Safety..............................................................2-25
(6) Electrical Safety........................................................................................2-25
(7) Maintenance Safety..................................................................................2-26
(a) Maintenance and Repairs During Operation; Disposal of Parts and
Consumables.......................................................................................2-26
(8) Gas, Dust, Steam, Smoke........................................................................2-27
(9) Hazardous Substances............................................................................2-28
(10) Noise Levels.............................................................................................2-28
3 Technical Data............................................................................................. 3-2
3.1 Dimensions......................................................................................................3-3
(1) Working Range Diagrams...........................................................................3-3
(2) Transport Diagrams....................................................................................3-5
(3) Working Range Diagrams For Pre-Screen Model......................................3-7
(4) Transport Diagrams For Pre-Screen Model................................................3-9
3.2 Noise Levels.................................................................................................. 3-11
(1) Tier 4 Noise Levels................................................................................... 3-11
3.3 Operating Temperature Range......................................................................3-12
3.4 Machine Specifications..................................................................................3-12

Table of Content
3.5 Machine Components...................................................................................3-13

(1) Machine Components Specifications.......................................................3-14
(a) Vibrating Feeder..................................................................................3-14
(b) Bypass Conveyor (Standard VGF Model)............................................3-14
(c) Power Unit...........................................................................................3-14
(d) Magnetic Conveyor..............................................................................3-14
(e) Discharge Conveyor............................................................................3-14
(f) Tracks..................................................................................................3-15
(g) Jaw Crusher.........................................................................................3-15
(h) Feed Hopper........................................................................................3-15
(i) Dust Sprays.........................................................................................3-15
(j) Pre-Screen (Optional)..........................................................................3-15
(k) Short Pan Feeder.................................................................................3-15
3.6 Crusher Capacity...........................................................................................3-16
4 Machine Description................................................................................... 4-2
4.1 General Information.........................................................................................4-2
4.2 Systems...........................................................................................................4-3
(1) Electrical System........................................................................................4-3
(a) Power Unit.............................................................................................4-3
(2) Crushing System........................................................................................4-3
(a) Chutes....................................................................................................4-3
(b) Dust Suppression Sprays......................................................................4-3
(3) Conveying System......................................................................................4-4
(a) Discharge Conveyor..............................................................................4-4
(b) Dirt Conveyor.........................................................................................4-4
(4) Vibrating Feeder.........................................................................................4-4
(5) Maintenance Walkways..............................................................................4-4
(6) Chassis.......................................................................................................4-4
(7) Guards........................................................................................................4-4
4.3 Control and Display Elements.........................................................................4-5
4.4 Machine Information Decals............................................................................4-6
4.5 Optional Equipment.........................................................................................4-9
5 Transportation............................................................................................. 5-2
5.1 Preparation Prior to Transportation.................................................................5-2
5.2 Placing the Machine into the Transport Position.............................................5-3
(1) Placing Discharge Conveyor into the transport position.............................5-3
(2) Placing the dirt conveyor into the transport position (Standard Models)....5-5
(3) Placing the dirt conveyor into the transport position (Pre-Screen Models).5-7
(4) Placing the hopper flares into the transport position (Standard Models).. 5-10
(a) Placing the hopper flares into the transport position (Pre-Screen
Models)................................................................................................5-12
(5) Placing the platform ladders into the transport position............................5-15
5.3 Loading..........................................................................................................5-16
5.4 Unloading......................................................................................................5-17
5.5 Transport Tie-Down Points............................................................................5-18

Table of Content
6 Initial Setup and Adjustments................................................................... 6-2

6.1 Initial Inspection...............................................................................................6-2
6.2 Location Considerations..................................................................................6-2
6.3 Setting Up The Machine..................................................................................6-3
6.4 Initial Setup......................................................................................................6-4
(1) Placing the Discharge Conveyor into working position...............................6-4
(2) Placing the hopper flares into working position (Standard Model).............6-6
(a) Placing the hopper flares into working position (Pre-Screen Model).....6-8
(3) Placing the Dirt Conveyor into the working position (Standard Model).... 6-11
(4) Placing extended dirt conveyor into working position (Pre-Screen Model).6-13
(5) Placing the platform ladders into the working position.............................6-16
6.5 Adjusting the crusher discharge opening......................................................6-17
(1) XA Model..................................................................................................6-17
(2) XR Models................................................................................................6-20
6.6 Setting up and using the Fuel Transfer Pump (Optional).............................6-23
6.7 Setting up and using the Water Pump (Optional).........................................6-25
6.8 Setting up the Deflector Plate (Optional)......................................................6-26
6.9 Initial Startup and Running In........................................................................6-28
7 Standard Operating Procedures............................................................... 7-2
7.1 Pre-Operating Checks.....................................................................................7-2
7.2 Start Up...........................................................................................................7-3
(1) Starting the Engine.....................................................................................7-3
7.3 Manoeuvring....................................................................................................7-5
(1) Umbilical Tracking......................................................................................7-6
(2) Remote Tracking........................................................................................7-8
7.4 Standard Operation.......................................................................................7-10
(1) Putting the Machine into Operation..........................................................7-10
(a) Manual Mode.......................................................................................7-10
(b) Auto Mode............................................................................................7-15
(c) Setting the Vibrating Feeder to Local or PDM Mode...........................7-18
7.5 Introducing Material to the Machine..............................................................7-21
7.6 Shutdown......................................................................................................7-22
(1) Manual Shutdown.....................................................................................7-22
(2) Automatic Shutdown.................................................................................7-25
7.7 Blocked Crusher............................................................................................7-26
(1) Stalled Crusher Procedure.......................................................................7-27
8 Emergency Operating Procedures............................................................ 8-2
8.1 Lockout and Tagout.........................................................................................8-2
(1) Before Carrying out any Work on the Plant................................................8-2
(2) After Carrying out Work on the Machine.....................................................8-4
8.2 Emergency Stop..............................................................................................8-5
8.3 Restarting after Emergency Stop....................................................................8-6
9 Maintenance................................................................................................ 9-4
9.1 Safety Before and During Maintenance..........................................................9-4

Table of Content
(1) Diesel Engine.............................................................................................9-6

(2) Crusher.......................................................................................................9-6
(3) Feeder........................................................................................................9-7
(4) Discharge Conveyor...................................................................................9-7
(5) Dirt Conveyor (Optional).............................................................................9-7
9.3 General Machine Maintenance Schedule.......................................................9-8
(1) First 8 Hour Maintenance Schedule...........................................................9-8
(2) Daily Maintenance (10 Hour) Schedule......................................................9-9
(3) Weekly Maintenance (50 Hour) Schedule................................................9-10
(4) First 100 Hour Maintenance Schedule.....................................................9-12
(5) Every 200 Hour Maintenance Schedule...................................................9-12
(6) Monthly Maintenance (250 Hour) Schedule.............................................9-13
(8) Monthly Maintenance (1000 Hour) Schedule...........................................9-14
9.4 Tier 4 Engine Maintenance Schedules..........................................................9-16
(1) First Time at First Start.............................................................................9-16
(2) Daily Maintenance Schedule....................................................................9-16
(3) Maintenance Schedule At Interval (50 Hours)..........................................9-16
(4) Maintenance Schedule At Interval (250 Hours)........................................9-16
(5) Maintenance Schedule (First time at 500 Hours).....................................9-16
(7) Maintenance Schedule at Interval (1000 Hours)......................................9-17
(10) Maintenance Schedule (Annually)............................................................9-18
(11) Maintenance Schedule (Every 5 Years)...................................................9-18
9.5 Greasing Schedule........................................................................................9-19
9.6 Recommended Lubricants............................................................................9-20
(1) Grease Lubrication...................................................................................9-20
(2) Hydraulic Oil and Antifreeze.....................................................................9-20
(3) Recommended Lubricants For the Gearbox on the Tracks......................9-21
(4) Engine......................................................................................................9-21
(5) Vibrating Feeder Lubrication.....................................................................9-22
9.7 Hydraulic Maintenance..................................................................................9-23
(1) Hydraulic System Overview......................................................................9-23
(a) Hydraulic Fluids...................................................................................9-23
(b) Oil Tank, Pipes & Fittings.....................................................................9-24
(2) Filtration....................................................................................................9-25
(a) Suction Line Filter................................................................................9-25
(b) Return Line Filters................................................................................9-25
(c) Pressure Filter......................................................................................9-26
(d) Hydraulic Oil Tank Breather.................................................................9-27
(3) Changing Hydraulic Filters & Oil...............................................................9-28
(a) Changing Return Filter.........................................................................9-28
(b) Changing Suction Filters......................................................................9-29

Table of Content
(c) Changing Pressure Filters...................................................................9-30

(d) Changing Hydraulic Oil........................................................................9-31
(e) Changing Condensation Control Breather...........................................9-33
9.8 Conveyor Maintenance.................................................................................9-34
(1) Belt Adjustment on Discharge Conveyor..................................................9-35
(a) Belt Tracking Main Conveyor...............................................................9-35
(b) Belt Tensioning on Main Conveyor......................................................9-35
(2) Belt Adjustment on Dirt Conveyor (Optional)............................................9-36
(a) Belt Tracking Dirt Conveyor.................................................................9-36
(b) Belt Tensioning Dirt Conveyor (Optional).............................................9-36
9.9 Vibrating Feeder Maintenance......................................................................9-37
(1) Changing Vibrating Feeder Gearbox Oil...................................................9-37
(a) Checking Oil Level and Refilling..........................................................9-37
(b) Changing Oil........................................................................................9-37
(2) Changing Vibrating Feeder Screen Meshes.............................................9-38
9.10 Pre-screen Maintenance...............................................................................9-39
(1) Changing Mesh on Pre-screen (Option)...................................................9-39
9.11 Tier 4 Engine Maintenance...........................................................................9-40
(1) Tier 4 Engine Overview............................................................................9-40
(2) Changing Engine Filters & Oil..................................................................9-42
(a) Checking Engine Oil............................................................................9-42
(b) Changing Engine Oil............................................................................9-43
(c) Maximum angles of inclination during operation..................................9-44
(d) Changing the Oil Filter.........................................................................9-45
(e) Changing Air Filter Element.................................................................9-47
(3) Cleaning the Centrifugal Oil Cleaner........................................................9-49
(4) Checking Engine Coolant Level...............................................................9-54
(5) Fuel System..............................................................................................9-55
(a) Changing Fuel Filter.............................................................................9-55
(b) Draining the Water Trap.......................................................................9-56
(c) Changing Water Trap Filter..................................................................9-56
(d) Bleeding the Fuel System....................................................................9-58
(e) Refuelling Diesel Tank.........................................................................9-59
9.12 Urea Tank Maintenance................................................................................9-60
(1) Changing the Reductant Filter..................................................................9-60
(2) Refilling the Urea Tank..............................................................................9-61
9.13 Track Maintenance........................................................................................9-63
(1) Changing Gearbox Oil in Tracks...............................................................9-64
(2) Track Adjustment......................................................................................9-66
(a) To Release Track Tension....................................................................9-66
(b) To Increase Track Tension...................................................................9-67
9.14 Jaw Crusher Maintenance.............................................................................9-68
(1) Checking components for wear................................................................9-68
(a) Daily Component Checks....................................................................9-68
9.15 Vee Belt Maintenance...................................................................................9-69
(1) Alignment..................................................................................................9-70

Table of Content
(2) Adjustment................................................................................................9-71
(a) Manual Adjustment..............................................................................9-71
(3) Drive Belt Tension.....................................................................................9-73
(a) Belt Tensioning Measurements............................................................9-74
(4) Replacement of Vee Belts........................................................................9-75
9.16 Electrical Maintenance..................................................................................9-76
(1) Prior to Welding........................................................................................9-76
(2) Safely Remove and Install the Battery.....................................................9-77
9.17 Hydraulic Ram Maintenance.........................................................................9-80
10 Troubleshooting........................................................................................ 10-2
10.1 General Troubleshooting...............................................................................10-3
10.2 Engine Troubleshooting................................................................................10-4
(1) Accessing Diagnostic Data.......................................................................10-4
(a) Viewing the Engine Information Screen...............................................10-5
(2) Viewing SPN and FMI Codes...................................................................10-7
(3) SPN and FMI Explanations......................................................................10-9
(a) FMI Code Explanations (Fault type identifier (FMI)).........................10-9

(b) SPN Code Explanations (Engine Fault Codes).................................10-10
10.3 Machine Troubleshooting............................................................................10-14
(1) Machine diagnostic fault list....................................................................10-14
(a) Machine Fault Icons...........................................................................10-15
10.4 Hydraulics System Troubleshooting............................................................10-16
10.5 Urea Troubleshooting..................................................................................10-18
(1) Urea Faults/Indication.............................................................................10-18
(a) Urea indication status table................................................................10-19
(2) SCR Faults / Indication ..........................................................................10-20
(a) SCR indication status table................................................................10-21
10.6 Vee Belt Troubleshooting............................................................................10-22
11 Storage.......................................................................................................11-2
12 Glossary of Terms.................................................................................... 12-1
13 Appendix................................................................................................... 13-1
Appendix A EC Declaration of Conformity................................................. A-1
Appendix B Warranty................................................................................. B-1
Appendix C Schematics............................................................................ C-3
(1) XA/XR400S Electrical Schematics............................................................ C-3
(2) XA/XR400S Pre-Screen Electrical Schematics......................................... C-4
(3) Hydraulic Schematics................................................................................ C-5

Introduction 1
Table of Content
1 Introduction................................................................................................. 1-2
1.1 Notes to the Operations Manual.....................................................................1-2
(1) Units...........................................................................................................1-2
(2) Optional Equipment....................................................................................1-2
1.2 Safety Information...........................................................................................1-3
(3) California Proposition 65 Warnings............................................................1-3
1.3 Intended Use...................................................................................................1-4
1.4 Prohibited Use.................................................................................................1-4
1.5 Declaration of Conformity................................................................................1-4
1.6 Copyright.........................................................................................................1-4

Premiertrak 400/R400 Page 1-1
1 introduction
1 Introduction
1.1 Notes to the Operations Manual

This operations manual contains important information on how to operate the machine safely
and correctly. Read this manual carefully to learn how to operate your machine. Failure to do
so could result in personal injury or equipment damage. Consider this manual a permanent part
of your machine. Keep it with the machine at all times.
The following procedure bar indicates the start of a procedure. Any safety warnings related to
the procedure will be highlighted before the procedure.
PROCEDURE
Any results from a step in the procedure will be indicated in italic below that step. The end of a
procedure is indicated with a line under the last step or the last image in a procedure.
Follow all applicable safety regulations and recommendations in this manual as appropriate to
your machine and the situation/conditions prevailing at the time.
Federal, State, National and Local laws and safety regulations must be complied with at all times
to prevent possible danger to person(s) or property from accidents or harmful exposure.
Where supplied as a basic machine only, (with or without optional extras, e.g. drive elements,
etc.), The machine is intended for incorporation into a complete processing machine that is NOT
designed and/or constructed by Terex. In these circumstances, or where supplied as a replacement
machine, Terex will NOT be responsible for addressing environmental issues and/or health and
safety protection measures for the machine installation as a whole and will bear NO responsibility
for ensuring compliance with any regulations and/or statutory requirements that may apply unless
specifically included in the Contract of Sale.
INFORMATION AND ADVICE
Terex Powerscreen
200 Coalisland Road
Dungannon, Co. Tyrone
BT71 4DT
Telephone: +44 (0) 28 8774 0701
E mail: aftersales@powerscreen.com
(1) Units
Within this operations Manual figures shown within brackets ( ) after the Metric unit of measure
are approximate conversions from the actual metric measurement of the item concerned to the
imperial measurement.
(2) Optional Equipment

Terex machines can include optional equipment and/or special features additional to the standard
specification. These may affect the information given in this operations manual.
Look in the appendix of this operations manual for any addendum which may relate to additional
equipment or variations to the standard specification. Take note of any variations to the standard
procedures and/or component specifications.

Page 1-2 Premiertrak 400/R400
Introduction 1
1.2 Safety Information
(1) Safety Warning Symbol
In conjunction with the text which follows it, this safety warning symbol is used as a “safety
warning system” in these operating instructions. The safety warning symbol indicates a risk of
personal injury. Follow all instructions which appear after this safety warning symbol in order to
avoid injury or fatal accidents.
(2) ANSI Hazard Classification System

A multi-tier hazard classification system is used to alert you to potential personal injury hazards.
Signal words used with the safety alert symbol indicate a specific level of severity of the potential
hazard. Signal words used without the safety alert symbol relate to property damage and
protection only. All are used as attention-getting devices throughout this manual as well as on
ANSI type decals and labels fixed to the machine.
nn DANGER
This indicates a hazardous situation which, if not avoided, will result in death or serious injury.
The safety alert symbol must be shown with this danger classification.
nn WARNING
This indicates a hazardous situation which, if not avoided, could result in death or serious injury.
nn CAUTION
This indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
The safety alert symbol must be shown with this danger classification
NOTICE
This indicates a message related to property damage. The safety alert symbols not shown with
this danger classification.
All hazards associated with each procedure will be listed before each procedure as described
above.
(3) California Proposition 65 Warnings

Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and reproductive harm. WASH HANDS AFTER
HANDLING.
Diesel engine exhaust and some of it’s constituents are known to the State of California to cause
cancer, birth defects, and other reproductive harm.

1 introduction
1.3 Intended Use

This product and its approved attachments are designed to be used in Material Processing
crushing and screening applications. Compliance with the operating instructions, the performance
of maintenance work as specified and adherence to maintenance intervals are all aspects of
proper use. Use of this product in any other way is prohibited and contrary to its intended use.
1.4 Prohibited Use

Operating the machine outside of its recommended range of applications or for any use which
it is not intended, will result in a loss of any guarantee. The manufacturer or supplier cannot be
held liable for any damage or injury resulting from such misuse.
Use of this product in any way other than its intended use is prohibited. The manufacturer will
not be liable for any damage resulting from such use.
1.5 Declaration of Conformity

This machine is in conformity with the provisions of the EC Machinery Directive 06/42/EC together
with appropriate EN Harmonised Standards and National BS Standards and Specifications.
A Declaration of Incorporation certificate is applicable to each machine.
1.6 Copyright
The copyright of this operations manual is reserved by Powerscreen.
This operations manual contains information and technical drawings, which may not be copied,
distributed, altered, stored on electronic media, revealed to others or used for the purpose of
competition, either partially or in its entirety.
The right is reserved to alter any details contained in this manual without notice.
Copyright 2011.
Terex Powerscreen
200 Coalisland Road
Dungannon, Co. Tyrone
BT71 4DT
Telephone: +44 (0) 28 8774 0701
E mail: aftersales@powerscreen.com
To order additional copies contact your local Terex dealer.

Safety 2
Table of Content
2 Safety........................................................................................................... 2-2
2.1 General Safety................................................................................................2-2
(3) Description of Safety Symbols....................................................................2-3
2.2 Positions of Safety Signs on the Machine.......................................................2-8
2.3 Personal Safety.............................................................................................2-22
(1) Personal Protective Equipment................................................................2-22
2.4 Work Area Safety..........................................................................................2-23
(1) General Work Area Guidelines.................................................................2-23
(2) Safety Warnings and Labels.....................................................................2-23
(a) Modifications........................................................................................2-23
(3) Transportation Safety...............................................................................2-23
(4) Operation Safety.......................................................................................2-24
(5) Hydraulic and Pneumatic Safety..............................................................2-25
(6) Electrical Safety........................................................................................2-25
(7) Maintenance Safety..................................................................................2-26
(a) Maintenance and Repairs During Operation; Disposal of Parts and
Consumables.......................................................................................2-26
(8) Gas, Dust, Steam, Smoke........................................................................2-27
(9) Hazardous Substances............................................................................2-28
(10) Noise Levels.............................................................................................2-28

2 Safety
2 Safety
This safety section covers a wide variety hazardous situations, (but not necessarily limited to those
described), which may or may not apply to any specific machine installation. They are given for
general guidance only to assist the operator in setting up and maintaining an appropriate regime
for the protection of health and safety. Where the machine is supplied for incorporation into
machine/equipment designed, supplied and located by others, Terex cannot be aware of particular
hazards that may be present or might occur and therefore accept no liability for addressing or
resolving these issues.
2.1 General Safety

The following signs and designations are used in the manual to designate instructions of particular
importance.
(1) Safety Warning Symbol
In conjunction with the text which follows it, this safety warning symbol is used as a “safety
warning system” in these operating instructions. The safety warning symbol indicates a risk of
personal injury. Follow all instructions which appear after this safety warning symbol in order to
avoid injury or fatal accidents.
(2) ANSI Hazard Classification System

A multi-tier hazard classification system is used to alert you to potential personal injury hazards.
Signal words used with the safety alert symbol indicate a specific level of severity of the potential
hazard. Signal words used without the safety alert symbol relate to property damage and
protection only. All are used as attention-getting devices throughout this manual as well as on
ANSI type decals and labels fixed to the machine.
nn DANGER
This indicates a hazardous situation which, if not avoided, will result in death or serious injury.
nn WARNING
This indicates a hazardous situation which, if not avoided, could result in death or serious injury.
nn CAUTION
This indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
The safety alert symbol must be shown with this danger classification
NOTICE
This indicates a message related to property damage. The safety alert symbols not shown with
this danger classification.

Safety 2
(3) Description of Safety Symbols
Table 2.1 - Description of Safety Symbols

Symbol Description
Electrocution hazard
Electrical shock/ electrocution from conveyor to power line contact.
Stay sufficient distances from electrical power lines.
Entanglement hazard
Entanglement in belt drive or conveyor.
Entanglement hazard
Arm entanglement in belt drive.
Stay clear of conveyor.
Install covers and guards before operation.
Turn machine off and remove the key.
Lockout machine.
Read and understand operations manual before using equipment.
Injection hazard
Skin injection from high pressure fluid.
Use cardboard or wood to check for leaks.
Crush hazard
Crushed foot from support leg.

2 Safety
Symbol Description
Stay clear of support legs and jacks.
Falling material hazard

Struck from falling or flying material.
Stay clear of hopper during operation.
Fall Hazard
Falling from a height.
Do not climb onto the machine.
Use personnel lift to reach high places.
Check tyre pressures prior to transport.
Check wheel nut torque. Recheck wheel nut torque every 150 miles
(200km).
Connect and check braking system.
Crush hazard
Crushing of fingers or hand. Force applied in one direction.
Keep hands clear of openings.
Hand entanglement in pulley/ winch
Keep hands clear of moving components

Safety 2
Symbol Description
Electrocution hazard
Electric shock/ electrocution.
Hearing hazard
Loss or degradation of hearing.
Wear hearing personal protective equipment.
Explosion hazard
Explosion during an operation or service procedure.
Burn hazard
Burns from corrosive material.
Keep open flame away.
Emergency Stop
Press to engage, twist to reset.
Flying Material Hazard

Face struck by flying objects
Wear eye personal protective equipment
Crush Hazard
Crush from overhead impact.
Stay clear of moving conveyors.
Unauthorized persons prohibited.
Flying Material Hazard

Struck by flying material.

2 Safety
Symbol Description
Do not stand on platform while machine is in operation
Do not stand on machine while in operation.
Inhalation Hazard
Inhalation of poisonous/ toxic fumes or dust.
Use dust suppression (water spray) or dust collection (filter) during

operation of this equipment.
Wear respiratory personal protective equipment.
Cutting Hazard
Contact with knives in trommel drum will result in death or serious injury.
Stay clear of sharp knives in trommel drum.
Crush Hazard
Crush from track machine run over.
Stay clear of track machine.
Crush Hazard
Crush from wheel machine run over.
Stay clear of wheeled machine.
Explosion Hazard
Battery Explosion.
Keep welding sparks away from the battery area.

Safety 2
Symbol Description
Burn Hazard
Burn from hot surface or liquid
Stay clear of hot surface or liquid.
Impact Hazard
Impact from spring loaded door.
Stay clear of spring loaded door while opening.
Magnetic Hazard
Magnetic fields can disturb pacemaker operation if within 3 metres of the
magnet and result in serious injury or death to pacemaker wearer.

2 Safety
2.2 Positions of Safety Signs on the Machine

Table 2.2 lists the safety signs that are on this machine. The item number indicates the position
of the safety sign on the machine, Ref: Figure 2.1 to Figure 2.4.
Table 2.2 - Safety Signs

Sign
Item ISO ANSI
1
0 to 50 kv 10 ft (3 m)
50 to 200 kv 15 ft (4.6 m)
200 to 350 kv 20 ft (6.1 m)
350 to 500 kv 25 ft (7.6 m)
500 to 750 kv 35 ft (10.7 m)
750 to 1000 kv 45 ft (13.7 m)
1500- IO
1502- IO

Safety 2
Sign
Item ISO ANSI
3
1504- IO

2 Safety
Sign
Item ISO ANSI
6
1506- IO
1507- IO
1508- IO

Safety 2
Sign
Item ISO ANSI
9
10
11

2 Safety
Sign
Item ISO ANSI
12
1524- IO
13
15
1513- IO

Safety 2
Sign
Item ISO ANSI
16
17
18
1515- IO

2 Safety
Sign
Item ISO ANSI
19
20
21
1514- IO

Safety 2
Sign
Item ISO ANSI
22
1518- IO
23
24
1520 - IO

2 Safety
Sign
Item ISO ANSI
25
2
1
1523- IO
26
27
2
1
1522- IO

Safety 2
Sign
Item ISO ANSI
28
1530- IO
29
1531- IO
30

2 Safety
Sign
Item ISO ANSI
31
1533- IO
32
1536- IO
Figure 2.1 to Figure 2.4 show the positions of these safety signs on the machine.

Safety 2
32
32
26,2,32,
23
20
11
3,12,15,
30,
20
4
7,8,
OMA00326
Figure 2.1 - Right Hand Side Safety Sign Positions

2 Safety
7,8
26,31
8
11 3,12,15,
24,30,
2,16
4,13,28,
30
8
29
8
4,19
26,2,32,
7,23
32
32
OMA00327
Figure 2.2 - Left Hand Side Safety Sign Positions

Safety 2
20,32,
26
8,22 31 31 8,22 OMA00328

Figure 2.3 - Back Safety Sign Positions
28
13,15,21, 29
16,28,29,
30 OMA00329
Figure 2.4 - Power Unit Safety Sign Positions

2 Safety
2.3 Personal Safety

Ascertain from the appropriate authority and observe all statutory and any other regulations that
may apply to the planned location before operating the machine. Operators must be trained in
the correct and safe use of all equipment.
Before operation the operator(s) must:
• Have received specific and adequate training in the task to be carried out.
• Have read and understood the operations manual and the Safety Signs in this manual and
around the machine(s).
• Knows the location and function of controls and safety features such as emergency stop buttons
and safety guards.
• Be aware of all moving parts of the machine.
Any work on and/or with the machine must be executed by trained, reliable and authorised
personnel only. Statutory minimum age limits must be observed.
Work on electrical system and equipment of the machine must be carried out only by a skilled
electrician or by instructed persons under the supervision and guidance of a skilled electrician
and in accordance with electrical engineering rules and regulations.
Work on the hydraulic system must be carried out only by personnel with special knowledge and
experience of hydraulic equipment.
(1) Personal Protective Equipment

Where possible when working close to engines or machinery, only do so when they are stopped.
If this is not practical, remember to keep tools, test equipment and all other parts of your body
well away from the moving parts. Loose or baggy clothing can get caught in running machinery.
For reasons of safety, long hair must be tied back or otherwise secured, garments must be close
fitting and no jewelry such as rings may be worn. Injury may result from being caught up in the
machinery or from rings catching on moving parts.
Always wear correctly fitting (EN/ANSI approved) protective clothing.
Protective clothing includes: Hard Hat, Safety Glasses, Ear Protection, Dust Mask, Close fitting
Overalls, Steel Toed Boots and a High Visibility Vest.

Safety 2
2.4 Work Area Safety
(1) General Work Area Guidelines

The guards provided are designed and manufactured to ensure so far as reasonably practicable
that the machinery and machine on which they are fitted can be operated safely and without risk to
health when properly used. However, it cannot be guaranteed that the guards provided will meet
the requirements laid down by individual Inspectors and any additional guard and/or modification
to guarding supplied, which may be required for any reason whatsoever, will be charged as an
addition to the Contract Price.
(2) Safety Warnings and Labels

You can be injured if you do not obey the safety instructions as indicated on warning signs.
Observe all safety instructions and warnings attached to the equipment.
Ensure that safety instructions and warnings attached to the equipment are always complete and
perfectly legible. Keep warnings and instruction labels clean and up to date.
Replace unreadable or missing labels with new ones before operating the machinery. Make sure
replacement parts include warning or instruction labels where necessary.
(a) Modifications
Never make any modifications, additions or conversions which might affect safety without the
supplier’s approval.
In the event of safety relevant modifications or changes in the behavior of the machinery during
operation, stop the machine and lock out immediately and report the malfunction to the competent
authority/ person.
(3) Transportation Safety

Before transporting the machine, observe the prescribed transport position, admissible speed and
itinerary. Only use appropriate means of transport and lifting gear of adequate capacity. Know
the overall height to avoid contacting overhead obstructions such as bridges, power lines etc.
The preparations to move equipment by an articulated lorry should be supervised by a minimum of
two persons. Ensure persons transporting the machine adhere to all safety signs and procedures.
Before transportation on public roads, ensure the machine has been properly secured with no loose
material left in or on the machine. Always observe the valid traffic regulations and, if necessary,
ensure beforehand that the machine is in a condition compatible with these regulations.
Extreme caution is required when transporting machinery on site. Soft or uneven ground may
cause accidents. On sloping terrain, always adapt your travelling speed to the relevant ground
conditions. Never change to a lower gear on a slope. Always change gear before reaching a slope.
On wheeled machine:
Ensure wheel nuts are torqued between 500 to 550 ft.lb (69 to 76 kg.m) prior to transport.
Check your tires for:-
• Correct pressure
• Cuts or bulges
• Nails or spikes
• Uneven or excessive wear

2 Safety
• Missing valve caps

Check your wheels for:-
• Damaged rims
• Missing or loose wheel nuts or bolts
• Obvious misalignment
Have cuts or punctures repaired by authorised personnel before adding air. Beware that an over-
inflated tire can explode and cause serious injury or death.
(4) Operation Safety

Before attempting to operate the machine, DO read, fully understand and observe the contents
of this manual. Also any other relevant manual for other equipment incorporated in the machine,
e.g. Engine manual.
It is emphasized that all safety aspects are checked before starting the machinery.
NEVER leave the machine unattended whilst it is in operation.
Make sure that you fully understand the operating procedures for the machine before attempting
to start.
Take the necessary precautions to ensure that the machine is used only when in a safe and
reliable state.
Operate the machine only for it’s designed purpose and only if all guarding, protective and safety
orientated devices, emergency shut-off equipment, sound proofing elements and exhausts, are
in place and fully functional.
Before starting the engine ensure it is safe to do so. Avoid frequent starting and stopping of the
crusher as it will be detrimental
DO NOT allow a build up of solid material or dust in any part of the machine. In the event of
material blockage, any malfunction or operational difficulty, stop the machine immediately and
lockout. Have any defects rectified immediately.
In-running nip points on moving machinery can cause serious injury or even death. Do not reach
into unguarded machinery. Your arm could be pulled in and amputated. Switch off and lockout
the machine before removing any safety devices or guarding.
Never work or stand beneath machinery or attachments as it is raised or lowered. Never work or
stand beneath machinery as they are being loaded with and/or discharging material.
Follow safe operating practices. Operate the machine controls smoothly. Avoid sudden stops,
starts or changes in direction. Only use emergency stop buttons or emergency stop lines (if fitted)
in emergency situations or during safety drills.
Return idler roller guards should be checked for wear/damage during routine maintenance. The
gap between the guard and the idler roller should not exceed 6mm. Contact your local Terex
dealer to obtain an approved replacement.
DO check frequently the stability of the machine. The chassis SHOULD NOT have undue vibration
during operation.

Safety 2
(5) Hydraulic and Pneumatic Safety

Only persons having special knowledge and experience in hydraulic and pneumatic systems may
carry out work on hydraulic and pneumatic equipment.
Turn off the machine and isolate power supply before any pipes, filter caps, filters or hydraulic
fittings are disconnected or removed. Depressurize all system sections and pressure pipes
(hydraulic system, compressed air system) to be removed in accordance with the specific
instructions for the unit concerned before carrying out any repair work. Always use a piece of
cardboard to check for leaks. Do not use your hand. Hydraulic fluid under pressure can penetrate
the skin causing serious injury. If fluid is injected under the skin, it must be surgically removed
or gangrene will result. Get medical help immediately
Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Splashed
oil may cause injury and fire. Repair damage immediately.
Hydraulic and compressed air lines must be laid and fitted properly. Ensure that no connections
are interchanged. The fittings, lengths and quality of the hoses must comply with the technical
requirements.
Always practice extreme cleanliness servicing hydraulic components.
(6) Electrical Safety

Work on the electrical system or equipment may only be carried out by a skilled and qualified
electrician or by specially instructed personnel under the control and supervision of such an
electrician and in accordance with applicable electrical engineering rules.
Use only original fuses with the specified current rating. Switch off the machine immediately if
trouble occurs in the electrical system.
Machines with high voltage electrical equipment must be suitably earth bonded by a qualified
electrician prior to activating the main isolator switch.
When working with the machine, maintain a safe distance from overhead electric lines. If work
is to be carried out close to overhead lines, the working equipment must be kept well away from
them. Check out the prescribed safety distances.
If your machine comes into contact with a live wire:
• Warn others against approaching and touching the machine.
• Have the live wire de-energised.
If provided for in the regulations, the power supply to machines and parts of machines, on which
inspection, maintenance and repair work is to be carried out, must be cut off. Before starting
any work, check the de-energised parts for presence of power and ground or short circuit them
in addition to insulating adjacent live parts and elements.
The electrical equipment of the machine is to be inspected and checked at regular intervals.
Defects such as loose connections or scorched or otherwise damaged cables must be rectified
immediately.
Necessary work on live parts and elements must be carried out only in the presence of a second
person, who can cut off the power supply in the case of danger by actuating the emergency
shut off or main power switch. Secure the working area with a red and white safety chain and a
warning sign. Use insulated tools only.
Before starting work on high voltage assemblies and after cutting out the power supply, the feeder
cable must be grounded and components such as capacitors short-circuited with a grounding rod.
Tracked machines are wired with negative earth. Always observe correct polarity.

2 Safety
Always disconnect battery leads before carrying out any maintenance to the electrical system.
The battery contains sulphuric acid, an electrolyte which can cause severe burns and produce
explosive gases. Wear personal protective equipment and avoid contact with the skin, eyes or
clothing.
(7) Maintenance Safety

Understand service procedure before doing work. Keep working area clean and dry. Never
lubricate, clean, service or adjust machinery while it is moving. Keep hands, feet and clothing
clear of power driven parts and in running nip-points. Disengage all power and operate controls
to relieve pressure. Stop the engine, Implement the lockout and tag out procedure and allow the
machinery to cool before carrying out any maintenance.
Keep all parts in good condition. Ensure that all parts are properly installed. Fix damage
immediately. Replace worn and broken parts. Remove any build up of grease, oil and debris.
Disconnect battery ground cable before making adjustments on electrical systems or welding on
machinery. For the execution of maintenance work, tools and workshop equipment adapted to
the task on hand are absolutely indispensable.
(a) Maintenance and Repairs During Operation; Disposal of Parts and Consumables
Observe the adjusting, maintenance and intervals set out in these operating instructions, except
where:
• Warning, horn/light/gauge or indicator calls for immediate action.
• Adverse conditions necessitate more frequent servicing.
Observe information on the replacement of parts and equipment. These activities may be executed
by skilled personnel only.
When the machine is completely shutdown for maintenance and repair work, it must be secured
against inadvertent starting by:
• Switching off the engine and remove the ignition switch/key or isolate the electrical supply as
applicable.
• Implementing the lockout procedure.
• Attaching a warning sign(s) to the machinery in appropriate positions.
Carry out maintenance and repair work only if the portable/mobile machine is positioned on stable
and level ground and has been secured against inadvertent movement and buckling.
Never allow unqualified or untrained personnel to attempt to remove or replace any part of the
machine, or anyone to remove large or heavy components without adequate lifting tackle.
To avoid the risk of accidents, individual parts and large assemblies being moved for replacement
purposes should be carefully attached to lifting tackle and secured. Use only suitable and
technically adequate lifting gear. Never work or stand under suspended loads.
Keep away from the feed hoppers and stockpile conveyor discharge points, where there is risk
of serious injury or death due to the loading and removal of material.
Falling from and/or onto Terex machines can cause injury or even death. Do not climb on the
machine whilst it is in operation. Never use machine parts as a climbing aid.
Beware of moving haulage and loading equipment in the vicinity of the machine.

Safety 2
For carrying out overhead assembly work always use specially designed or otherwise safety-
oriented ladders and working platforms. Always use any walkway/platforms provided or a safe and
secure platform approved by the regional safety enforcing authority. Do not use any unauthorized
structures.
Always use an EN/ANSI approved safety harness when reaching any points 7ft (2m) or more
above the ground level. Keep all handles, steps, handrails, platforms, landing and ladders free
from dirt, oil, snow and ice.
The fastening of loads and instructing of crane operators should be entrusted to experienced
persons only. The marshals giving the instructions must be within sight or sound of the operator.
After cleaning, examine all fuel, lubricant, and hydraulic fluid lines for leaks, loose connections,
chafe marks and damage. Any defects found must be rectified without delay.
Any safety devices removed for setup, maintenance or repair purposes must be refitted and
checked immediately upon completion of the maintenance and repair work to ensure full working
order.
Improperly disposing of waste can threaten the environment and ecology. Potentially harmful
waste used with Terex equipment includes such items as oil, fuel, coolant, filters and batteries,
etc. Use leakproof containers when draining fluids. Do not use food or beverage containers
that may mislead someone into drinking from them. Do not pour waste onto the ground, down
a drain or into any water source. Ensure that all Consumables and replaced parts are disposed
of safely and with minimum environmental impact.
Always ensure that any safety fitment such as locking wedges, securing chains, bars or struts
are utilized as indicated in these operating instructions.
Particularly make sure that any part of the machine raised for any reason is prevented from falling
by securing in a safe reliable manner. Never work under unsupported equipment. Never work
alone.
Diesel fuel is highly flammable. Never remove the filler cap, or refuel, with the engine running.
Never add gasoline or any other fuels mixed to diesel because of increased fire or explosion
risks. Do not carry out maintenance on the fuel system near naked lights or sources of sparks,
such as welding equipment or whilst smoking.
(8) Gas, Dust, Steam, Smoke

Death, serious injury or delayed lung disease may result from breathing dusts that are generated
when certain hazardous materials are crushed, screened or conveyed with this equipment.
Always operate internal combustion engines and fuel operated heating systems only out of doors
or in a well-ventilated area. Before starting the machine in enclosed areas, make sure that there
is sufficient ventilation.
Observe the regulations in force at the respective site.
Dust found on the machine or produced during work on the machine should be removed by
extraction, not blowing. Dust waste should be dampened, placed in a sealed container and
marked, to ensure safe disposal.
When dusts are generated by the operation of this equipment, use approved respiratory protection,
as required by Federal, State and Local safety and health regulations.
Carry out welding, flame cutting and grinding work on the machine only if this has been expressly
authorised, as there may be a risk of explosion and fire.

2 Safety
Before carrying out welding, flame cutting and grinding operations, clean the machine and
its surroundings from dust and other flammable substances and make sure the premises are
adequately ventilated as there may be a risk of explosion.
Ensure operators wear a suitable face mask where exposed to possible harmful effects of air
pollution of any kind.
(9) Hazardous Substances

Ensure that correct procedures are formulated to safely handle hazardous materials by correct
identification, labelling, storage, use and disposal.
All hazardous materials must be handled strictly in accordance with the manufacturers instructions
and all applicable regulations observed at all times.
(10) Noise Levels

HEARING HAZARD EXCEEDS 90 dB (A)
May cause loss or degradation of hearing over a period of time.
Always ensure that operators are provided with ear defenders of approved pattern and that these
are worn at all times when the machine is operating.

Technical Data 3
Table of Content
3 Technical Data............................................................................................. 3-2
3.1 Dimensions......................................................................................................3-3
(1) Working Range Diagrams...........................................................................3-3
(2) Transport Diagrams....................................................................................3-5
(3) Working Range Diagrams For Pre-Screen Model......................................3-7
(4) Transport Diagrams For Pre-Screen Model................................................3-9
3.2 Noise Levels.................................................................................................. 3-11
(1) Tier 4 Noise Levels................................................................................... 3-11
3.3 Operating Temperature Range......................................................................3-12
3.4 Machine Specifications..................................................................................3-12
3.5 Machine Components...................................................................................3-13
(1) Machine Components Specifications.......................................................3-14
(a) Vibrating Feeder..................................................................................3-14
(b) Bypass Conveyor (Standard VGF Model)............................................3-14
(c) Power Unit...........................................................................................3-14
(d) Magnetic Conveyor..............................................................................3-14
(e) Discharge Conveyor............................................................................3-14
(f) Tracks..................................................................................................3-15
(g) Jaw Crusher.........................................................................................3-15
(h) Feed Hopper........................................................................................3-15
(i) Dust Sprays.........................................................................................3-15
(j) Pre-Screen (Optional)..........................................................................3-15
(k) Short Pan Feeder.................................................................................3-15
3.6 Crusher Capacity...........................................................................................3-16

3 Technical Data
3 Technical Data
Every endeavour will be made to supply equipment as specified, but we reserve the right, where
necessary, to amend specifications without prior notice as we operate a policy of continual product
development.
It cannot be guaranteed that the plant will meet any specific requirements in respect of noise or
vibration levels, dust emissions, or any other factors relevant to health and safety measures or
environmental protection needs.
The technical data given in this section are given as approximations for reference only.

Technical Data 3
3.1 Dimensions
(1) Working Range Diagrams

3903 (12’ - 10”)
3721 (12’ - 3”)
14956 (49’ - 1”)
4135 (13’ - 7”) 4135 (13’ - 7”)
OMA00358
Figure 3.1 - Working Range Dimensions

3 Technical Data
4179 (13 - 9”)
2166 (7’ - 1”)

2283 (7’ - 6”)
OMA00359

Technical Data 3
(2) Transport Diagrams
3148 (10’ - 3”)
15375 (50’ - 4”)
2705 (8’ - 9”)
OMA00360
Figure 3.3 - Transport Dimensions

3 Technical Data
2705 (8’ - 9”)
2790 (9’ - 1”) OMA00361

Figure 3.4 - Front View Transport Dimensions

Technical Data 3
(3) Working Range Diagrams For Pre-Screen Model
3657
14927
3806 4989
OMA00573

3 Technical Data
6611
2960
OMA00574
Figure 3.6 - Rear Working Range Dimension

Technical Data 3
(4) Transport Diagrams For Pre-Screen Model
3148
15395
2900 3650
OMA00571
Figure 3.7 - Transport Dimensions

3 Technical Data
2900
2800 OMA00572
Figure 3.8 - Rear Transport Dimension

Technical Data 3
3.2 Noise Levels
(1) Tier 4 Noise Levels
72.5dB
76.3dB
84.5dB
74.8dB
83.2dB
77.2dB
87.2dB
82.3dB
79dB
1 m (3’-3’’)
5 m (16’-4’’)
10 m (32’-8’’)
74dB
71.4dB
68.4dB
OMA00324
Figure 3.9 - Tier 4 Noise Level

3 Technical Data
3.3 Operating Temperature Range

The normal operating temperature range of the plant is from -10oC to +40oC (+14oF to +104oF).
For use in temperatures outside of this range, contact your local dealer.
If high or low ambient temperature conditions apply, specific details need to have been advised at
the time of order as special equipment may be necessary. The Caterpillar engine cooling system
is protected to -15º C (+ 5º F) with 30% Caterpillar antifreeze concentration when shipped from
the factory, unless special requirements have been defined.
On the Scania engine there is no risk of damage by freezing with a minimum antifreeze content
of 35 percent by volume.
Appropriate oil and coolant to suit the local operating conditions must be used. (Refer to the
engine manufacturer operations and maintenance manual).
3.4 Machine Specifications

Weight (approximate)
Complete machine (for standard XA machine with magnet and bypass)
Complete machine (for standard XR machine with magnet and bypass)
Complete machine (for standard XA machine with magnet and bypass & Pre-
Screen)
Complete machine (for standard XR machine with magnet and bypass & Pre-
Screen)

Technical Data 3
3.5 Machine Components
10
11
12
13
8
1 6
2 5
3 4
Figure 3.10 - Machine Components OMA00325
1 Discharge Conveyor
2 Magnetic Conveyor (Optional)
3 Water Pump (Optional)
4 Control Caninet/Storage Compartment
5 Tracks
6 Pre-Screen (Optional)
7 Dirt Conveyor (Optional)*
8 Vibrating Feeder
9 Feed Hopper
10 Jaw Crusher
11 Engine Compartment
12 Urea Tank
13 Hydraulic Oil Tank
*Pre-Screen Models - A different model of dirt conveyor is fitted. The conveyor has a larger
stockpile capacity.

3 Technical Data
(1) Machine Components Specifications
(a) Vibrating Feeder
Weight Approx 3500kg

Width 1630mm
Length 4400mm
Drive unit Hydraulic motor via flange mounted gearbox
Lubrication Oil Gearbox
Control Auto/Manual variable speed
(b) Bypass Conveyor (Standard VGF Model)
Belt type Plain Troughed Belt

Belt Width 1280mm
Belt Length 3940mm
Weight 700kg
Discharge height 2300mm
Drive Direct drive via hydrualic motor
(c) Power Unit
Engine SCANIA DC9 Tier 4

Performance 275 kW (345 hp) at 2000 rpm
Fuel tank capacity 450 liters
Clutch type HPTO PT Tech
Operating -12°C to +40°C (10°F to 104°F)
temperature
(d) Magnetic Conveyor
Belt type Self cleaning cross belt

Belt Width 750mm
Weight 900kg (Single Pole) 1500kg (Twin Pole)
Drive Direct drive via hydraulic motor
(e) Discharge Conveyor
Belt type EP603/4 with 6mm top and 2mm bottom heavy duty rubber covering
vulcanized joint
Belt Width 1000mm (40”)
Weight 3000kg
Discharge height 3900mm
Drive Direct drive via hydraulic motor
Optional equipment Hydraulic folding head section

Technical Data 3
(f) Tracks
Type Bolt on Tracks with 2 Speed ‘soft start’

Length 4600mm
Width 500mm
Weight 3230kg (Per track)
Drive 2 x integral hydraulic motors
Control Dual speed handset
(g) Jaw Crusher
Size 700mm x 1100mm

Weight XA 16100kg / XR16300kg
Liners Optional liners
Drive Via Clutch
(h) Feed Hopper
Type Hydraulic hopper flares with hydraulic wedge locks

Width 2600mm
Weight 3000kg
Length 4900mm
Hopper body 8mm Hardened steel
(i) Dust Sprays
Type Clean water multi atomising nozzle spray bars

Positions Crusher feed and discharge conveyor heads
Inlet Single point for user’s pressure supply
Required supply Up to approx.. 7litres/min (2 US galls) @ 2.8 bar (42 psi)
Frost protection System drain valves
(j) Pre-Screen (Optional)
Weight 2100kg
Width 1800mm
Length 2080mm
Drive unit Hydraulic motor via flange mounted gearbox
(k) Short Pan Feeder
Weight 2000kg
Width 1800mm
Length 2000mm

3 Technical Data
3.6 Crusher Capacity
NOTICE
On the XR model, DO NOT feed non crushable material larger than 200mm (8 inches) into the
Hydraulic Release Jaw Crusher as serious damage may result.
On the XA model DO NOT feed non crushable material larger than the closed jaw gap setting.
In order to obtain the optimum output from the crusher, it’s feed should be continuous and regulated.
Additionally, all feed should be of a size that will readily enter the crusher chamber and, in order to
avoid packing of the discharge opening and excessive wear of the plant jaws, under size material
should be removed from the feed prior to entry to the crusher.
The discharge rates given are based on crushing clean, dry limestone weighing approximately
1600kg/m³ (100lbs/ft³) loose and having a specific gravity of 2.6. Wet feed material reduces the
crusher discharge rate.
Closed jaw settings 1* and 2* are for re-cycling operations only. The crusher must not be operated
at a discharge opening less than 75mm (3 inches) for quarry applications without prior consultation
with Powerscreen®. The only exception to this being for crushing bricks and demolition materials.
Operating the crusher below this setting may result in extensive damage.
Table 3.1 - Settings Table

Setting Range + Typical Output
1* : 50mm* 140 tonnes/hour
2* : 63mm* 160 tonnes/hour
3* : 75mm 185 tonnes/hour
4 : 100mm 220 tonnes/hour
5 : 125mm 250 tonnes/hour
1* - 2* - 3 - 4 - 5
OMA00330
Figure 3.11 - Closed Jaw Settings

Technical Data 3
The percentage of oversize output from the crusher, for a given discharge opening, will depend
largely on the quality and character of the feed material. The graph shows an estimated analysis
of the product for different discharge openings.
Note:- The crusher has been designed to work with feed materials having a 10% fines value not
exceeding 390kN (87675 lbf).
Product gradings are typical only and will vary depending on material characteristics.
When the optional dirt conveyor is fitted, material passing through the vibrating feeder bars will
by-pass the crusher. The coarser material discharges to the product conveyor and finer material
to the dirt conveyor.
The optional magnetic over band separator, where fitted, is intended to extract ferrous materials
from the crushed product but this material in the feed must be limited to a size that will not cause
damage to the crusher.
PRODUCT ANALYSIS
PERCENTAGE PASSING (%)
OMA00331
mm SCREEN MESH SIZE

3 Technical Data
Intentionally Left Blank.

Machine Description 4
Table of Content
4 Machine Description................................................................................... 4-2
4.2 Systems...........................................................................................................4-3
(1) Electrical System........................................................................................4-3
(a) Power Unit.............................................................................................4-3
(2) Crushing System........................................................................................4-3
(a) Chutes....................................................................................................4-3
(b) Dust Suppression Sprays......................................................................4-3
(3) Conveying System......................................................................................4-4
(a) Discharge Conveyor..............................................................................4-4
(b) Dirt Conveyor.........................................................................................4-4
(4) Vibrating Feeder.........................................................................................4-4
(5) Maintenance Walkways..............................................................................4-4
(6) Chassis.......................................................................................................4-4
(7) Guards........................................................................................................4-4
4.3 Control and Display Elements.........................................................................4-5
4.4 Machine Information Decals............................................................................4-6
4.5 Optional Equipment.........................................................................................4-9

4 Machine Description
4.1 General Information
nn WARNING
This machine is designed for stone crushing applications. It is vitally important that large pieces
of steel or similar uncrushable objects are not allowed to enter the crushing chamber as severe
damage and injury may occur.
This machine has been designed for stone crushing applications, to maximise throughput and
product shape in a wide rage of quarrying applications. Its features include:
• Suitable for many sizes of rock or stone materials.
• Unique design giving excellent product shape and high reduction ratios.
• Vibrating Feeder fitted as standard.
• Easily transported on and off site.
• Magnetic Conveyor (Optional)
• Dust suppression sprays
• Caterpillar/ Scania water cooled diesel engine with hydraulically controlled clutch.
• Hydraulic rams to assist setting up and packing for transportation.
• Choice of Jaw Liners

4.2 Systems
(1) Electrical System
(a) Power Unit

The power unit is attached to the chassis of the machine alongside the crusher. The power unit
is completely enclosed, sound suppressed and lockable. The power unit contains the SCANIA
DC9 or the CAT C9 engine. Hydraulic power is provided from the engine to drive the conveyors,
operate the hydraulic cylinders and give power to the tracks. All connecting pipe work is provided
with steel pipe being used in inaccessible areas. It also provides power to the control panel.
(2) Crushing System

Crusher XR and XA
Single toggle jaw crusher with feed gape of 650mm (26in) and width of 1100mm (44in), operated
by eccentric shaft driven by vee belts and pulleys from the engine.
The XR model has an automatic overload release facility and discharge setting adjustment by
hydraulic operation and pairs of shims.
The XA model has setting adjustment by hydraulic operation and pairs of shims.
(a) Chutes
The crusher discharge chute is fabricated from abrasion resistant plate and is designed to direct
the crushed material onto the discharge conveyor.
(b) Dust Suppression Sprays

Spray bars with atomiser nozzles are mounted over the crusher mouth and the product conveyor
feed and discharge points to reduce the amount of dust produced by the machine. They are piped
to an inlet manifold to be attached to the clients pressurised water supply. The client is to supply
pressurised, 3 bar (44 psi), clean water supply at approximately 24 liters (6.34 gallons) per minute.

(3) Conveying System
(a) Discharge Conveyor

The discharge conveyor is attached to the front of the chassis to convey crushed material away
from the crusher to the stock pile.
Impact rollers are provided immediately below the crusher outlet under the conveyor feed point,
and aluminium type dust covers are provided over the exposed section of the conveyor.
(b) Dirt Conveyor

The side discharge dirt conveyor has a plain belt and hydraulic folding facility for transportation.
A removable mesh can be used in conjunction with the optional dirt conveyor. If the material is
able to be screened, it allows the extraction of smaller fines onto the dirt conveyor with the coarser
material being fed to the vibrating discharge feeder then on to the product conveyor.
When the optional dirt conveyor is fitted, material passing through the vibrating feeder bars will
by-pass the impactor. The coarser material discharges to the product conveyor and finer material
to the dirt conveyor.
By removing the mesh entirely all the fines are directed to the dirt conveyor via the two way fines
chute.
(4) Vibrating Feeder

Spring mounted vibrating feeder, driven by a heavy duty vibrating mechanical unit with twin
eccentric rotating shafts. Drive is supplied by a hydraulic motor mounted on the vibrating unit with
variable speed control. An optional remote control to start and stop the feeder can be supplied.
(5) Maintenance Walkways

Provided for inspection and maintenance, allowing access to each side of the crusher and engine,
back of engine, and to one side of feed conveyor head section. They are made from steel flooring
with steel toe boards, double row handrails and access ladders.
(6) Chassis
Fabricated steel frame with supports for the feed conveyor, crusher, product conveyor, power
unit, track frame and control systems
(7) Guards
Wire mesh or sheet metal guards are provided for all drives, flywheels, pulleys, couplings, wedge
belts and belt conveyors.
The guards provided are designed and manufactured to ensure so far as reasonably practicable
that the machinery and machine on which they are fitted can be operated safely and without risk
to health when properly used.
However, it cannot be guaranteed that the guards provided will meet the requirements laid down
by individual Inspectors and any additional guard and/or modification to guarding supplied, which
may be required for any reason whatsoever, will be charged as an addition to the Contract Price.

4.3 Control and Display Elements

The crushing control is fully integrated into the machine PLC control system. The panel consists
of a 320 x 240 pixel backlit screen complete with user controls.
The control panel is used to operate the following machine functions:
• Engine speed
• Feeder (start, stop and speed)
• Conveyors (start, stop)
• Jaw Crusher (start, stop)
• Crusher control
• Machine diagnostics.
An umbilical control unit is provided for controlling the tracking function and giving a tracking
speed of approximately 1km/hour and a ‘creep’ facility for loading, off loading and precise slewing
movements, Ref: Figure 4.1.
A radio control unit is also available as an option for controlling the tracking function.
Figure 4.1 - Manual Tracking Handset
1 Left Track Forward

2 Right Track Forward
3 Left Track Reverse
4 Right Track Reverse
5 Unused
6 Unused
7 Stop Tracks
8 Start Tracks

4.4 Machine Information Decals

Table 4.1 lists the information signs that are on this machine. The item number indicates the
position of the safety sign on the machine, Ref: Figure 4.2 to Figure 4.3.
Table 4.1 - Machine Information Decals

Item ISO ANSI
1
Drain water overnight.
Switch off machine and disconnect

battery terminals and remote unit prior to
welding.
Improper shutting down of the machine

can result in equipment damage. Switch
off engine and remove key. After at least
20 seconds, turn he battery isolator
switch to the ‘off’ position.

Item ISO ANSI

4
Check filter condition indicator regularly.

Check oil level weekly. Refer to manual
for oil grades.
Do not engage hydraulic clutch when

engine speed is above 1250 rpm (low
idle)
Diesel Specification
Figure 4.2 to Figure 4.3 show the positions of these information signs on the machine.

1 6 2,5 OMA00332
Figure 4.2 - Information Sign Positions Left Hand Side
2,3,4
OMA00333
Figure 4.3 - Information Sign Positions on Power Unit

4.5 Optional Equipment

1 A remote radio control and receiver can be fitted for operating the tracks to move the machine.
The radio remote control can also be set to control other machine components.
2 Belt Weigher with integrator and speed sensing wheel fitted to the discharge conveyor.
3 Hydraulically driven water pump assembly to provide pressurised water supply to the dust
suppression sprays.
4 Fuel transfer pump, electrically driven from the engine 24v supply.
5 Crusher mounted camera with display on machine control panel screen.
6 Alternative blow bar configurations and materials are available to suit various applications.
7 Over band magnetic separator with permanent magnet, suspended over the product conveyor.
It is intended to extract ferrous materials from the crushed product.
8 Dirt Conveyor, allows the extraction of smaller fines onto the dirt conveyor with the coarser
material being fed to the vibrating discharge feeder then on to the product conveyor.


Transportation 5
Table of Content
5 Transportation............................................................................................. 5-2
5.1 Preparation Prior to Transportation.................................................................5-2
5.2 Placing the Machine into the Transport Position.............................................5-3
(1) Placing Discharge Conveyor into the transport position.............................5-3
(2) Placing the dirt conveyor into the transport position (Standard Models)....5-5
(3) Placing the dirt conveyor into the transport position (Pre-Screen Models).5-7
(4) Placing the hopper flares into the transport position (Standard Models).. 5-10
(a) Placing the hopper flares into the transport position (Pre-Screen
Models)................................................................................................5-12
(5) Placing the platform ladders into the transport position............................5-15
5.3 Loading..........................................................................................................5-16
5.4 Unloading......................................................................................................5-17
5.5 Transport Tie-Down Points............................................................................5-18

5 Transportation
5 Transportation
5.1 Preparation Prior to Transportation
nn WARNING
Prior to transportation always check the machine for loose and/or damaged components. Fasten
all loose parts, replace missing items or make repairs as found necessary to ensure that all
components are safely secured during transportation.
Nip Point Hazard.

Nip points exist where pins and rams need to be reconnected.
Moving Object Hazard.

When lifting any heavy sub assemblies there is always risk of the object unexpectedly moving.
Ensure adequate distance is kept from the assembly when being raised from the ground. Failure
in doing so may result in serious injuries.
Always wear correct personal protective equipment.
nn DANGER
Fluid injection hazard
Escaping fluid under pressure can penetrate skin, causing serious injury. Wear personal protective
equipment. Relieve pressure before disconnecting hydraulic lines. Keep away from leaks and
pin holes. Use a piece of cardboard to search for leaks. Do not use hand. If fluid is injected
under skin, get medical help immediately.
nn CAUTION
Ensure that a full and thorough risk assessment has been carried out prior to carrying out any
reassembly of the machine.
NOTICE
When transporting the machine, it is the responsibility of the haulage contractor to safely secure
it to the transporter.
PROCEDURE
1. Prior to stopping the machine ensure that all material has been processed through the
machine.
2. Ensure that there is no material on the conveyors, feeder or in the crusher
3. Stop the machine according to the procedure in Section 7.
4. Wash the machine to remove all debris.
5. Prior to transportation always check the machine for loose or damaged components
6. Ensure there is no personnel on or around the machine prior to putting the machine into the
transport position and manoeuvring the machine.

Transportation 5
5.2 Placing the Machine into the Transport Position
(1) Placing Discharge Conveyor into the transport position
PROCEDURE
1. Observe all safety warnings.
2. Ensure the isolator switch is at the ‘ON’ position (item 1), Ref: Figure 5.1.
1 2
OMA00004
Figure 5.1 - Isolator Switch
3. Start the engine.

4. On the Main Menu Screen highlight the Setup Icon (Item 7). Ref: Figure 5.2.
1 8
2 7
3 4 5 6 OMA00311
Figure 5.2 - Main Menu
5. Press Enter F6 (Item 6) or the Scroll button (Item 3).

»»The Setup Screen will appear Ref: Figure 5.3.

5 Transportation
2 3 4 5 6 7 8 OMA00318
Figure 5.3 - Setup Screen
6. On the Setup Screen highlight the Discharge Conveyor Icon (Item 1, Ref: Figure 5.3) and
press enter.
»»The F2 & F3 buttons (Items 4 & 5) will now display the Discharge Conveyor Raise and Lower selection.
• F2 Raise
• F3 Lower
7. Press and hold the F3 Button (Item 5) to lower the Discharge Conveyor.
»»An audible warning siren will sound for a few seconds and then the conveyor will lower.
8. Lower the conveyor fully until it is in the transport position.

Transportation 5
(2) Placing the dirt conveyor into the transport position (Standard Models)
nn WARNING
Nip Point Hazard.
Nip points exist at pin and ram pivot points.
Ensure all personell are clear of moving assemblies and other objects.
PROCEDURE
1 8
2 7
3 4 5 6 OMA00311

2 3 4 5 6 7 8 OMA00319
4. On the Setup Screen highlight the Dirt Conveyor Icon (Item 1, Ref: Figure 5.5) and press enter.
»»The F2 & F3 buttons (Items 4 & 5) will now display the Dirt Conveyor Raise and Lower selection.
• F2 Raise

5 Transportation
• F3 Lower
5. Press and hold the F2 Button (Item 4) to raise the Dirt Conveyor.
6. Raise the conveyor fully until it is in the transport position.

Transportation 5
(3) Placing the dirt conveyor into the transport position (Pre-Screen Models)
NOTICE
The extended dirt conveyor head section is only applicable to the Pre-screen machine model.
PROCEDURE
1 8
2 7
3 4 5 6 OMA00311

»»The Setup Screen will appear and a flashing control bank icon (Item 1, Ref: Figure 5.7) will flash
for approx 7 secs. Then the timer symbol will change to a tick.
2 3 4 5 6 7 8 OMA00372
4. When the control bank icon (Item 1, Ref: Figure 5.7) displays the tick the control bank is
enabled.

5 Transportation
5. Remove the securing pin (Item 1, Ref: Figure 5.8) to allow the head section to move in and out.
OMA00374
Figure 5.8 - Head Section Securing Pin
6. Proceed to the control bank at the rear of the machine. Item 1, Ref: Figure 5.9.
1 OMA00373
Figure 5.9 - Rear Control Bank (Pre-Screen Models Only)
7. Familarise with the controls before operating.

8. Press and hold the control lever (Item 3, Ref: Figure 5.10) until the head section has completely
retracted.

Transportation 5
1 2 3 4
OMA00371
Figure 5.10 - Rear Control Bank Levers
9. Replace the securing pin (Item 1, Ref: Figure 5.8) into the transport hole.
10. Press and hold the control lever (Item 4, Ref: Figure 5.10) to fully raise the dirt conveyor into
the transport position.

5 Transportation
(4) Placing the hopper flares into the transport position (Standard Models)
nn WARNING
Nip Point Hazard.
nn DANGER
NOTICE
It is important that you carefully check and understand what each control valve operates. Misuse
of these control valves may result in damaging the hopper components and other assemblies.
PROCEDURE
2. Remove the hopper wedges on both sides of the machine (Items 1, Ref: Figure 5.11). There
are four wedges in total.
OMA00336
Figure 5.11 - Hopper Wedges
3. Start the machine.

4. Proceed to the rear valve bank (Item 1, Ref: Figure 5.12).

Transportation 5
1 OMA00334
Figure 5.12 - Location of rear control bank
5. Familiarise yourself with the control bank before operating.

6. Observe the area around the hopper flares and ensure no personnel or obstructions are near.
1 2 OMA00335
Figure 5.13 - Hydraulic Hopper Control Levers
7. Operate the control lever (Item 2, Ref: Figure 5.13) to fold the rear flare into the transport
position
8. Operate the control lever (Item 1, Ref: Figure 5.13) to fold both side flares into the transport
position.

5 Transportation
(a) Placing the hopper flares into the transport position (Pre-Screen Models)
PROCEDURE
1 8
2 7
3 4 5 6 OMA00311

2 3 4 5 6 7 8 OMA00372
enabled.

Transportation 5
1 OMA00373

7. Press and hold the control lever (Item 1, Ref: Figure 5.17) until the hydraulic wedge locks
on both corners of the flares are completely released.
1 2 3 4
OMA00371
8. Press and hold the control lever (Item 2, Ref: Figure 5.17) until both of the side hydraulic
wedge locks are completely released.

5 Transportation
1 OMA00334
10. Familiarise yourself with the controls before operating.

1 2 OMA00335
12. Operate the control lever (Item 2, Ref: Figure 5.19) to fold the rear flare into the transport
position
13. Operate the control lever (Item 1, Ref: Figure 5.19) to fold both side flares into the transport
position.

Transportation 5
(5) Placing the platform ladders into the transport position
nn WARNING
Nip Point Hazard.
Nip points exist at hinge points of ladders.
PROCEDURE
1. Remove the securing bolts (Items 1, Ref: Figure 5.20).
OMA00338
Figure 5.20 - Ladder Working Position
2. Securely hold the platform ladder to prevent it from falling when lifting, and fold into the
transport position (Ref: Figure 5.21).
2 OMA00337
Figure 5.21 - Platform Ladder Transport Position
3. With the ladder in the transport position secure into place with the fasteners (Items 1, Ref:
Figure 5.21).
4. Place the securing bolts (Items 1, Ref: Figure 5.20) into the second hole (Item 2, Ref: Figure
5.21) to prevent them from being lost.

5 Transportation
5.3 Loading
NOTICE
Securing the machine and any loose items to the low loader trailer is the responsibility of the
haulage contractor.
PROCEDURE
1. Position suitable ramps at the end of the transporter.
2. Ensure that the machine is in the transport position.
3. Ensure that all loose items are carefully stowed and secured if these are to be transported
on the machine.
5. Ensure the engine speed is at idle.
6. Slowly track the machine onto the transporter, Ref: Section 7.
7. Stop the engine.
8. Remove ramps from the end of the transporter.
9. Secure the machine using the tie down transport brackets (Ref: Section 5.5) and all loose
items to the transporter

Transportation 5
5.4 Unloading
NOTICE
Removing the fastenings securing the machine and any loose items to a transporter is the
responsibility of the haulage contractor.
PROCEDURE
1. Remove the fastenings securing the machine and any loose items to a transporter.
2. Position suitable ramps at the end of the transporter.
3. Ensure that any loose items transported with the machine will not cause any hazards during
unloading.
5. Ensure the engine speed is at idle.
6. Slowly track the machine off the transporter, Ref: Section 7.
7. Stop the engine.
8. Remove ramps from the end of the transporter.

5 Transportation
5.5 Transport Tie-Down Points
NOTICE
When transporting the machine, it is the responsibility of the haulage contractor to safely secure
it to the transporter.
This machine is fitted with transport tie down brackets the brackets are indicated on the machine
by a safety symbol (Ref: Figure 5.22). Under NO circumstances should these be ever used as a
lifting point for the machine.
OMA00588
Figure 5.22 - Transport Tie Down Point Symbol
There are four tie down points to the outer sides of the machine. The location of these points are
shown in Figure 5.22, Figure 5.23. There are also four inner tie down points. The inner points
are located at the front and back of the machine Ref: Figure 5.25 and Figure 5.26.
1 2 OMA00583
Figure 5.23 - Transport Tie Down Points

Transportation 5
3 4 OMA00584
Figure 5.24 - Transport Tie Down Points
OMA00587
Figure 5.25 - Front and Rear Transport Tie Down Points

5 Transportation
OMA00589
Figure 5.26 - Front Transport Tie Down Points

Initial Setup and Adjustments 6
Table of Content
6 Initial Setup and Adjustments................................................................... 6-2
6.1 Initial Inspection...............................................................................................6-2
6.2 Location Considerations..................................................................................6-2
6.3 Setting Up The Machine..................................................................................6-3
6.4 Initial Setup......................................................................................................6-4
(1) Placing the Discharge Conveyor into working position...............................6-4
(2) Placing the hopper flares into working position (Standard Model).............6-6
(a) Placing the hopper flares into working position (Pre-Screen Model).....6-8
(3) Placing the Dirt Conveyor into the working position (Standard Model).... 6-11
(4) Placing extended dirt conveyor into working position (Pre-Screen Model).6-13
(5) Placing the platform ladders into the working position.............................6-16
6.5 Adjusting the crusher discharge opening......................................................6-17
(1) XA Model..................................................................................................6-17
(2) XR Models................................................................................................6-20
6.6 Setting up and using the Fuel Transfer Pump (Optional).............................6-23
6.7 Setting up and using the Water Pump (Optional).........................................6-25
6.8 Setting up the Deflector Plate (Optional)......................................................6-26
6.9 Initial Startup and Running In........................................................................6-28

6 Initial Setup and Adjustments

The buyer shall be responsible for ensuring that a suitably prepared, flat and level site is available
for the plant and that the ground is capable of sustaining the working of the equipment. Unit
dimensions and loadings can be provided to the buyer for both transportation and operating
purposes.
On arrival of the plant on site Powerscreen® or your local dealer can provide an Engineer if
required at extra cost to commission the plant.
Feed material, and other essentials to be provided by the buyer in good time for the commissioning
being carried out.
6.1 Initial Inspection

When the plant is delivered, thoroughly check for any damage that might have occurred during
transport. Do not set up the unit until the inspection is complete. Complete any delivery and start-
up forms that were supplied with the equipment. Take note of any damage found, and photos if
possible, and have the driver initial your description of any problem(s).
Check all loose parts, small-parts boxes, and tools against the packing list to ensure all items
shipped are present. Check in and around the plant that may have been shipped inside the plant.
6.2 Location Considerations

Prior to setting up the plant, consideration should be given to a suitable layout to prevent oversize
material or metal from entering the plant. In order to prevent bridging of the crusher, no material
above the size recommended should be fed into the plant.
Position the plant in a safe, level, operating position making sure both tracks are in full contact
with the ground to minimise movement of the plant. Confirm that the foundations which are to
support the plant and ancillary equipment are firm and level and are able to support the plant
when in use. Regularly check that the plant is level and stable.
Pay attention to access from the loading area and to where material is to be deposited.
Ensure the area under the tail drum of the product conveyor is free of large stones etc. Which
may cause damage to the belt.
For dusty conditions some account should be taken of the prevailing wind direction to minimize
the possibility of dust entering the air intake.
When setting up the plant ensure that enough space is available around the plant to enable easy
set up, servicing and repair work.
Machines arranged before and after this plant will have to be placed on the site accordingly.

6.3 Setting Up The Machine
NOTICE
When the machine arrives it will be in the transport position: Before carrying out any setup
procedures ensure the machine is located in a suitable position and all personnel are clear of
moving parts.
nn WARNING
Nip Point Hazard.
Nip points exist where pins need removed or replaced. Stay clear of moving assemblies.
Moving Object Hazard.

When lifting any heavy sub assemblies there is always risk of the object unexpectedly moving.
Ensure an adequate distance is keep from the assembly when being raise from the ground.
Failure in doing so may result in serious injuries.
Always wear correct personnel protective equipment.
nn DANGER
nn CAUTION
Ensure that a full and thorough risk assessment has been carried out prior to carrying out any
setup procedures on the machine.

6.4 Initial Setup
(1) Placing the Discharge Conveyor into working position
PROCEDURE
2. Ensure the isolator switch is at the ‘ON’ position (item 1), Ref: Figure 6.1.
1 2
OMA00004
4. On the Main Menu Screen highlight the Setup Icon (Item 7). Ref: Figure 6.2
1 8
2 7
3 4 5 6 OMA00311
»»The Setup Screen will appear Ref: Figure 6.3

2 3 4 5 6 7 8 OMA00318
6. On the Setup Screen highlight the Discharge Conveyor Icon (Item 1, Ref: Figure 6.3) and
press enter.
»»The F2 & F3 buttons (Items 4 & 5) will now display the Discharge Conveyor Raise and Lower selection.
• F2 Raise
• F3 Lower
7. Press and hold the F2 Button (Item 4 ) to raise the Discharge Conveyor.
»»An audible warning siren will sound for a few seconds and then the conveyor will raise.
8. Raise the conveyor fully up until it is in the working position.

(2) Placing the hopper flares into working position (Standard Model)
nn WARNING
Nip Point Hazard.
NOTICE
It is important that you carefully check and understand what each control valve operates. Misuse
of these control valves may result in damaging the hopper components and other assemblies.
nn DANGER
PROCEDURE
1 OMA00334
4. Familiarise yourself with the control bank before operating.

1 2 OMA00335
6. Operate the control lever (Item 1, Ref: Figure 6.5) to raise both side flares into the working
position.
7. Operate the control lever (Item 2, Ref Figure 6.5) to raise the rear flare into the working
position.
8. Fit the hopper wedges on both sides of the machine (Items 1, Ref: Figure 6.6). There are
four wedges in total.
OMA00336
Figure 6.6 - Hopper Wedges
9. Fit the hopper wedge securing chains to prevent them from falling out.

(a) Placing the hopper flares into working position (Pre-Screen Model)
PROCEDURE
1 8
2 7
3 4 5 6 OMA00311
2 3 4 5 6 7 8 OMA00372
4. When the control bank icon (Item 1, Ref: Figure 6.8) displays the tick the control banks are
enabled.

1 OMA00334
Figure 6.9 - Rear Control Bank
8. Press and hold the control lever (Item 1, Ref: Figure 6.10) and fully raise the both of the
side flares.
1 2 OMA00335
9. Press and hold the control lever (Item 2, Ref: Figure 6.10) until the rear flare is completely
raised.
10. Proceed to the opposite control bank (Item 1, Ref: Figure 6.11).

1 OMA00373
on both sides of the flares are in the locked position.
1 2 3 4
OMA00371
on both corners of the flares are in locked position.
14. Visually inspect the hydraulic wedge locks to ensure they are in the locked position

(3) Placing the Dirt Conveyor into the working position (Standard Model)
nn WARNING
Nip Point Hazard.
PROCEDURE
2. On the Main Menu Screen highlight the Setup Icon (Item 7, Ref: Figure 6.7).
1 8
2 7
3 4 5 6 OMA00311
2 3 4 5 6 7 8 OMA00319

4. On the Setup Screen highlight the Dirt Conveyor Icon (Item 1, Ref: Figure 6.8) and press enter.
»»The F2 & F3 buttons (Items 4 & 5) will now display the Dirt Conveyor Raise and Lower selection.
• F2 Raise
• F3 Lower
5. Press and hold the F3 Button (Item 5) to lower the Dirt Conveyor.
6. Lower the conveyor fully until it is in the working position.

(4) Placing extended dirt conveyor into working position (Pre-Screen Model)
NOTICE
The extended dirt conveyor head section is only applicable to the Pre-screen machine model.
PROCEDURE
1 8
2 7
3 4 5 6 OMA00311

2 3 4 5 6 7 8 OMA00372
enabled.

1 OMA00373
7. Press and hold the control lever (Item 4, Ref: Figure 6.18) until the dirt conveyor is fully
unfolded.
1 2 3 4
OMA00371
8. Remove the securing pin (Item 1, Ref: Figure 6.19 ) to allow the head section to move in
and out.
OMA00380
Figure 6.19 - Head Section Securing Pin

9. Press and hold the control lever (Item 3, Ref: Figure 6.18) to fully extend the dirt conveyor
head section into the working position.
10. Replace the securing pin (Item 1, Ref: Figure 6.19) to prevent the head section from moving
in or out.

(5) Placing the platform ladders into the working position
nn WARNING
Nip Point Hazard.
Nip points exist at hinge points of ladders.
PROCEDURE
1. Remove the securing bolts (Items 2, Ref: Figure 6.20) from both sides of the ladder.
2 OMA00337
Figure 6.20 - Platform Ladder Transport Position
2. Securely hold the platform ladder to prevent it from falling and release the fasteners (Items
1, Ref: Figure 6.21).
3. Lower the ladder into the working position (Ref: Figure 6.21).
OMA00338
Figure 6.21 - Ladder Working Position
4. Refit the securing bolts (Items 2, Ref: Figure 6.20) into the working position holes (Items 1,
Ref: Figure 6.21).

6.5 Adjusting the crusher discharge opening
nn WARNING
Nip Point Hazard.
Always lift the spacing shims by the lifting loops provided. Accedental closure will result in serious
injury.
Keep clear of the shim opening whilst peforming the discharge setting
NOTICE
When the jaw in or out buttons are pressed the alarm will siren, together with a flashing beacon.
(1) XA Model
PROCEDURE
2. On the Main Menu Screen highlight the setup Icon (Item 7, Ref: Figure 6.22).
1 8
2 7
3 4 5 6 OMA00311
»»The Machine Setup Screen will appear Ref: Figure 6.23 for Pre-Screen machine and Ref: Figure
6.24 for Standard machines..

2 3 4 5 6 7 8 OMA00376
Figure 6.23 - Jaw Adjust Screen (Pre-Screen Machines Only)
2 3 4 5 6 7 8 OMA00591
Figure 6.24 - Jaw Adjust Screen (Standard Machines Only)
4. Highlight the jaw adjust icon (Item 1, Ref: Figure 6.23 or Item 1, Ref: Figure 6.24) and press
enter.
»»The F2 and F3 buttons (Items 4 & 5) will now display the jaw in and out icons.
5. On the jaw adjust screen press and hold the ‘Jaw In’/ F3 button (Item 5, Ref: Figure 6.23 or
Figure 6.24) to fully open the jaw and release the shims.
6. Insert the jaw locking pin stored in the tool box, into the tail bracket to lock the jawstock into
the forward position whilst changing the shims.
7. Remove the shim locking bars (Items 1, Ref: Figure: 6.25).

1 OMA00377
Figure 6.25 - XA400 Shim Locking Bars
8. Remove any dirt that may prevent shims from seating correctly.
9. Insert or remove the required amount of shims in order to achieve the desired discharge
opening. Add shims to reduce the setting dimensions.
10. Replace the shim locking bars (Items 1, Ref: Figure 6.25).
11. Remove the jaw locking pin when the adjustment is complete.
12. Press and hold the ‘Jaw Out’/F2 button (Item 4, Ref: Figure 6.23 or Figure 6.24) until the
jaw is fully closed.
13. Check the discharge opening measurement and adjust if necessary.

(2) XR Models
PROCEDURE
2. On the Main Menu Screen highlight the setup Icon (Item 7, Ref: Figure 6.26).
1 8
2 7
3 4 5 6 OMA00311
»»The Machine Setup Screen will appear Ref: Figure 6.27 for Pre-Screen machine and Ref: Figure
6.28 for Standard Models.
2 3 4 5 6 7 8 OMA00376
Figure 6.27 - Jaw Adjust Screen (Pre-Screen Machines Only)

2 3 4 5 6 7 8 OMA00591
Figure 6.28 - Jaw Adjust Screen (Standard Machines Only
4. Highlight the jaw adjust icon (Item 1, Ref: Figure 6.27 or Figure: 6.28) and press enter.
»»The F2 and F3 buttons (Items 4 & 5) will now display the jaw in and out icons.
5. On the jaw adjust screen press and hold the ‘Jaw Out’/ F2 button (Item 4, Ref: Figure 6.27
or Ref: Figure 6.28 ) to fully open the jaw and release the shims.
6. Remove the shim guards from each side of the machine. Items 1, Ref: Figure 6.29.
OMA00378
Figure 6.29 - XR400S Shim Guards
7. Remove the shim locking bars (Items 1, Ref: Figure 6.30).

OMA00379
Figure 6.30 - Shim Locking Bar
8. Remove any dirt that may prevent shims from seating correctly.
9. Insert or remove the required amount of shims in order to achieve the desired discharge
opening. Add shims to reduce the setting dimensions.
10. Replace the shim locking bars (Items 1, Ref: Figure 6.30).
11. Replace both of the shim guards (Items 1, Ref: Figure 6.29).
12. Press and hold the ‘Jaw In’/F3 button (Item 5, Ref: Figure 6.28) until the jaw is fully closed.
13. Check the discharge opening measurement and adjust if necessary.

6.6 Setting up and using the Fuel Transfer Pump (Optional)
nn WARNING
Do not use the fuel transfer pump for any other purpose than filling the diesel fuel tank on a
Powerscreen machine.
nn DANGER
Diesel fuel is highly flammable and is an explosion/burns hazard. NEVER remove the filler cap
or re-fuel, with the engine running.
NEVER add petrol, gasoline or any other fuel mixes to diesel because of increased fire or explosion
risks.
DO NOT smoke while refilling or carrying out maintenance on the fuel system. DO NOT carry out
maintenance on the fuel system near naked lights or sources of sparks, such as welding equipment.
FLASHPOINT BELOW 37°C (99°F) PETROL, GASOLINE, BENZINE (DO NOT USE)
FLASHPOINT ABOVE 37°C (99°F) DIESEL, GAS OIL, FUEL OIL (TO BE USED)
NOTICE
Do Not fill the tank to overflow or full capacity. Allow room for expansion and wipe up spilt fuel
immediately.
Do not use a trigger nozzle for delivery into the fuel tank.
DO NOT ALLOW THE PUMP TO RUN DRY.
PROCEDURE
1. With a continuous feed of fuel at a temperature of 40°C there should be a 3 metre (9.8ft)
distance from the bottom of the fuel supply tank to the delivery line. Ref: Figure 6.31.
Figure 6.31 - Fuel Setup

2. Ensure the temperature range is no less than -30°C (-22°F) and no more than +50°C (+122°F).

3. Ensure both hoses to the pump are secure to prevent leakage and insert the suction hose
into the fuel supply.
4. Remove the filler cap and insert the delivery hose into the plant fuel tank.
5. Operate the switch on the pump to top up the fuel tank
6. Switch off the fuel pump immediately when the delivery of fuel is completed and stow the
hoses.

6.7 Setting up and using the Water Pump (Optional)
NOTICE
The pump is to provide a pressurised supply of clean water to the dust suppression spray nozzles
included on the machine. The pump is permanently mounted in a suitable position on the plant
near to the water system inlet and is driven by the plant hydraulic system.
PROCEDURE
1. Connect a clean water supply to the pump inlet fitting.
2. Place the valve lever into the ‘ON’ position.
3. Use the screw type valve to regulate the supply to the water system.

6.8 Setting up the Deflector Plate (Optional)
NOTICE
If the machine is fitted with the optional deflector plate, it may not be in the working position. To
place the deflector plate into the operating position follow the procedure below.
PROCEDURE
2. On the Main Menu Screen highlight the Machine Opertaion Icon (Item 1, Ref: Figure 6.32).
1 8
2 7
3 4 5 6 OMA00311
»»The Machine Operation Screen will appear Ref: Figure 6.33.
2 3 4 5 OMA00375
Figure 6.33 - Machine Operations Screen
4. Highlight the setup icon (Item 1, Ref: Figure 6.33) and press enter.
»»The setup screen will appear . Ref: Figure 6.34.

1 2 OMA00576
Figure 6.34 - Deflector Plate
5. On the Setup Screen the F2 & F3 buttons (Items 1 & 2) will now display the Deflector plate
open and close.
• F2 Close
• F3 Open
6. Set the deflector plate to the desired position.

6.9 Initial Startup and Running In
nn WARNING
Entanglement hazard. Contact with moving belts can cause serious injury or death. Stay clear of
moving belts. Before checking belt tension ensure the plant is completely stopped and implement
the lock out and tag out procedure.
NOTICE
Some operators build a ramp at the side of the plant to give their shovel loader a better reach into
the hopper. Avoid any contact with the shovel, excavator or ramp against the side of the plant.
PROCEDURE
1. Initial feed rate should be low gradually increasing up to normal rate over the first days of
operation.
2. After initial period, stop the plant and visually check belts, scrapers, skirting rubbers, rollers
and nip guards for abnormal wear and obstructions.
3. Conveyor belts may behave different with material on them, re tracking may be necessary.
4. Frequently check the oil level in the vibrating feeder.
5. Frequently check the grease in the Pre-Screen bearings.
6. Check the hydraulic system for leaks.
7. Check the plant for unusual noises, vibration, excessive heat, leaks of lubricating oil.
8. Check the quality of the crushed material.
9. Check the crusher vee belts regularly for tension, particularly over the initial few weeks of
operation.

Standard Operating Procedures 7
Table of Content
7 Standard Operating Procedures............................................................... 7-2
7.1 Pre-Operating Checks.....................................................................................7-2
7.2 Start Up...........................................................................................................7-3
(1) Starting the Engine.....................................................................................7-3
7.3 Manoeuvring....................................................................................................7-5
(1) Umbilical Tracking......................................................................................7-6
(2) Remote Tracking........................................................................................7-8
7.4 Standard Operation.......................................................................................7-10
(1) Putting the Machine into Operation..........................................................7-10
(a) Manual Mode.......................................................................................7-10
(b) Auto Mode............................................................................................7-15
(c) Setting the Vibrating Feeder to Local or PDM Mode...........................7-18
7.5 Introducing Material to the Machine..............................................................7-21
7.6 Shutdown......................................................................................................7-22
(1) Manual Shutdown.....................................................................................7-22
(2) Automatic Shutdown.................................................................................7-25
7.7 Blocked Crusher............................................................................................7-26
(1) Stalled Crusher Procedure.......................................................................7-27

7 Standard Operating Procedures

7.1 Pre-Operating Checks
nn WARNING
Wear personal protective equipment.
PROCEDURE
1. Ensure the machine is placed on solid ground capable of carrying the machine‘s weight.
2. Ensure there is adequate space around the machine for operation, material stockpiles,
maintenance and vehicular movement.
3. Ensure that the crusher is empty of material prior to starting.
4. Ensure the material being fed into the crusher is below the size limitations recommended
by the manufacturer
5. Ensure all guards are fully secured in correct/closed position.
6. Remove all loose items from the belt by untying the securing ropes.
7. Ensure that all conveyor belts are sufficiently tensioned.
8. Check the feeder gearbox oil level and the hydraulic oil level and replenish if necessary.
9. Check the engine oil level, coolant level, hydraulic oil level and the fuel level and replenish
if necessary.

7.2 Start Up
(1) Starting the Engine
NOTICE
Faults displayed on the electrical control panel screen should be investigated and rectified
immediately by suitably qualified personnel. Shut down the machine and implement the lockout
and tag out procedure before carrying out any work on the machine.
PROCEDURE
1. Ensure that all of the emergency stop buttons have been released.
2. Turn the isolator switch to the “ON” position (item 1), Ref: Figure 7.1.
1 2
OMA00004
3. Turn the ignition key (Item 1, Ref: Figure 7.2) to the “ON” position (Item 2, Ref: Figure 7.3).
»»The main menu will be displayed on the control panel display screen, The warning siren will sound
for approximately 7 seconds. If any faults are present, a warning sign will be displayed. If not
proceed to step 4.
1 2
OMA00343
Figure 7.2 - Control Panel
4. Turn the key to the crank position, Ref: Figure 7.3 (item 3).

5. If the engine fails to start within 30 seconds, turn the ignition key back to the ‘ON’ position
and allow the starter motor to cool for 2 minutes before attempting to start again.
OMA00095
Figure 7.3 - Ignition Key Positions
6. When the engine starts, allow it to idle for approximately 3 minutes before operating the
machine.

7.3 Manoeuvring
nn DANGER
Do not stand on any of the platforms or ladders on the machine whilst it is being manoeuvred.
When manoeuvring the machine ensure you stand well clear of the machine but are in a position
to have all-round vision to see any obstacles or hazards that may lie ahead e.g personnel,
overhead cables, ditches, unsafe roadways etc. Do not manoeuvre the machine on a gradient
steeper than 30 degrees.
nn WARNING
Crush hazard from tracking machine run over. Ensure all personnel are clear of moving machine.
Prior to attempting any manoeuvring of the machine ensure that all material has been processed
through it and that no material is left in the feed hopper or crusher and that all material has run
off the conveyors..
Ensure that the tracks are free of all obstructions including crushed material and fines.
NOTICE
Avoid manoeuvring the machine over extremely uneven ground as damage may occur.
In cold weather conditions before manoeuvring the machine, run the machine for approx. 10
minutes with the discharge conveyor running, but ensure it is stopped before manoeuvring.

(1) Umbilical Tracking
PROCEDURE
1. Ensure the engine stop button at the base of the handset is released.
2. On the Main Menu Screen (Figure 7.4) select the tracking Icon (Item 2).
1 8
2 7
3 4 5 6 OMA00311
Figure 7.4 - Main Menu Screen
»»The Tracking screen will appear (Figure 7.5).
3. On the tracking screen select the Umbilical Handset Icon by pressing the F3 button (Item
2). Ref; Figure 7.5
1 2 3 4 5 OMA00316
.
Figure 7.5 - Track Mode Display Screen
4. Press the ‘tracks start’ button (Button 8) on the umbilical tracking handset, Ref: Figure 7.6.
»»The Led Indicator on the handset will illuminate red. The safety siren will sound and the safety
beacon will flash. After a period of 7 seconds the LED indicator will illuminate green.
5. Press the track direction buttons (Buttons 1-4) on the umbilical tracking handset to manoeuvre
the machine, Ref: Figure 7.6.
6. When the machine has been tracked to the desired location, Press the ‘tracks stop’ button
(Button 7) on the umbilical tracking handset.
7. Press the F3 button (Item 2) on the control panel to disable the umbilical tracking mode,
Ref: Figure 7.5.

OMA00102
Figure 7.6 - Umbilical Tracking Handset
1 Left Track Forward
2 Right Track Forward
3 Left Track Reverse
4 Right Track Reverse
5 Unused
6 Unused
7 Stop Tracks
8 Start Tracks

(2) Remote Tracking
PROCEDURE
1. Ensure the engine stop button at the base of the Remote handset is released.
3. On the ‘Main Menu’ display screen select the ‘Track Mode’ icon (Item 2) by using the scroll
button (Item 3) or the navigation buttons F4 and F5 (Items 4 & 5), Ref: Figure 7.7.
1 8
2 7
3 4 5 6 OMA00311
Figure 7.7 - Main Menu Display Screen
4. Press enter F6 (item 6) or press the scroll button.
»»The ‘Track Mode’ Display Screen will open, Ref: Figure 7.8.
1 2 3 4 5 OMA00316
.
Figure 7.8 - Track Mode Display Screen
5. Press and hold both of the remote start buttons (Buttons 9 & 0) on the handset for 2 seconds,
Ref: Figure 7.9.
»»The LED Indicators on the handset will flash.
6. Release the radio start buttons.
»»The bottom LED indicator will illuminate green and the other two LEDs will be off.
7. Press the F4 button (Item 4) on the control panel to put the machine into radio tracking mode,
Ref: Figure 7.8.

8. Press the ‘tracks start’ button (Button 9) on the handset, Ref: Figure 7.9.
»»The safety siren will sound and the safety beacon will flash until the ‘tracks stop’ button is pressed..
9. After a period of 7 seconds, press the track direction buttons (Buttons 1-4) on the radio
handset to manoeuvre the machine.
10. When the machine has been tracked to the desired location, press the ‘tracks stop’ button
(Button 9) on the radio handset.
11. Press the F3 button (Item 3) on the control panel to disable the remote tracking mode, Ref:
Figure 7.8.
12. Press the stop button at the base of the handset to disable the radio control unit. Ref; Figure
7.9.
OMA00101
Figure 7.9 - Remote Control Handset
1 Left track forward
2 Right track forward
3 Left track reverse
4 Right track reverse
5 Discharge Conveyor Raise (Standard Models Only)
6 Discharge Conveyor Lower (Standard Models Only)
7 Top Apron Open
8 Feeder speed
9 Radio start button and tracks start/stop
0 Radio start button and feeder start/stop

7.4 Standard Operation
(1) Putting the Machine into Operation
NOTICE
The crusher must be started in the correct sequence.
• Discharge Conveyor
• Jaw Crusher
• Dirt Conveyor
• Pre-Screen and Vibrating Feeder
When all components of the machine have been put into operation, allow the machine to run
empty for a short period of time to check for abnormal noises, vibration or excessive heat from
the shaft bearings, fluid leaks, etc.
Before loading material onto the hopper the entire machine must be running.
nn WARNING
Nip point hazard.
Do not reach into a moving machine.
Flying material hazard.
If flying material hits the head or body it can cause serious injury or death.
Wear personal protective equipment.
(a) Manual Mode
PROCEDURE
1. On the ‘Main Menu’ display screen select the ‘Machine Operation’ icon (Item 1) by using the
scroll button (Item 3) or the navigation buttons F4 and F5 (Items 4 & 5), Ref: Figure 7.10.
1 8
2 7
3 4 5 6 OMA00311
»»The ‘Machine Operation’ Display Screen will open, Ref: Figure 7.11.

2 3 4 5 6 OMA00312
Figure 7.11 - Machine Operation Display Screen
3. On the machine operation display screen use the scroll button (Item 2) or navigation buttons
(Items 4 & 5) to highlight the product conveyor (Item 1) and press enter. Ref; Figure 7.11.
»»A pre-start audible warning will sound and the conveyor icon will flash before movement takes place.
4. Scroll to the Jaw Crusher Icon (Item 8) and press enter.
»»A pre-start audible warning will sound and the Jaw Crusher icon will flash before movement takes
place. When the clutch is fully engaged the engine RPM will increase.
2 3 4 5 6 OMA00313

5. Use the scroll button or function buttons to highlight the Dirt Conveyor Icon (Item 1, Ref:
Figure 7.13) and press enter.
2 3 4 5 6 OMA00315
6. To start the Vibrating Feeder and vibrating feeder, highlight the Feeder Icon (Item 1, Ref:
7
1
2 3 4 5 6 OMA00314
7. Proceed to the vibrating feeder control module. Ref: Figure 7.15.

OMA00340
Figure 7.15 - Vibrating Feeder Control Module
8. Press the ‘ON’ button (Item 1, Ref: Figure 7.15).
»»There will be a delay of 3 seconds and then the Pre-screen will start. After a further delay of 3
seconds the vibrating feeder will start.
9. To adjust the feeder speed via the control module, ensure the feeder configuration is in
‘LOCAL’ mode (Ref: Section 7.4(1)(c)) this will enable speed adjustment through the scroll
button on the feeder control module (Item 3, Ref: Figure 7.15).
10. To adjust the feeder speed via the control panel (Item 7, Ref: Figure 7.14) ensure the feeder
configuration is in ‘PDM’ mode (Ref: Section 7.4(1)(c)).
11. Use the scroll button (Item 2) to highlight the feeder speed icon (Item 7) and press enter.
Ref: Figure 7.14.
»»The feeder speed can now be adjusted by using the scroll button (Item 2) or the navigation buttons
F4 & F5 (Items 4 & 5). Ref: Figure 7.14.
12. If the remote control handset is fitted (optional) and is powered on, the feeder can be started
and stopped by pressing button ‘0’ when the handset is activated.
OMA00101
Figure 7.16 - Remote Handset
13. The feeder speed can also be adjusted if the machine is in ‘PDM’ mode, To increase the feeder
speed using the remote handset push in button (8) fully on the handset. Ref; Figure 7.15.
»»The feeder speed will increase.

14. To decrease the feeder speed using the remote handset push button (8) half way in on the
handset.
»»The feeder speed will decrease.
15. There are 3 ways in which the vibrating feeder can be switched off:
• To switch the feeder off via the control use the scroll button (Item 2, Ref: Figure 7.14) to
move the arrow above the feeder icon and press enter.
• To switch the feeder off via the remote control handset press button (8). Ref: Figure 7.16.
• To switch the feeder off via the vibrating feeder control module pressing the ‘OFF’ button
(Item 2, Ref: 7.15).

(b) Auto Mode
PROCEDURE
1. On the ‘Main Menu’ display screen select the ‘Machine Operation’ icon (Item 1) by using the
scroll button (Item 3) or the navigation buttons F4 and F5 (Items 4 & 5), Ref: Figure 7.17.
1 8
2 7
3 4 5 6 OMA00311
»»The ‘Machine Operation’ Display Screen will open, Ref: Figure 7.18.
3. Use the scroll button or function buttons to highlight the Dirt Conveyor Icon (Item 1, Ref:
2 3 4 5 6 OMA00315

4. Start the Vibrating Feeder by highlight the Feeder Icon (Item 1, Ref: Figure 7.18) and press
enter.
7
1
2 3 4 5 6 OMA00314
5. The machine will now begin the Auto Run procedure and the following components will
activate in sequence:
• Discharge conveyor (& optional magnet)
• Jaw Crusher (Rpm will also increase)
• Pre-Screen and Vibrating Feeder (Must be started manually)
6. To adjust the feeder speed via the control panel (Item 7, Ref: Figure 7.19) ensure the feeder
configuration is in ‘PDM’ mode (Ref: Section 7.4(1)(c)).
7. Use the scroll button (Item 2) to highlight the feeder speed icon (Item 7) and press enter.
Ref: Figure 7.19.
»»The feeder speed can now be adjusted by using the scroll button (Item 2) or the navigation buttons
F4 & F5 (Items 4 & 5). Ref: Figure 7.19.
8. To adjust the feeder speed via the control module, ensure the feeder configuration is in ‘Local’
mode (Ref: Section 7.4(1)(c)) this will enable speed adjustment through the scroll button on
the feeder control module (Item 3, Ref: Figure 7.20).
OMA00340
Figure 7.20 - Vibrating Feeder Control Module

9. If the remote control handset is fitted (optional) and is powered on the feeder can be started
and stopped by pressing button ‘0’ when the handset is activated.
OMA00101
Figure 7.21 - Remote Handset
10. The feeder speed can also be adjusted if the machine is in ‘PDM’ mode, To increase the feeder
speed using the remote handset push in button (8) fully on the handset. Ref; Figure 7.21.
»»The feeder speed will increase.
11. To decrease the feeder speed using the remote handset push button (8) half way in on the
handset.
»»The feeder speed will decrease.
12. There are 3 ways in which the vibrating feeder can be switched off:
• To switch the feeder off via the control use the scroll button (Item 2, Ref: Figure 7.19) to
move the arrow above the feeder icon and press enter.
• To switch the feeder off via the remote control handset press button (8). Ref: Figure 7.21.
• To switch the feeder off via the vibrating feeder control module pressing the ‘OFF’ button
(Item 2, Ref: 7.20).

(c) Setting the Vibrating Feeder to Local or PDM Mode
NOTICE
The vibrating feeder speed can be adjusted from the control panel display screen or from the
control module and remote handset.
• To control the vibrating feeder via the control panel the feeder configuration must be set
to ‘PDM’ mode.
• To control the vibrating feeder via the control station and remote control handset the feeder
configuration must be set to ‘LOCAL’ mode.
Selecting ‘PDM’ or ‘LOCAL’ mode can be done whilst the machine is running or idling. If changed
whilst the machine is running the feeder will shut down but can be restarted once the desired
mode has been selected.
PROCEDURE
2. With the machine running or idiling highlight the Information Icon (Item 8, Ref: Figure 7.22).
1 8
2 7
3 4 5 6 OMA00311
3. Press enter (Item 6, Ref: Figure 7.22).
»»The machine information screen will appear (Ref: Figure 7.23)

1 10
2 9
3 8
4 5 6 7 OMA00366
Figure 7.23 - Information Display Screen
4. On the Information Display screen highlight the configuration icon (Item 1, Ref: Figure 7.23)
and press enter.
»»The configuration screen will appear. Ref: Figure 7.24.
OMA00577
Figure 7.24 - Configuration Screen
5. Select the Feeder Diagnostics icon (Item 1, Ref: Figure 7.24) and press enter.
»»The feeder setup screen will appear. Ref: Figure 7.25).

OMA00578
Figure 7.25 - Feeder Setup Screen
6. Using the scroll button (Item 2) highlight the ‘Feeder Speed Control’ tab (Item 1). Ref: Figure
7.25 and press enter.
7. With the Feeder Speed Control now selected the scroll button will now allow you to toggle
between ‘LOCAL and ‘PDM’ mode.
8. When done press ESC to return back to the main menu screen.

7.5 Introducing Material to the Machine

Some operators build a ramp at the side of the machine to give their shovel loader a better reach
into the Hopper. If you do build a ramp avoid contact with the side of the machine.
Initial feed rate should be low gradually increasing up to normal rate over first days of operation.
During this period the belt pressure on each conveyor should be checked to ensure they are
running at the correct pressure (Max pressure is 210 Bar-3050 psi). After initial period stop the
machine and visually check belts, scrapers, skirting rubbers, rollers and nip guards for abnormal
wear and obstructions. Conveyor belts may behave different with material on them, re tracking
may be necessary
• Check the quality of the crushed material.
• Check the crusher vee belts regularly for tension, particularly over initial few weeks of
operation.
• Frequently check the oil levels in the vibrating unit.

7.6 Shutdown
NOTICE
Before stopping the machine ensure that the feeder and crusher are empty and that the product
conveyor and dirt conveyor are clear of material.
The machine must not be shut down at the end of a working shift by only switching off the engine,
pressing an emergency stop button or switching the isolator switch to the off position. The machine
must be stopped in the correct sequence.
In an Emergency situation the emergency stops can be activated to stop the machine, Note that
if this happens all material needs to be cleared from the machine before it can be started again.
It is recommended that at the end of operation for the day the machine is routinely cleaned down
and thoroughly examined to check for any damage, breakages, wear, leaks etcetera which should
be rectified before further operation.
(1) Manual Shutdown
PROCEDURE
1. Ensure the feeder is empty of material.
2. On the machine operation display screen use the scroll button or navigation buttons to move
the arrow above the feeder icon (Item 1) and press the enter button F6 (Item 6) to stop the
feeder. Ref: Figure 7.26.
7
1
2 3 4 5 6 OMA00314
3. Ensure the Jaw Crusher is empty of material.

4. Use the scroll button (Item 2) to move the arrow above the crusher icon (Item 1) and press
the enter to stop the crusher. Ref: Figure 7.27.
2 3 4 5 6 OMA00313
5. Ensure discharge conveyor is empty of material.
6. Use the scroll button to move the arrow above the discharge conveyer icon (Item 1, Ref:
Figure 7.28) and press the enter to stop the conveyor.
2 3 4 5 6 OMA00312
7. Ensure dirt conveyor is empty of material.

8. Use the scroll button (Item 2) to highlight the dirt conveyer icon (Item 1, Ref: Figure 7.29)
and press the enter to stop the dirt conveyor.
2 3 4 5 6 OMA00315
9. Turn the ignition key to the off position and remove the key.
10. Wait for at least 20 seconds before turning the isolator switch to the off position.

(2) Automatic Shutdown
PROCEDURE
1. With the machine fully running ensure that the Feeder, Jaw Crusher, Discharge conveyor
and Dirt conveyor are empty of material.
2. Use the scroll button (Item 2) to highlight the dirt conveyer icon (Item 1, Ref: Figure 7.30)
and press the enter to stop the dirt conveyor.
2 3 4 5 6 OMA00315
3. Select the discharge conveyor icon (Item 1, Ref: Figure 7.31) and press enter.
»»The machine will automatically shut down in the correct sequence:
• Feeder and Pre-Screen
• Jaw Crusher (Rpm will Decrease)
• Discharge Conveyor
2 3 4 5 6 OMA00312

7.7 Blocked Crusher
nn DANGER
Switch off and lockout before working at a machine. Dangerous nip points exist.
If flying material hits the head or body it can cause serious injury or death.
When manually clearing crusher always isolate the machine and lockout.
When manually clearing crusher be aware that pressure in jaws may cause movement and
potential nip points.
nn WARNING
Before operation you must read and understand the safety section in section 2 of this manual.
Always wear correctly fitting protective clothing.
It is the responsibility of the owner, machine operator and safety officer of the Terex® Powerscreen
crusher to provide a safe means of unblocking a stalled crusher unit.
To comply with Health and safety law it is necessary to carry out adequate risk assessments of
the procedures for unblocking a crusher.
If the Crusher begins to come under load the crusher hydraulic pressure increases and will cut
the feeder off automatically after 3 seconds, this time delay allows the crusher more time to
process the material. If after a further 7 seconds the crusher is still blocked and under pressure
the crusher will come to a stop.
If the crusher stops during operation i.e. Emergency stop activated or lack of fuel, the crusher
may not be able to continue without clearing the crusher unit.
If tramp metal is causing the blockage and cannot be removed by hydraulic adjust opening of the
crusher. In this situation the complete machine must be shut down and locked out. The blockage
can then be cleaned manually. Refer to the stalled crusher procedure (Ref: Section 7.7(1)).
When clearing the crusher by hand extreme caution must be taken, pressure in the jaws may
cause the crusher to move after materials have been removed, dangerous nip points and flying
material hazards exist.

(1) Stalled Crusher Procedure

In the situation where an oversize or tramp piece of material causes the crusher to stall, and the
toggle plate does not fail, it is possible that very high pressure will be sustained on the moving
swing jaw (dependant on which position the stall occurred in the crushing cycle). This pressure
may result in the object to be ejected upwards under high force and therefore will need to be
released under controlled conditions to enable safe removal of the material that has created the
stall condition.
nn WARNING
Cutting through the toggle plate will cause the release of Stored energy in the moving jaw which
may swing violently back Towards the operator performing the cutting operation. Before Any
attempt to carry out the procedures to clear the stalled Condition of the crusher the machine must
be isolated from all Sources of supply and the safety grid at the mouth of the Crusher must be
securely fastened in place. Suitable personal Protection equipment must be worn.
NOTICE
The procedure indicated below or any other procedure developed to remove tramp metals, or
any other material that results in the stalling of the crusher should be incorporated into a permit
to work procedure. This procedure should be maintained under the control of the component
person appointed by the management.
The system should cover all factors of safety including notification to the manager, isolation of
systems and locking out procedure, methods of removal, safe positions for persons and any other
precautions as may be deemed necessary.
PROCEDURE
2. Isolate machine from all energy sources.
3. Ensure the safety grid is over the mouth of the crusher.
4. If the crusher is equipped with hydraulic drive, attempt to start the machine in reverse. (Non
applicable to this machine).
5. If the crusher is equipped with a hydraulic wedge adjust system, attempt to release the
pressure on the jaw by pressing the jaw open button.
6. If none of the above operations are applicable, or successful, then the toggle plate must be
cut. Before the cutting operation is commenced adequate and appropriate provision MUST
be made to support the weight of the stored energy in order to prevent the violent swinging
movement of the jawstock.
7. The toggle plate should heated across the centre line (i.e. between the holes), using a long-
handled ‘oxy acetylene torch’ or similar, such that the operator can stand in a protected
position, well clear of the back of the crusher frame. Heat the material to a dull red - starting
at the mid-point, and working outwards either side in turn. Ideally, the toggle plate should be
heated until it yields. The yielding of the toggle plate will reduce or eliminate the pressure
on the trapped object. If the plate does not yield, then it is recommended that small cuts are
made in either side of the toggle plate with an acetylene torch (say 50 mm from each side)
and the heating procedure repeated until yielding occurs. After the pressure is released due
to the toggle plate yielding, the toggle plate should be cut in two and removed.


Emergency Operating Procedures 8
Table of Content
8 Emergency Operating Procedures............................................................ 8-2
8.1 Lockout and Tagout.........................................................................................8-2
(1) Before Carrying out any Work on the Plant................................................8-2
(2) After Carrying out Work on the Machine.....................................................8-4
8.2 Emergency Stop..............................................................................................8-5
8.3 Restarting after Emergency Stop....................................................................8-6

8 Emergency Operating Procedures
8.1 Lockout and Tagout

This procedure is designed to prevent injuries caused by the unexpected start-up or movement of a
machine. These procedures are to be followed every time a machine is to be cleaned,maintained,
adjusted or repaired. When used as intended, Lockout also protects personnel from energy stored
in devices such as springs, accumulators, batteries, hydraulic systems, etc.
Where the lock out and tagout symbols (Ref: Safety Section) appear on a safety sign it indicates
that the machine must be switched off and locked out before any work is carried out.
nn WARNING
Never give your key to anyone else and where more than one person is working on the equipment
they must fit their lock also
(1) Before Carrying out any Work on the Plant
NOTICE
Depending on the type of machine, there may still be several kinds of energy remaining after
the power is turned off. The written lock-out procedure should have a complete list of all these
secondary energy sources. Secondary energy sources may be hydraulic (fluid under pressure),
pneumatic (air under pressure), kinetic (force of moving parts) and/ or potential (force contained
in weights that have been raised).
PROCEDURE
1. Turn off the engine at the starter panel and remove the key (item 1), Ref: Figure 8.1.
1 2
OMA00343
Figure 8.1 - Starter Panel
2. Lock the panel and put the key in a safe place.

3. After 20 seconds, rotate the isolator switch from the “ON” position (item 1) to the “OFF” position
(item 2), Ref: Figure 8.2.

1 2
OMA00004
4. Fit the lock out hasp (item 3) and unique padlock (item 2) on the main power isolator and keep
the key to make sure no one can remove your lock and turn the power back on, Ref: Figure 8.3.
5. Place a Tag (item 1) on the lock that identifies you (by your name, picture or number) as well
as the date and time you locked it out Ref: Figure 8.3.
1
1 2
OMA00005
Figure 8.3 - Isolator Switch Off, Locked and Tagged
6. Release stored energy from the system so that the machine is in a zero energy state.
7. Try to start or activate the machine to make sure that the power is off. (Don’t forget to push
the stop button again, afterward.)

(2) After Carrying out Work on the Machine
PROCEDURE
1. Secure the work area by replacing guards and shields, removing blocks, picking up tools and
inspecting the work area.
2. Take your lock and tag off the main power Isolator.
3. If there are no other locks on then disconnect from the main power and turn on the power.
4. Unlock the operator’s control panel.
5. Warn others before starting the machine.
6. Start the machine and proceed with your work.

8.2 Emergency Stop
NOTICE
In an emergency situation stop the machine by pressing an emergency stop button on the machine.
nn WARNING
The stop button on the remote radio control, if fitted, is NOT an emergency stop as it may not be
operative at all times.
When an emergency stop has been initiated, the ignition switch stays on. Do not attempt to restart
the engine until it is safe to do so.
PROCEDURE
1. Press any emergency stop button to stop the engine and machine, Ref: Figure 8.4 & 8.5.
»»The safety alarm will sound until it is acknowledged and cancelled.
2. Turn the ignition key to the off position as soon as possible.
3. Remove the ignition key.
4. Set the isolator switch too the off position.
5. When safe, release the emergency stop button(s) by pulling or twisting.
1 2 OMA00341
Figure 8.4 - Emergency Stop Locations Right Hand Side
3 4 OMA00342
Figure 8.5 - Emergency Stop Locations Left Hand Side
8.3 Restarting after Emergency Stop
nn WARNING
Ensure that the problem has been solved and all personnel are clear of the machine. Before
restarting, ensure that all guards are correctly fitted and fully functional. Do not restart until
it is safe to do so.
NOTICE
The machine must not be restarted if there is any material in and/or on the machine Ensure there
is no material in and/or on the machine before restarting.
PROCEDURE
1. Release the emergency stop button(s) by pulling or twisting.
2. Restart the machine..

Maintenance 9
Table of Content
9 Maintenance................................................................................................ 9-4
9.1 Safety Before and During Maintenance..........................................................9-4
(1) Diesel Engine.............................................................................................9-6
(2) Crusher.......................................................................................................9-6
(3) Feeder........................................................................................................9-7
(4) Discharge Conveyor...................................................................................9-7
(5) Dirt Conveyor (Optional).............................................................................9-7
9.3 General Machine Maintenance Schedule.......................................................9-8
(1) First 8 Hour Maintenance Schedule...........................................................9-8
(2) Daily Maintenance (10 Hour) Schedule......................................................9-9
(3) Weekly Maintenance (50 Hour) Schedule................................................9-10
(4) First 100 Hour Maintenance Schedule.....................................................9-12
(5) Every 200 Hour Maintenance Schedule...................................................9-12
9.4 Tier 4 Engine Maintenance Schedules..........................................................9-16
(1) First Time at First Start.............................................................................9-16
(2) Daily Maintenance Schedule....................................................................9-16
(3) Maintenance Schedule At Interval (50 Hours)..........................................9-16
(5) Maintenance Schedule (First time at 500 Hours).....................................9-16
(10) Maintenance Schedule (Annually)............................................................9-18
(11) Maintenance Schedule (Every 5 Years)...................................................9-18
9.5 Greasing Schedule........................................................................................9-19
9.6 Recommended Lubricants............................................................................9-20
(1) Grease Lubrication...................................................................................9-20
(2) Hydraulic Oil and Antifreeze.....................................................................9-20
(3) Recommended Lubricants For the Gearbox on the Tracks......................9-21
(4) Engine......................................................................................................9-21
(5) Vibrating Feeder Lubrication.....................................................................9-22
9.7 Hydraulic Maintenance..................................................................................9-23
(1) Hydraulic System Overview......................................................................9-23
(a) Hydraulic Fluids...................................................................................9-23
(b) Oil Tank, Pipes & Fittings.....................................................................9-24
(2) Filtration....................................................................................................9-25
(a) Suction Line Filter................................................................................9-25
(b) Return Line Filters................................................................................9-25

9 Maintenance
(c) Pressure Filter......................................................................................9-26

(d) Hydraulic Oil Tank Breather.................................................................9-27
(3) Changing Hydraulic Filters & Oil...............................................................9-28
(a) Changing Return Filter.........................................................................9-28
(b) Changing Suction Filters......................................................................9-29
(c) Changing Pressure Filters...................................................................9-30
(d) Changing Hydraulic Oil........................................................................9-31
(e) Changing Condensation Control Breather...........................................9-33
9.8 Conveyor Maintenance.................................................................................9-34
(1) Belt Adjustment on Discharge Conveyor..................................................9-35
(a) Belt Tracking Main Conveyor...............................................................9-35
(b) Belt Tensioning on Main Conveyor......................................................9-35
(2) Belt Adjustment on Dirt Conveyor (Optional)............................................9-36
(a) Belt Tracking Dirt Conveyor.................................................................9-36
(b) Belt Tensioning Dirt Conveyor (Optional).............................................9-36
9.9 Vibrating Feeder Maintenance......................................................................9-37
(1) Changing Vibrating Feeder Gearbox Oil...................................................9-37
(a) Checking Oil Level and Refilling..........................................................9-37
(b) Changing Oil........................................................................................9-37
(2) Changing Vibrating Feeder Screen Meshes.............................................9-38
9.10 Pre-screen Maintenance...............................................................................9-39
(1) Changing Mesh on Pre-screen (Option)...................................................9-39
9.11 Tier 4 Engine Maintenance...........................................................................9-40
(1) Tier 4 Engine Overview............................................................................9-40
(2) Changing Engine Filters & Oil..................................................................9-42
(a) Checking Engine Oil............................................................................9-42
(b) Changing Engine Oil............................................................................9-43
(c) Maximum angles of inclination during operation..................................9-44
(d) Changing the Oil Filter.........................................................................9-45
(e) Changing Air Filter Element.................................................................9-47
(3) Cleaning the Centrifugal Oil Cleaner........................................................9-49
(4) Checking Engine Coolant Level...............................................................9-54
(5) Fuel System..............................................................................................9-55
(a) Changing Fuel Filter.............................................................................9-55
(b) Draining the Water Trap.......................................................................9-56
(c) Changing Water Trap Filter..................................................................9-56
(d) Bleeding the Fuel System....................................................................9-58
(e) Refuelling Diesel Tank.........................................................................9-59
9.12 Urea Tank Maintenance................................................................................9-60
(1) Changing the Reductant Filter..................................................................9-60
(2) Refilling the Urea Tank..............................................................................9-61
9.13 Track Maintenance........................................................................................9-63
(1) Changing Gearbox Oil in Tracks...............................................................9-64
(2) Track Adjustment......................................................................................9-66
(a) To Release Track Tension....................................................................9-66
(b) To Increase Track Tension...................................................................9-67

Maintenance 9
9.14 Jaw Crusher Maintenance.............................................................................9-68

(1) Checking components for wear................................................................9-68
(a) Daily Component Checks....................................................................9-68
9.15 Vee Belt Maintenance...................................................................................9-69
(1) Alignment..................................................................................................9-70
(2) Adjustment................................................................................................9-71
(a) Manual Adjustment..............................................................................9-71
(3) Drive Belt Tension.....................................................................................9-73
(a) Belt Tensioning Measurements............................................................9-74
(4) Replacement of Vee Belts........................................................................9-75
9.16 Electrical Maintenance..................................................................................9-76
(1) Prior to Welding........................................................................................9-76
(2) Safely Remove and Install the Battery.....................................................9-77
9.17 Hydraulic Ram Maintenance.........................................................................9-80

9 Maintenance
9 Maintenance
9.1 Safety Before and During Maintenance
nn WARNING
Practice safe maintenance. Read and understand the operators manual before doing any work.
nn CAUTION
Maintenance should only be carried out by trained and qualified personnel.
PROCEDURE
1. Whenever maintenance or service is being carried out a minimum of two (2) persons should
be present at all times. NEVER WORK ALONE.
2. Prepare yourself. Wear a hard hat, safety goggles, hearing protection and other protective
equipment as required by job conditions. Do not wear loose clothing or jewelry that can
catch on controls or moving parts. Long hair must be tied back.
3. Prepare the machine. Move the machine onto a level surface and apply parking brakes and/
or wheel chocks. Shut off the engine and remove the key. Relieve all hydraulic pressure by
returning controls to neutral. Secure all hydraulically operated attachments with pins provided.
4. Isolate all electrical supplies to the machine before starting any maintenance work.
5. Never attempt repairs or adjustments to the machine while it is running. Exempt to this
rule: Belt tracking adjustments are only possible during working process (see Belt Tracking
& Tensioning).
6. Remove only guards or covers that provide access. Wipe away excess grease and oil.
7. Never leave guards off or access doors open when unattended. Keep bystanders away if
access doors are open.
8. When working beneath raised equipment, always use blocks, jack-stands or other rigid and
stable supports. Never work under unsupported equipment.
9. Performing work above 7 ft (2 m) always use an approved (EN/ANSI) safety harness. Always
use walkways and platforms provided or a safe secure platform approved by the machine
operators management. Do not use any unauthorized or unsafe platforms.
10. Never operate any type of engine without proper ventilation – EXHAUST FUMES CAN KILL.
(See Electrical and Engine Safety for more detailed checklist).
11. Checking for hydraulic leaks. Beware hydraulic fluid under pressure can penetrate the skin
or damage eyes. Fluid leaks under pressure may not be visible. Use a piece of cardboard
to find leaks but do not use bare hand.
12. Wear safety goggles for eye protection. If fluid enters skin or eye, get immediate medical
attention. (See Hydraulic Safety for more detailed checklist).
13. Clean or replace damaged, missing or painted over safety signs that cannot be read.
14. Rotating and moving parts must be inspected during maintenance and replaced if cracked
or damaged. Excessively worn or damaged parts can fail and cause injury or death.

Maintenance 9
15. After maintenance, tighten all bolts, fittings and connections. Install all guards, covers and
shields. Replace or repair any damaged ones. Refill and recharge pressure systems with
recommended fluids. Start the engine and check for leaks. Operate all controls and make
sure the machine is functioning properly. After testing, shut down, check the work you
performed (any missing cotter pins, washers, locknuts, etc.)? Recheck all fluid levels before
releasing machine for operation.
16. NEVER make any modifications, additions or conversions which might affect safety without
the supplier’s approval.

9 Maintenance
9.2 General Information
nn WARNING
Switch off and Lockout before working at the machine.
Dangerous nip points exist.
(1) Diesel Engine

The diesel engine is the heart of your machine and a great deal of care and thought has gone
into its selection. In the interest of continued peak performance from your machine the engine
must be maintained and cared for with meticulous attention in accordance with the manufacturers
instructions as detailed in the “Operators Handbook”, a copy of which is included with this manual.
OMA00111
Figure 9.1 - Water Cooled Diesel Engine
(2) Crusher
The best way to keep the crusher in good operating condition is to adopt a planned program of
inspection and preventative maintenance. It is recommended that a record be kept of the actual
operating hours of the crusher, the inspection intervals, and the maintenance required. A new
crusher should be examined after a relatively short period of operation. Detailed maintenance
instructions are outlined in the ‘Single Toggle Jaw crusher Instruction manual’ a copy of which is
included with this manual.
OMA00230
Figure 9.2 - Jaw Crusher

Maintenance 9
(3) Feeder
The greatest single factor extending the life of the vibrating feeder is proper lubrication. Insufficient
lubrication quickly damages the bearings. Also, excess oil in the vibrating unit increases oil
agitation causing high operating temperature and higher horse power requirements. Cleanliness
is vitally important. Dust and dirt will cause premature failure of the bearings. Clean all dirt from
openings before removing caps. Use only clean oil to fill the vibrator housing.
(4) Discharge Conveyor

The Discharge conveyor is height adjustable and has a plain troughed belt with a vulcanized
joint, with hydraulic motor drive at a pre-set speed. The conveyor is fully skirted and enclosed
from collection point to magnet separator. Canvas type removable dust covers are fitted at the
head end.
(5) Dirt Conveyor (Optional)

The side discharge dirt conveyor has a plain belt and hydraulic folding facility for transportation
and is fitted with a hydraulic motor at a pre-set speed. The dirt conveyor is fed by the smaller
material that falls through the pre-screen mesh with the coarser material being fed into the impactor.

9 Maintenance
9.3 General Machine Maintenance Schedule
(1) First 8 Hour Maintenance Schedule

M a i n t e n a n c e Notes Signature
Task
Change Vibrating Feeder Change
gear box oil

Maintenance 9
(2) Daily Maintenance (10 Hour) Schedule
General Maintenance
Task
Check For Material Build up Check/Remove
Check All Safety Guards are in Place Check/Replace
Check For Loose parts, missing nuts & Tighten/Replace
bolts
Check Hydraulic hoses, Rams & pumps for Tighten/Replace
leaks(When tightening fittings use a Torque
wrench and follow the torque setting on the
following page)
Check Hydraulic oil level in site gauge. Check/Top up
Check Diesel Level in fuel tank. Check/Refill
Check indicator on pressure inlet filter. Check
Conveyor Maintenance
Maintenance Notes Signature
Task
Check Conveyor belts for rips and tears Check/Repair
Check/Repair Check/Tension
Check Belt Alignment Check/Align
Check All rollers are free moving and free Check/Free
from obstruction
Track Maintenance
Task
Check Tension of Tracks Check/Tension
Check Tracks for oil leakage Check/Repair
Crusher Maintenance (See Crusher Operator’s Manual for More Details)

Maintenance Task Notes Signature
Check for loose bolts and Check
parts
Check the Vee belts for Check/Tension
slippage
Check for unusual noise Check
when operating
Feeder Maintenance
Check oil level in vibrating Check/Top up
feeder unit.
Check Mesh Securing Check
bolts are tight.
Check Mesh for wear. Check
9 Maintenance
(3) Weekly Maintenance (50 Hour) Schedule

General Maintenance
Grease all Bearings (See Grease
Greasing Schedule)
Drain the Watertrap Drain
After first 50 Hrs replace Replace
Return Filters
After First 50 Hrs. Change Change
Gearbox oil in Feeder
Conveyor Maintenance
Check Tension of Belt Scrapers Check/Adjust/Replace
Check Tension of Belt Skirting Rubbers - Check/Adjust/Replace
No spillage
Check For Obstruction to Drums Check/Remove
obstruction
Pre-Screen Maintenance
Check Maintenance Task Notes Signature
Grease drive shaft Grease
Bearings

Grease bearing while Crusher is warm and Grease
running.
Check Jaw face bolts are tight. Check/Tighten
Inspect Jaw face wedges for wear and Check/Replace
distortion.
Check that side liner bolts are secure. Check/Tighten
Check lower, middle, and Upper side liners for Check
wear.
Check condition of tension rod. Check
Check condition of pull rod bushes. Check/Rotate/
Replace

Maintenance 9
When tightening hydraulic fitting always use a torque wrench, as overtighting of fittings can break
internal seals. Please follow the torque settings in the table below.
Thread Size Torque Ft/Lb. Torque Kg/Mtr. Torque N/Mtrs

¼” BSP 15 2.07 20.3
3/8” BSP 18 2.49 24.4
½” BSP 40 5.50 53.9
¾” BSP 60 8.30 81.3
1” BSP 85 11.75 115.2
1¼” BSP 110 15.20 149.0
1½” BSP 130 17.98 176.2

9 Maintenance
(4) First 100 Hour Maintenance Schedule

Change Hydraulic Oil Change
Tank Breather
(5) Every 200 Hour Maintenance Schedule

Grease Cylinder Grease
pivots ; Conveyor
adjustment pivots
; Conveyor belt
tensioners

Maintenance 9
(6) Monthly Maintenance (250 Hour) Schedule

General Maintenance
Drain the Watertrap Drain
Change Hydraulic Remove/ Replace
Pressure Filters
Track Maintenance
After First 250 Hrs. Change Change
Gearbox oil in tracks

Check end of toggle and toggle Check/replace
seats for wear or cracking.
Inspect fixed and moving jaw Check
faces for wear, distortion or
growth.
Check the fixed Jaw face to Check/readjust
ensure that the growth of the
jaw faces is not sufficient to
allow them to contact the sides
of crusher frame.
Check tightness of bearing Check/Tighten
housing bolts.
Check fixed jaw face wedges Check/Replace
for distortion or wear preventing
adequate retention of the Jaw
face.
Check moving Jaw face Check/ Replace
retaining wedge for distortion
or wear preventing adequate
retention of the jaw face.
When tightening hydraulic fitting always use a torque wrench, as overtighting of fittings can break
internal seals. Please follow the torque settings in the table below.
Thread Torque Torque Torque

Size Ft/Lb. Kg/Mtr. N/Mtrs
¼” BSP 15 2.07 20.3
3/8” BSP 18 2.49 24.4
½” BSP 40 5.50 53.9
¾” BSP 60 8.30 81.3
1” BSP 85 11.75 115.2
1¼” BSP 110 15.20 149.0
1½” BSP 130 17.98 176.2

9 Maintenance

General Maintenance
Adjust Vee Belt Tension Check/Adjust
Change Hydraulic Return Remove/ Replace
Filters
Feeder Maintenance
Change the oil in the Change
Feeder Unit.

General Maintenance
Change Maintenance Task Notes Signature
Hydraulic Oil Analysis Oil and change if
required **
Suction Filters Remove & Replace
Hydraulic Oil Tank Change
Breather

Inspect the tension rod, Check
checking for damage, wear,
or cracks.
** Your local oil supplier will be able to analysis your hydraulic oil.

Maintenance 9

Change the Gearbox oil in Change
the tracks
Crusher Maintenance
Inspect drawback rod Check
assembly, pin/bush/rod end
wear.

9 Maintenance
9.4 Tier 4 Engine Maintenance Schedules
(1) First Time at First Start

Engine Maintenance (See Engine Operator’s Manual for More Details)
Check Engine Oil Level Check/Top up
Check Coolant antifreeze or Check/Top up
corrosion protection
Check Fuel Level Check
Check Electrolyte Level in Check/Top up
batteries
Check the state of charge in the Check
batteries
(2) Daily Maintenance Schedule

Check Engine Oil Level Check/Top up
Check Water Coolant Level Check/Top up
Check Engine Air Cleaner Service Check
Indicator
Check Fuel Level Check/Top up
Check For Leaks Check/Tighten
(3) Maintenance Schedule At Interval (50 Hours)

Check Electrolyte level in batteries Check/Top up

Change Primary (Outer) air filter Replace
element
(5) Maintenance Schedule (First time at 500 Hours)

Checking and adjusting the valve Check/Adjust
clearance

Maintenance 9

Change Engine Oil * Replace
Clean the Centrifugal Oil Cleaner * Clean
Change the Engine Oil Filter * Replace
Check Electrolyte level in the Check/Top up
batteries
Change Safety (Inner) air filter Replace
element
*More often if required.
(7) Maintenance Schedule at Interval (1000 Hours)

Clean the batteries Clean
Check the state of Check
charge in batteries
Check the Coolant Level Check
Monitor
Check the Engine Drive Check/Tension
Belts
Change Fuel Filter Replace
Change the Reductant Replace
Filter
Change the hydraulic oil Replace
tank breather

Check Coolant Antifreeze or Check/Top up
Corrosion Protection
Check the Engine for Leaks Check/Tighten
Checking and adjusting the valve Check/Adjust
clearance

9 Maintenance

Clean the Cooling System Clean/Replace
and Change Coolant *
(10) Maintenance Schedule (Annually)

Change Engine Oil Replace
Clean the Centrifugal Oil Clean
Cleaner
Change the Engine Oil Filter Replace
Check Coolant Antifreeze or Check/Top up
Corrosion Protection
Clean the batteries Clean
Check the State of Charge in Check
Batteries
Check the Coolant Level Check
Monitor
Check the Engine Drive Belts Check/Tension
(11) Maintenance Schedule (Every 5 Years)

Clean the Cooling System and Check/Top up
Change the Coolant *
Clean or Renew the Air Clean/Replace
Cleaner Filter Element
Change the Air Cleaner Safety Replace
Cartridge
Change the Fuel Filter Replace

Maintenance 9
9.5 Greasing Schedule

It is important that a strict routine of regular servicing is undertaken from the start of operation of
the machine. Regular checks on the lubrication of the machine in accordance with the schedule
is essential.
NOTICE
To deliver the speciﬁed quantity of grease to each of the four crusher eccentric shaft bearings,
ascertain the amount the grease gun will deliver with each ‘pump’. Do not guess or assume an
amount ! Check the greasing equipment used regularly.
1 2 10
8,9 8,9
4 5,6 OMA00344
Location Qty Frequency Capacity
1 Magnetic Conveyor Drive Side Bearings 2 50Hrs 4 grams/2 pumps
2 Magnetic Conveyor Non-Drive side bearings 2 50Hrs 4 grams/2 pumps
3 Dirt Conveyor Drive Side Bearings 2 50Hrs 4 grams/2 pumps
4 Dirt Conveyor Non-drive side Bearings 2 50Hrs 4 grams/2 pumps
5 Main Conveyor Idler Drum Bearings 2 50Hrs 24 grams/12 pumps
6 Main Conveyor Drive Drum Bearings 2 50Hrs 24 grams/12 pumps
7 Belt Adjusters 2 500Hrs 4 grams/2 pumps
8 Jaw Swingstock Bearings 2 8Hrs 17/20 grams 8/10
pumps*
9 Jaw Main Frame Bearings 2 8Hrs 17/20 grams 8/10
pumps*
10 Pre-Screen Drive Shaft Bearings 2 8Hrs 4 grams/2 pumps
*20 Grams if ambient temperature is above 35°C.

9 Maintenance
9.6 Recommended Lubricants
(1) Grease Lubrication

Special Screen Grease Screen Grease for Hot Materials
B.P ENERGREASE LSEP2 ---
TOTAL MULTIS EP2 ---
DUCKHAMS ADAMAX LEP2 ---
CASTROL SPHEEROL EPL2 ---
SHELL ALVANIA EP2 LIPLEX EP2
ESSO BECON EP2 UNIREX EP2
TEXACO MULTIFAK EP2 ---
CHEVRON DURALITH EP2 ---
GULF GULFCROWN EP2 SUPERCROWN EP2
MOBIL MOBILUX EP2 MOBILGREASE HP2
CENTURY REGULUSA2EP LUPLEX M2
F.A.G ARCANOL L135 ---
ROCOL SAPPHIRE BG 151
OPTIMOL LONGTIME PD ---
OMEGA --- 85
Above is a list of the recommended alternatives suitable for use with your machine. The above
special screen greases are lithium base greases of Class 2 with extreme pressure additives.
(2) Hydraulic Oil and Antifreeze

ISO VG 46 (Ambient Temperature 0ºC - 25ºC)
Hydraulic Oil Type
ISO VG 68 (Ambient Temperature 20ºC - 40ºC)
Antifreeze Type BS 6580

Maintenance 9
(3) Recommended Lubricants For the Gearbox on the Tracks

-20°C + 5°c +5°C + 30°c 30°C + 50°c 30°C + 65°c
Lubricant
IV 95 min IV 95 min IV 95 min IV 95 min
ESSO Spartan Spartan Spartan Compressor oil
EP 100 EP 150 EP 320 LG
150
AGIP Blasia Blasia Blasia Blasia
100 150 320 S 220
ARAL Degol Degol Degol Degol
BG 100 BG 150 BG 320 BS 220
BP MACH GR XP 100 GR XP 150 GR XP 320 SGR XP 200
CASTROL Alpha Alpha Alpha Alpha
SP100 SP150 SP 320 SN6
ELF Reduetell Reduetell Reduetell Oritis 125 MS
SP 100 SP 150 SP 320 Syntherma P30
CHEVRON Non leaded Gear Non leaded Gear Non leaded Gear
Compound 100 Compound 150 Compound 320
GULF EP lubricant EP lubricant
HD 150 HD 320
I.P Mellana Mellana Mellana Telesia
100 150 320 Oil 150
MOBIL Mobilgear Mobilgear Glycoyle 22/30
629 632 SHC 630
SHELL Omala Omala Omala Tivela
Oil 100 Oil 150 Oil 320 Oil SA
TOTAL Carter Carter Carter
EP 100N EP 150 EP 320N
KLUBER Lamora Lamora Lamora
100 150 320
ISO 3448 VG 100 VG 150 VG 320 VG 150-200
Machines are supplied with Mobilgear 629.
(4) Engine
Refer to Engine Operation and Maintenance Manual.

9 Maintenance
(5) Vibrating Feeder Lubrication

Ambient Temp. Ambient Temp.
40 to 95° F 0 to 65° F
4 to 35° C -18 to 18° C
CHEVRON Industrial Oil 220 Industrial Oil 150
EXXON Teresstic 220 Teresstic 150
MOBIL DTE Oil BB DTE Oil Extra Heavy
SHELL Molina 220 Molina 150
Texaco Regal R & O 220 Regal R & O 150
ISO No. ISO 220 ISO 150

Maintenance 9
9.7 Hydraulic Maintenance

nn DANGER
THIS IS A HIGH PRESSURE SYSTEM. Never carry out any maintenance work without ensuring
the hydraulic system is locked out and depressurised. Check the pressure gauges and control
screen to view the current system pressure. Do not amend the hydraulic system. In the event of
any problems these should only be dealt with by suitably experienced and qualified engineers.
nn WARNING
Before maintenance you must read and understand the safety sections in this manual.
(1) Hydraulic System Overview

The Hydraulic system which is used in your machine was chosen for its effectiveness and
resistance to climatic and operating conditions.
This must be kept topped up with the correct hydraulic fluid and regular checks must be made
to ensure this.
The filter element requires changing when the indicator is in the red at operating temperature.
The system should be checked for leaks and the hydraulic oil analyzed after 1000 hours and
every 500 hours afterwards and replaced if necessary.
(a) Hydraulic Fluids

Hydraulic fluids play an important part in any hydraulic system. They have two main functions.
• To transmit power
• To lubricate moving parts
As a power transmitting medium the fluid must flow easily and be as incompressible as possible.
In most hydraulic components, the fluid provides internal lubrication only. For long component
life, fluids are available containing additives that have high anti wear properties. The fluids are
known as anti-wear type hydraulic oils, which are recommended for your machine.
In most cases the fluid is the only oil seal present. For example, there are no sealing rings between
the spool and the body of the directional valve. As the sealing characteristics of the fluid depend
on its retaining viscosity, it is important that the oil selected is capable of maintaining the minimum
viscosity change over a wide range of operating temperatures.
Some adverse effects of incorrect viscosity are:
• Increased power consumption
• High oil temperatures
• Entrapment of air in oil
• Increase pressure drop
• Excessive wear or even seizure under heavy loads
• Poor pump performance
In addition to the qualities outlined earlier the selected fluid should also:
• Prevent rot
• Depress foaming

9 Maintenance
• Prevent formation of sludge, gum and varnish

• Retain its own stability, thereby reducing fluid replacement
• Prevent corrosion and pitting
For best operating results it is strongly recommended that the hydraulic fluid used is selected
from the recommended range listed in 9.7 “Recommended Lubricants”.
In the service it is recommended that the hydraulic system is analyzed every 500 hours and the
oil changed if necessary. The hydraulic fluid should be changed after the machine has stopped
work. The drain plug for the hydraulic system is mounted underneath the tank. In the event of
pump or motor failure, both suction line and return line filters must be changed.
(b) Oil Tank, Pipes & Fittings

In order to prevent contamination, the Oil Tank on your machine is of sealed construction.
Access to the tank, if required, is via inspection covers which are mounted on the top of the tank,
underneath the filler cap. The outside of the tank must be thoroughly cleaned before the removal
of any of these covers.
It is very important that hydraulic pipes and hoses are checked regularly for leaks, scuffing and
wear. Loose fittings should be securely tightened. Worn or leaking hoses should be replaced.
Replacement hoses are available on request.

Maintenance 9
(2) Filtration
nn DANGER
High pressure hydraulic fluid can penetrate the skin causing serious injuries.
In order to maintain the hydraulic oil at its peak performance, different types of filter namely are
fitted to the hydraulic system:
• Suction line filters (Item 1, Ref: Figure 9.3)
• Return line filters (Item 1, Ref: Figure 9.4)
• Pressure Filter (Item 1, Ref: Figure 9.5)
• Condensation Control Breather (Item 1, Ref: Figure 9.6).
(a) Suction Line Filter

A suction filter is fitted and matched to pump capacity, it is fitted inside the hydraulic tank shut off
valve (Item 1, Ref: Figure 9.3).
New filter element should be fitted at regular intervals (see routine maintenance schedul4 for
frequency).
OMA00345
Figure 9.3 - Suction Filter
(b) Return Line Filters

The 1 x 10 micron filter, which is fitted on the tank, removes any tiny particles which can cause
damage to the pumps and motors etc.
The filter element should be changed in accordance with the routine maintenance schedule.

9 Maintenance
OMA00346
Figure 9.4 - Return Line Filters
(c) Pressure Filter

The 2 x 6 micron filters remove any tiny particles which can cause damage to the pumps and
motors in the closed loop system.
The filter element should be changed in accordance with the routine maintenance schedule or
when the indicator turns red when at operating temperature.
1
OMA00350
Figure 9.5 - Pressure Filters

Maintenance 9
(d) Hydraulic Oil Tank Breather

The breather is also a filter and should be changed after the first 100 hours of operating and
thereafter after 1000 hours but in dusty atmosphere it is recommended to change more frequently
depending upon conditions.
OMA00351
Figure 9.6 - Hydraulic Oil Tank Breather

9 Maintenance
(3) Changing Hydraulic Filters & Oil

It is strongly recommended to change both Suction filter and Return filter elements when the
Hydraulic oil is being changed.
(a) Changing Return Filter
NOTICE
The hydraulic fluid filters have condition indicators to show when the filter element needs to be
renewed.
When the gauge changes from green to red whilst the system is running at normal operating
temperature the filter must be renewed.
In cold ambient temperatures the filter indicators may show an incorrect red condition until the
system reaches normal operating temperature.
nn DANGER
Switch off and lockout. Relieve all hydraulic pressure before working at a machine.
PROCEDURE
1. Close down the machine and implement the lockout procedure.
OMA00346
Figure 9.7 - Hydraulic Tank Return Line Filter
2. Make sure the fluid has cooled before changing a filters.

3. Clean the area around the Return line filter (Item 1, Ref: Figure 9.7) to prevent dirt
contaminating the hydraulic oil when the filters are removed.
4. Loosen the bolts on the filter head (Item 1, Ref: Figure 9.7) using a 13mm spanner.
5. Rotate the top plate slightly to remove along with internal spring.
6. Remove the Filter element by pulling the removal handles. Dispose of the old filters safely.
7. Insert new filter elements of approved pattern and specification.
8. Replace the spring which holds the filter in place.
9. Lightly smear the ‘O’ ring with fluid and make sure it is properly seated in the groove
10. Replace the cover plate and screws evenly to ensure a good seal.
Maintenance 9
(b) Changing Suction Filters
nn DANGER
Switch off and lockout. Relieve all hydraulic pressure before working at a machine.
PROCEDURE
1. Shut down the machine and implement the lockout procedure.
2. Locate the hydraulic suction filter (Item 1, Ref: Figure 9.8).
3. Make sure the oil has cooled before changing the filter.
OMA00345
Figure 9.8 - Hydraulic Tank Suction Filters
4. Fully screw out the shut off valve (Item 1, Ref: Figure 9.9).
OMA00352
Figure 9.9 - Suction Filter Cover Plates
5. Remove the six bolts (Item 2, Ref: Figure 9.9) around the cover plate.
6. Remove the cover plate (Item 3, Ref: Figure 9.9) to gain access to the suction filter.
7. Remove the filter element and replace with a new filter of the approved pattern and
specification.
8. Replace the cover plate (Item 3) and screw in fully the shut off valve (Item 1).

9 Maintenance
(c) Changing Pressure Filters

It is recommended that the Pressure Filter are changed every 250 Hrs or when the blockage
indicator changes from green to red.
nn DANGER
Switch off and lockout. Relieve all hydraulic pressure before working at a machine
High pressure hydraulic fluid can penetrate the skin causing serious injuries
PROCEDURE
2. Locate the hydraulic pressure filter within the engine canopy.
1
OMA00350
Figure 9.10 - Pressure Filters
3. Make sure the fluid has cooled before changing filter.

4. Place container below filters to collect spillage of fluid.
5. Unscrew the filter bowl (Item 1, Ref: Figure 9.10), turn anti-clockwise looking from below.
6. Remove the old filters and clean inside the bowl and housing with lint free cloth.
7. Fit new filter and small ‘O’ ring of the approved pattern and specification.
8. Lightly smear the ‘O’ ring with fluid and place on it’s seating in the bowl making sure it is
properly seated.
9. Replace and secure the filter bowls to ensure a good seal, taking care as it has a fine thread.

Maintenance 9
(d) Changing Hydraulic Oil
NOTICE
It is recommended that the machines hydraulic oil is warm. This will enable the oil to flow more
easily.
nn DANGER
Switch off and lockout. Relieve all hydraulic pressure before working at a machine
PROCEDURE
1. Return all Hydraulic Cylinders to their closed position to return as much hydraulic oil back
to the tank as possible.
2. Shut down the machine and implement the Lockout procedure.
3. Remove the drain plug (Item 1, Ref: Figure 9.11) at the base of the tank.
1
OMA00348
Figure 9.11 - Hydraulic Oil Drain Plug
4. Drain the hydraulic oil to an external container large enough to hold all the oil. (Hydraulic
Tank Capacity:530 litres or 140 US gallons).
5. Remove the cover plate (Item 1, Ref: Figure 9.12) on the hydraulic tank and flush the tank
out with hydraulic oil to remove dirt or other particles.

9 Maintenance
OMA00349
Figure 9.12 - Draining The Hydraulic Oil Tank
6. When the oil tank is cleaned satisfactory replace the drain plug (Item 1, Ref: Figure 9.11).
7. Refill the tank until the oil is between the Min. and max. Marks on the tank gauge (Item 2,
Ref: Figure 9.12)
8. Replace the cover plate (Item 1, Ref: Figure 9.12).
9. Run the machine and operate hydraulic equipment to circulate oil.
10. Stop the machine and top up the hydraulic system as required.

Maintenance 9
(e) Changing Condensation Control Breather
NOTICE
The breather is also a filter and should be changed after the first 100 hours of operating and
thereafter after 1000 hours but in dusty atmosphere it is recommended to change more frequently
depending upon conditions.
PROCEDURE
2. Locate the hydraulic oil tank breather (Item 1, Ref: Figure 9.13).
OMA00351
Figure 9.13 - Condensation Control Breather
3. Unscrew and renew the breather

9 Maintenance
9.8 Conveyor Maintenance

Oblique travel may cause fast deterioration of the belt. In order to assist you we have compiled
some of the reasons for oblique travel with appropriate remedies.
Reasons for Oblique Travel Remedies Examples of Oblique Travel

1. Insufficient aligning of a. Align all drums, carrying
drums and Idlers idlers and return idlers at
right angles to the travelling
direction of the belt.
b. Check that all drums and
idlers are level to each other. Fig.1 Turning carrying idlers
If a & b are as above then
carry out the following.
Adjustments are made as
indicated on Figs. 1, 2 & 3 by
turning drums and carrying
idlers in direction of arrow
until the belt is running
straight and centred on the Fig.2 Turn drums.
conveyor.
Also return idlers may
cause oblique belt travel
and therefore they must be
aligned at right angles to the
travelling direction of the belt
and after that adjustment can Fig.3 Turning both drum and
be made. carrying idlers.
2. Misalignment of frame. Oblique travel can be
reduced by turning forward
outer carrying idlers 1-3
degrees in travelling direction
of the belt. See Fig. 4 if this
does not correct the oblique
travel then align the frame.
Fig.4 Turning forward
carrying idlers.
3. Material built up on drums Clean idlers and drums.
and idlers. Check belt cleaners and
replace if necessary.
Possibly change to more
efficient type.

Maintenance 9
(1) Belt Adjustment on Discharge Conveyor
(a) Belt Tracking Main Conveyor

Belt Tracking Discharge Conveyor Belt tracking is performed at the Drive drum of the main
conveyor. Both sides of the drive drum are adjustable.
nn WARNING
Belt tracking and tensioning are the only maintenance tasks permitted when the machine is running.
nn DANGER
Do not reach into a moving machine dangerous nip points exist.
Do not climb onto or across moving Belts Fall hazards exist.
PROCEDURE
1. Firstly determine which side requires adjusting.
2. To adjust the belt loosen lock nut (Item 1, Ref: Figure 9.14).
3. Rotate the nut (Item 2, Ref: Figure 9.14) on the drum adjuster.
1 2
OMA00353
Figure 9.14 - Discharge Conveyor Drum Adjuster (Left)
A small movement in the adjuster i.e. less than 10 mm should be sufficient. A greater movement
will effect the tension of the belt.
(b) Belt Tensioning on Main Conveyor

Belt tensioning is performed at the drive drum on Discharge conveyor. Both sides of the drum
are adjustable.
By rotating the nut (Item 2, Ref: Figure 9.14) on both drum adjusters equally you can either tighten
or loosen the belt.
The belt should be sufficiently tight to prevent slippage at the drive drum. If over tight the life of
the belt will decrease.

9 Maintenance
(2) Belt Adjustment on Dirt Conveyor (Optional)
(a) Belt Tracking Dirt Conveyor

Belt tracking is performed at the Idler drum of the Dirt conveyor. Both sides of the idler drum are
adjustable.
nn DANGER
Do not reach or climb across moving belts nip points and fall hazards exist.
nn WARNING
Belt tracking and tensioning are the only maintenance tasks permitted when the machine is running.
PROCEDURE
1. Firstly determine which side requires adjusting.
2. To adjust the belt rotate the nut (Item 1, Ref: Figure 9.15) on the drum adjuster.
1
OMA00354
Figure 9.15 - Dirt Conveyor Drum Adjusters
A small movement in the adjuster i.e. Less than 10 mm should be sufficient. A greater movement
will effect the tension of the belt.
(b) Belt Tensioning Dirt Conveyor (Optional)

Belt tensioning is performed at the Idler drum on Dirt conveyor. Both sides of the drum are
adjustable.
By rotating the nut (Item 1, Ref: Figure 9.15) on both drum adjusters equally you can either tighten
or loosen the belt.
The belt should be sufficiently tight to prevent slippage at the drive drum. If over tight the life of
the belt will decrease.

Maintenance 9
9.9 Vibrating Feeder Maintenance
(1) Changing Vibrating Feeder Gearbox Oil

(See Maintenance Schedule for Frequency)
NOTICE
After the initial 8 hours of operation, renew the oil in the feed hopper vibrating unit oil baths.
(a) Checking Oil Level and Refilling
PROCEDURE
1. Turn off the engine. Proper oil level can only be determined when unit is level and cold.
2. View the oil level sight glass (Item 2, Ref: Figure 9.16).
»»The oil level should be half way on the viewing glass in both of the oil baths.
1 2 3 OMA00016
Figure 9.16 - Vibrating Feeder Gearbox Oil Unit
3. Add recommended lubricant as necessary through the refill plug (Item 1) if needed. Allow
time for oil to flow into centre housing.
4. Once the oil is at the proper level, re-install the refill plug.
(b) Changing Oil
nn WARNING
Do not overfill the gearbox.
PROCEDURE
1. Remove the drain plug (Item 3, Ref: Figure 9.16) and drain to a container capable of holding
the oil. Dispose of the oil safely. Reinsert drain plug.
2. Follow the same procedure as 9.9(1)(a) to fill the gearbox.

9 Maintenance
(2) Changing Vibrating Feeder Screen Meshes
PROCEDURE
2. Shut down the machine and implement the lockout procedure.
3. Locate the four screen mesh tensioner bolts (Items 1, Ref: Figure 9.17) underneath the
vibrating feeder.
1 OMA00224
Figure 9.17 - Screen Mesh Tension Bolts
4. Remove the mesh tensioner bolts (Item 1, Ref: Figure 9.17).

5. Proceed to the front of the feeder.
6. Remove the screen mesh clamp (Item 1, Ref: Figure 9.18).
1 OMA00225
Figure 9.18 - Screen Mesh Clamp
7. Safely remove the screen mesh and clean the material from around the mesh clamps.
8. Fit he new mesh ensuring it is correctly seated.
9. Refit the mesh clamp (Item 1, Ref: Figure 9.18) and tensioner bolts (Items 1, Ref: Figure 9.17).
10. Tighten the tensioner bolts until the mesh is completely secured

Maintenance 9
9.10 Pre-screen Maintenance
(1) Changing Mesh on Pre-screen (Option)

To change the Pre-screen mesh:
PROCEDURE
2. Access to the Pre-screen (Item 1, Ref: Figure 9.19) can be gained underneath the Feeder.
1
OMA00355
Figure 9.19 - Pre-screen Option
3. Loosen the mesh bolts (Items 1, Ref: Figure 9.20). There are four in total.
»»The Mesh tension will loosen.
1 2 OMA00227
Figure 9.20 - Accessing Meshes
4. Remove the rubber clamps (Items 2, Ref: Figure 9.20) and remove the rubber.
5. Clean material from around the mesh clamps, replace with new mesh.

9 Maintenance
9.11 Tier 4 Engine Maintenance
(1) Tier 4 Engine Overview

The diesel engine is the heart of your machine and a great deal of care and thought has gone
into its selection. In the interest of continued peak performance from your machine the engine
must be maintained and cared for with meticulous attention in accordance with the manufacturers
instructions as detailed in the “Operators Handbook”, a copy of which is included with this manual.
OMA00231
Figure 9.21 - Tier 4 Engine

Maintenance 9
Below are two illustrations which show a normal version of a DC9 engine. The actual engine may
have different equipment.
Figure 9.22 - Tier 4 Engine (Front)
Figure 9.23 - Tier 4 Engine (Back)
1 Turbocharger 9 Type designation

2 Oil cooler 10 Water separating suction filter (fuel)
3 Oil filler 11 Pressure filter (fuel)
4 Engine serial number on the cylinder 12 Hand pump (fuel)
block
5 Oil filter 13 Starter motor
6 Coolant pump 14 Oil dipstick
7 Draining coolant 15 Oil drain valve
8 Oil filter unit 16 EMS control unit

9 Maintenance
(2) Changing Engine Filters & Oil

(See the engine Operators Manual for more detailed information regarding the Engine)
nn CAUTION
Hot surfaces beware of burns from hot oil
NOTICE
Renew the oil filter and clean the centrifugal oil cleaner when changing oil.
(a) Checking Engine Oil
PROCEDURE
1. If the engine is running turn off the engine and allow a minimum of 3 minutes to allow oil to
run back into the sump. Open the Engine Inspection Doors (Item 1, Ref: Figure 9.24).
OMA00026
Figure 9.24 - Engine Filters Inspection Door
2. Remove dipstick (Item 2, Ref: Figure 9.25) from the engine and clean. Re-insert the dipstick
fully.
OMA00027
Figure 9.25 - Engine Oil Dipstick

Maintenance 9
3. Remove the dipstick again and observe that the oil level is between the min. and max. Levels.
If the level is below the minimum mark oil must be added through the filler cap (Item 3, Ref:
Figure 9.26).
OMA00028
Figure 9.26 - Engine Oil Filler Cap
4. It is important the oil level is not above the maximum level. If this happens some oil must
be removed.
(b) Changing Engine Oil
NOTICE
Renew the oil filter and clean the centrifugal oil cleaner when changing oil.
Change oil more often if the engine is subjected to particularly demanding operations, such as
a dusty environment, or if deposits in the centrifugal oil cleaner are thicker than 28 mm (1.1”).
PROCEDURE
1. Operate the engine to ensure the oil is warm, this enables the oil to flow more easily.
2. Stop the engine and open the engine oil filler cap (Item 3, Ref: Figure 9.26).
3. Remove the oil drain plug (Item 1, Ref: Figure 9.27
1
OMA00356
Figure 9.27 - Engine Oil Sump Drain Bung

9 Maintenance
4. Open the drain valve located inside the engine compartment (Item 1, Ref: Figure 9.28) and
drain the oil to an external container large enough to hold all the oil. (Approx 38 liters)
OMA00249
Figure 9.28 - Engine Oil Drain Valve
5. Close off the drain valve (Item 1, Ref: Figure 9.28) when the oil has completely drained.
6. Refit the oil drain plug (Item 1, Ref: Figure 9.27).
(c) Maximum angles of inclination during operation.

Maximum permissible angles during operation vary, depending on the type of oil sump; see
illustration.
OMA00031
Figure 9.29 - Engine Oil Inclination

Maintenance 9
(d) Changing the Oil Filter

When renewing the oil filter it should ONLY be replaced with a Scania replacement filter. It is
recommended to change the Oil filter when changing the oil.
nn CAUTION
Hot surfaces beware of burns from hot oil
nn WARNING
Clean the centrifugal oil cleaner when renewing the oil filter. Otherwise, the oil filter will be blocked
and resistance in the filter will increase. If this happens, an overflow valve in the filter restrainer
opens and lets the oil pass without being filtered.
Do not use an adjustable spanner Or other open tool as there is Risk of damaging the filter cover.
PROCEDURE
1. Locate the oil filter element (Item 1, Ref: Figure 9.30).
OMA00032
Figure 9.30 - Engine Oil Filter
2. Unscrew the filter cover with a 36 mm socket.

3. Lift out the filter housing cover with filter element. The filter housing will drain automatically
once the filter has been removed.
4. Detach the old filter from the cover by holding the cover and carefully tapping the entire
element (Item 2, Ref: Figure 9.31) against something hard. Remember that there will be oil
splashes.

9 Maintenance
OMA00033
Figure 9.31 - Detaching the Old Filter
5. Fit the new filter (Item 3, Ref: Figure 9.32) and tighten the filter cover to 25 Nm (18 lbf ft).
OMA00034
Figure 9.32 - Fitting the New Filter

Maintenance 9
(e) Changing Air Filter Element

(For more details of Engine Air Filter Maintenance view the Engine Operators Manual) The Air
filter service indicator (Item 1, Ref: Figure 9.33) sends a signal to the control panel when the filter
element needs changed. When this happens the machine must be stopped and the Filter should
be changed immediately. Otherwise change the element every 2000 Hrs.
1 OMA00035
Figure 9.33 - Service Indicator
nn WARNING
Do not start the engine without the air filter as this could cause injury and severe engine damage.
NOTICE
Check the vacuum indicator on a daily basis
The filter element must not be washed in water.
The filter element can only be cleaned a maximum of 4 times. After cleaning it will have a poorer
capacity than a new filter element.
There is always a risk the filter Element will be damaged when it is Cleaned.
PROCEDURE
1. Turn off the engine and ‘Lockout’.
2. Unfasten the Filter Cover (Item 2) by unclipping the holding clamps (Items 3). Ref: Figure:
9.34.

9 Maintenance
OMA00036
Figure 9.34 - Air Filter Housing
3. To renew the filter elements, remove (Items 4 & 5, Ref: Figure 9.35) and replace with new
filter elements of the same specification.
4. The safety filter element (Item 5) should only be changed if required.
5
OMA00037
Figure 9.35 - Air Filter Components
5. To clean the filter elements remove (Items 4 & 5, Ref: Figure 9.35) and carefully blowing
from the inside with dry compressed air.
6. Mark the filter element when it has been cleaned.
7. Carry out a check by inserting an inspection lamp into the element and checking from the
outside that there are no holes or cracks in the filter paper.
8. Assemble the air cleaner.

Maintenance 9
(3) Cleaning the Centrifugal Oil Cleaner
nn WARNING
The oil may be hot. Carefully remove the cover from the centrifugal oil cleaner.
The rotor must not be put in a vice. This may cause damage resulting in rotor imbalance.
Never strike on the rotor directly as this may damage the bearings.
Do not over tighten the lock nut as this may damage the Centrifugal oil cleaner.
PROCEDURE
1. Clean the outside cover of the Centrifugal Oil Cleaner (Item 1, Ref: Figure 9.36)
1 OMA00038
Figure 9.36 - Centrifugal Oil Cleaner
2. Unscrew the nut and remove the Cover (Item 2, Ref: Figure 9.37).

9 Maintenance
OMA00039
Figure 9.37 - Centrifugal oil cleaner nut
3. Lift out the Rotor (Item 3, Ref: Figure 9.38) and wipe off the outside. Unscrew the rotor cover
nut approximately one and a half turns.
OMA00040
Figure 9.38 - Centrifugal rotor
4. If the rotor nut has jammed: Turn the rotor upside down and fasten the nut in a vice. Turn
the rotor approximately one and a half turns counter-clockwise by hand or use an M20 bolt
as illustrated (Item 4, Ref: Figure 9.39).

Maintenance 9
OMA00041
Figure 9.39 - Centrifugal oil Rotor if Jammed
5. Hold the rotor and tap lightly on the rotor nut with a plastic mallet or against the workbench,
so that the Rotor Cover (Item 5, Ref: Figure:9.40) comes loose from the bottom plate.
OMA00042
Figure 9.40 - Centrifugal Oil Remove Rotor Cover
6. Remove the strainer from the rotor cover (Item 6). If the strainer is stuck, insert a screwdriver
between the rotor cover and strainer and carefully prise them apart (Item 7). Ref: Figure 9.40.
7. Scrape away the deposits inside the rotor cover (Item 8, Ref: Figure 9.41) with a knife. If
there are no deposits, the centrifugal oil cleaner is not working. Clean more often if the
deposits are thicker than 28 mm (1.1”).

9 Maintenance
8 OMA00043
Figure 9.41 - Cleaning Centrifugal Oil Cleaner
8. Wash the parts in diesel oil. Inspect the two nozzles on the rotor. Ensure that they are not
blocked or damaged. Renew any damaged nozzles.
9. Check the bearings to ensure that they are not damaged.
10. Fit a new O-Ring (Item 11) by sliding it over the Strainer (Item 12). Ref: Figure 9.42.
10
11
12
OMA00044
Figure 9.42 - Centrifugal Oil O Ring
11. Refit the Rotor Cover (Item 10). Making sure the O-ring sits correctly on the inside.
12. Tighten the Rotor Nut (Item 9) by hand.
13. Check that the shaft is not loose. If it is, it should be locked using thread locking fluid. Clean
carefully with a suitable solvent. Tighten the rotor shaft using a tool wrench.
14. Refit the rotor (Item 13, Ref: Figure 9.43) and screw it by hand to make sure it rotates easily.

Maintenance 9
13
OMA00045
Figure 9.43 - Centrifugal Oil Refit Rotor
15. Renew the O ring (Item 14) on the centrifugal oil cleaner housing cover and tighten the lock
nut (Item 15) to 15 Nm (11 lb ft). Ref: Figure 9.44.
15
14
OMA00046
Figure 9.44 - Centrifugal Oil Refit Rotor

9 Maintenance
(4) Checking Engine Coolant Level

(For more details of approved Engine Coolant and Coolant Level view the Engine Operators
Manual)
nn WARNING
Hot coolant can cause serious burns. To open the coolant system, stop the engine and wait until
system has cooled. Remove filler cap slowly to relieve pressure.
Ethylene glycol is highly dangerous if imbided it can also cause skin irritation and eye damage.
Never fill a large amount of cold coolant in a hot engine. There is great risk of cracks forming in
the cylinder block and cylinder heads.
NOTICE
This machine has a low coolant sensor installed and if the coolant falls below the minimum level
the machine will automatically shut down
PROCEDURE
1. Check the engine coolant level when the engine is stopped and cool.
2. Open the Radiator Inspection guard (Item 1, Ref: Figure 9.45).
OMA00047
Figure 9.45 - Radiator Inspection Doors
3. Remove the cooling system filler cap slowly in order to relieve pressure.
4. View the Coolant Level through the top of the radiator.
5. The coolant level should be maintained within 25 mm (1”) over the lower edge of the filler neck.

Maintenance 9
(5) Fuel System
(a) Changing Fuel Filter

Engines are equipped with dual filters in the form of a water separating filter and a pressure filter.
nn WARNING
Fit the filter elements in the filter covers before placing them in the fuel filter housings or the filter
elements may be damaged.
In order to prevent back pressure in the filter housings when the filter elements are screwed on,
the bleed nipple (Item 4,: Ref: Figure 9.46) must be open.
The filter housing must be kept clean at all times. Under no circumstances should the filter housing
be pre-filled with diesel during servicing. Doing so may result in contamination causing engine
failure.
nn CAUTION
Avoid naked flames when working on the fuel system. Do not smoke.
PROCEDURE
1. Unscrew the fuel covers with a 36 mm socket.
2. The fuel filter housings will drain automatically once the filter elements have been removed.
Suction the fuel out of the filter housings if necessary.
3. Undo the old filter elements from the covers by carefully bending them to one side.
4. Renew the O-rings in the covers. Lubricate the O-rings with O-ring grease.
5. Press new filter elements into the snap fasteners on the covers.
6. Press down the filter elements into the fuel filter housings with the covers. Screw on the filter
covers firmly with a 36 mm socket and torque to 25 Nm (18 lb ft) (ensuring the bleed nipple
Item 4, Ref: Figure 9.46 is open).
OMA00048
Figure 9.46 - Engine Fuel Filters
• 1. Water separating filter

• 2. Pressure filter
• 3. Hand pump

9 Maintenance
7. Check that there is no gap between the filter covers and the filter elements. If there is a
gap, repeat the procedure and ensure the bleed nipple (Item 4, Ref: Figure 9.46) is open.
8. Bleed the fuel system as per instructions. (See bleeding the fuel system section)
(b) Draining the Water Trap
PROCEDURE
1. Loosen the drain tap (Item 1, Ref: Figure 9.47) on the base of the water trap.
1 OMA00019
Figure 9.47 - Water Trap
2. Allow the water to drain off. Tighten the drain tap when all the excess water has been drained
off.
(c) Changing Water Trap Filter

To change the water trap filter element (Item 2, Ref: Figure 9.47) follow the procedure outlined.
nn CAUTION
Avoid naked flames when working on the fuel system. Do not smoke
PROCEDURE
1. Stop the machine and ‘Lockout’.
2. Remove the element (Item 2, Ref: Figure 9.47).
3. Remove the water trap bowl (Item 3, Ref: Figure 9.47) from the filter element.
4. Attach the new element to the water trap bowl.
5. Attach the filter element.
6. Use the priming hand pump (Item 4, Ref: Figure: 9.48) to fill the element and the water trap.

Maintenance 9
OMA00049
Figure 9.48 - Priming Hand Pump

9 Maintenance
(d) Bleeding the Fuel System
nn CAUTION
Avoid naked flames when working on the fuel system. Do not smoke
PROCEDURE
1. Attach a clear plastic hose to the bleed nipple on the fuel filter housing (Item 1, Ref: Figure
9.49). Place the end of the plastic hose in a container that holds at least 3 liters.
OMA00050
Figure 9.49 - Bleeding The Fuel System
2. Loosen the hand pump handle (Item 2, Ref: Figure 9.49).

3. Open the bleed nipple (Item 1, Ref: Figure 9.49).
4. Pump by hand until the fuel comes out of the hose. This may take around 100 pump strokes.
Depending on the installation, a significantly greater number of pump strikes may be required
before the fuel comes out.
5. Close the bleed nipple (Item 1).
6. Start the engine and open the bleed nipple (Item 1) carefully.
7. Check that fuel without air bubbles comes out of the hose. Normally, about 3 liters of fuel
must be drained before no more air bubbles come through the hose.
8. Close the bleed nipple (Item 1), remove the hose and tighten the hand pump handle (Item 2).

Maintenance 9
(e) Refuelling Diesel Tank
nn DANGER
Diesel fuel is highly flammable and is an explosion / burns hazard.
Avoid naked flames when working on the fuel system. Do not smoke.
NOTICE
Do not fill the tank to overflow or full capacity.
Allow room for expansion and clean up any spilt fuel immediately
PROCEDURE
1. Switch on the machine and observe the diesel level on the screen display.
2. Switch off the machine and locate the diesel filler point (Item 1, Ref: Figure 9.50).
1
OMA00357
Figure 9.50 - Refuelling Diesel Tank
3. Clean off any dirt and debris from around the filler cap.
4. Remove the filler cap and top up fuel level as required with specified diesel fuel. Refer to the
engine manufacturer’s operation manual.
OMA00052
5. Replace the filler cap.

9 Maintenance
9.12 Urea Tank Maintenance
(1) Changing the Reductant Filter
NOTICE
Do not over tighten the filter cover as this may damage the housing.
PROCEDURE
1. Remove the cover (Item 1, Ref: Figure 9.51) on the rear of the redundant tank.
OMA00053
Figure 9.51 - Removing the Cover
2. Place a suitable container underneath.

3. Unscrew the filter cover (Item 2, Ref: Figure 9.51) using a 46 mm socket.
4. Lift out the filter cover (Item 2, Ref: Figure 9.51) and filter element (Item 3, Ref: Figure 9.52).
5. Renew the filter element and check the O-ring and insulation (Item 4, Ref: Figure 9.52).
OMA00054
Figure 9.52 - Filter Element
6. Wipe clean with lukewarm water before you refit the filter cover to remove any crystals.
7. Screw on the filter cover again. Tightening torque 80 Nm (59 lb ft).

Maintenance 9
(2) Refilling the Urea Tank
NOTICE
It is recommended to use AD BLUE - DIN70070 diesel exhaust fluid (DEF), if using a different
supplier ensure that the def complies with this standard.
If flushing or cleaning urea associated parts do not use diesel or any other cleaning fluids. Use
only clean water or urea to carry out the procedure.
When the Urea level falls below 10% the machine’s performance will derate and become idle.
Whilst the machine is in idle mode it may still be tracked but the machine will not run its crushing
process until the urea has been filled.
PROCEDURE
1. Switch on the machine and on the Main Menu Screen view the Urea level (Item 1, Ref:
Figure 9.53).
OMA00362
Figure 9.53 - Main Menu Screen (Urea Level)
2. Switch off the machine and access the Urea tank. Ref: Figure 9.54.
OMA00363
Figure 9.54 - Urea Tank
3. Clean off any dirt and debris from around the filler cap (Item 1, Ref: Figure 9.54).

9 Maintenance
4. Remove the filler cap and top up Urea level as required. Refer to the engine manufacturer’s
operation manual.
5. Refit the filler cap.
6. Switch on machine and re-check the Urea Level on the screen display is satisfactory.

Maintenance 9
9.13 Track Maintenance

Tracks - Operating Precautions
When travelling up a gradient, the tracks should be driven forward (i.e. idlers first, drive sprocket
to the rear). When travelling down a gradient, tracks should be driven sprocket first.
Always:-
• Park the machine on flat, level ground. If it is necessary to park the machine on a gradient,
the tracks should be solidly blocked.
• Ensure the terrain the machine is working on is firm enough to adequately support the
machine.
• Ensure the machine is tracked at least 10 m in either direction on a daily basis, to minimise
risk of track chain seizure.
• Ensure the track systems are free from debris before moving the machine.
• Ensure the tracks are not frozen to the ground before moving the machine.
Never:-
• Attempt to track the machine if there is any build up of material around the tracks and drive
sprockets.
• Attempt to track the machine if the tracks are frozen to the ground. Push or tow the machine
when unable to free itself.

9 Maintenance
(1) Changing Gearbox Oil in Tracks

(See Maintenance Schedule for frequency)
nn DANGER
Switch off and lockout before working at a machine.
Dangerous nip points exist. Close guards after maintenance.
NOTICE
The gearbox oil must be changed in accordance with the maintenance schedules in section 9.3
Otherwise your warranty will be effected.
More effective draining will take place if the oil is hot.
PROCEDURE
1. Turn off the engine.
2. To drain the gearbox. Clean the area around the gearbox plugs. Position the Plugs (Items
1 & 2) as shown in the photograph ensuring the plug (Item 2) is at the bottom. Remove the
plug (Item 1) this will allow air into the gearbox to allow it to drain. Ref: Figure 9.55.
OMA00058
Figure 9.55 - Tracks Gearbox in Drain Position
3. Remove the Drain plug (Item 2) and drain the oil to an external container large enough to
hold all the oil.
4. Start the engine and move the tracks until the Gearbox is in the Fill Position with the Plugs
(Items 3 & 4, Ref: Figure 9.56) in the correct position.

Maintenance 9
OMA00059
Figure 9.56 - Tracks Gearbox in Fill Position
5. Now refill the gearbox through the Filler plug (Item 3) until the oil begins to flow from the level
plug (Item 4). DO NOT OVERFILL THE GEARBOX.
6. Replace the plugs (Item 3 & 4).
7. After a short period of operation visually check the oil level.

9 Maintenance
(2) Track Adjustment

As the track wears, they become slack,and should be checked daily. To establish if the tracks
require adjustment move the machine, a few metres, backwards and forwards on level ground, in
a straight line. This enables the track to adopt its natural degree of tension. Measure the droop
as shown in Fig 9.57 This measurement must be between 5 mm - 20 mm.
OMA00060
Figure 9.57 - Track Adjustment
(a) To Release Track Tension
PROCEDURE
1. Remove the adjuster cover plate (Item 1, Ref: Figure 9.58).
OMA00061
Figure 9.58 - Track Adjustment Access Plate
2. Loosen the Grease fitting (Item 2, Ref: Figure 9.59) on the end of the track tensioning cylinder
by one half turn only. Allow grease to leave the tension cylinder therefore reducing the track
tension.

Maintenance 9
OMA00062
Figure 9.59 - Track Adjustment Grease Fitting
3. Retighten the Grease fitting (Item 2, Ref: Figure 9.59) and replace the cover plate (Item 1,
Ref: Figure 9.59).
(b) To Increase Track Tension
PROCEDURE
1. Remove the adjuster cover plate (Item 1, Ref: Figure 9.58).
2. Using the special grease gun adaptor (Item 3, Ref: Figure 9.60) attach to a standard grease
gun and place over the grease fitting (Item 2, Ref: Figure 9.59).
OMA00063
Figure 9.60 - Track Adjustment Grease gun Fitting
3. Pump the track out to the correct adjustment.

4. When the track droop appears to be correct, move the machine backwards and forwards,
and recheck the droop.
5. Replace the cover plate (Item 1, Ref: Figure 9.58).

9 Maintenance
9.14 Jaw Crusher Maintenance
(1) Checking components for wear
(a) Daily Component Checks
PROCEDURE
1. Check the wearing components daily to determine the wear rates. Monitor and record wear
from new to estimate the component life.
2. Examine all wearing components for cracks or breakage and renew items if necessary.
3. Check for any components becoming loose and secure them if necessary to prevent damage.
4. Check main crusher components and drive pulleys for damage.
5. Check for unusual noise when operating.

Maintenance 9
9.15 Vee Belt Maintenance

The Vee belt drive is a highly efficient power transmission medium, but optimum performance
will not be achieved without correct tensioning and alignment. Vee belt drives are used on the
machine between the crusher and the engine.
nn WARNING
Do not inspect or carry out work on belt drives before closing down the machine and implementing
the Lockout Procedure. Never operate the machine without effective drive guarding in place.
NOTICE
Drive belts should be inspected regularly for wear and also to monitor any pattern in the wear if
it is occurring. Insufficient belt tension will cause slippage leading to loss of drive efficiency, heat
generation and belt failure. Over tensioning will exert excessive loading on the shaft bearings
and can lead to premature failure.
When replacing a multi-belt drive always use a set of ‘matched’ new belts so that equal force
can be applied to all the belts. Ensure that any ventilation provided in the drive guarding is kept
clear to avoid overheating.
Do not allow contaminating material to come into contact with the drive elements.

9 Maintenance
(1) Alignment
It is important to align the pulleys, otherwise the belt flanks will wear quickly. Ensure axis are
parallel when viewed from all planes. Ref: Figure 9.61.
OMA00072
Figure 9.61 - Vee Belt Alignment Diagram
A - Correct installation, both shafts and pulleys are parallel and in alignment.
B - Incorrect, shafts are parallel from above but not from end view.
C - Incorrect, shafts are parallel and in alignment but pulleys are not in alignment.
D - Incorrect, shafts are not parallel to one another when seen from above.

Maintenance 9
(2) Adjustment
NOTICE
Belt adjustment is by means of adjusting screws to increase or decrease the distance between
the shaft centres. Locknuts on the tension screws must be tight whilst running the machine.
After replacing Vee Belts remember to check the tension after 4 hours run in time, check again
after 24 hours.
(a) Manual Adjustment
nn DANGER
Dangerous nip points exist close guards after maintenance.
nn WARNING
Under no circumstances should any check on the belt tension be made whilst the machine is
running. There is an entanglement hazard and risk of trapping parts of the body.
PROCEDURE
2. Close down the machine and implement the Lockout Procedure.
3. Open the vee belt access panel (Item 1, Ref: Figure 9.62).
1
OMA00364
Figure 9.62 - Vee Belt Access Panel
4. Proceed to the belt temsioner bolts (Items 1, Ref: Figure 9.63) at the front of the machine.
There is one on each side of the machine.

9 Maintenance
1 OMA00365
Figure 9.63 - Vee Belt Tensioner
5. Rotate the bolt (Item 1, Ref: Figure 9.63) in the desired direction to either loosen or tighten
the vee belt. Rotate both bolts the same number of turns to ensure an equal adjustment on
both sides.
6. To establish correct belt tension, use the method described in ‘drive belt tensioning’. Ref:
Section 9.15 (3) & 9.15(3)(a).
7. Ensure that all the drive guarding is replaced and secured before start the machine.

Maintenance 9
(3) Drive Belt Tension
nn WARNING
Under no circumstances should any check on the belt tension be made whilst the machine is
running. There is an entanglement hazard and risk of trapping parts of the body.
NOTICE
After the drive has been running for 15 to 20 minutes, the plant should be stopped and the
tension checked. If necessary, re-adjusted to the basic setting force value by repeating the below
procedure from step 1.
PROCEDURE
2. Close down the machine and implement the Lockout Procedure.
3. Remove the guards from around the belt.
4. Calculate the deflection distance in mm (or inches) on a basis of 16mm (0.6in) deflection per
1 metre (1 yard) of belt span.*
»»METRIC: Centre to Centre Distance in metres x 16 = Deflection in mm.
5. If a belt tension indicator is available:
• Set the lower marker ring at the deflection distance required on the lower scale.
• Set the upper marker ring against the bottom edge of the top tube.
• Place the belt tension indicator on top of the belt at the centre of the belt span, and apply
a force at right angles to the belt deflecting it to the point where the lower marker ring is
level with the top of the adjacent belt.
• Read off the setting force value indicated by the top edge of the upper marker ring.
• Compare this value to the value shown in the table.
6. If a belt tension indicator is not available:
• Use a spring balance to pull the belt down at the centre of the span.
• When the belt has been pulled down [measure using a rule] by the deflection calculated
in step 4, read off the force from the spring balance.
7. If the measured force falls within the values given, the drive should be satisfactory. A measured
force below the lower value indicates under-tensioning. Some new drive belts are tensioned
to the x1.25 Setting Force value to allow for the normal drop in tension during the running-in
period. This is not recommended for all belts.
8. Replace all guards before start-up.
* Refer to Section 9.15.(3)(a) for guidance on measuring belt tension and setting forces.

9 Maintenance
(a) Belt Tensioning Measurements
OMA00074
Figure 9.64 - Belt Tensioning Measurement
A - 16mm deflection per metre (0.6in per 3ft).

B - Belt tension indicator applied to mid-span.
C - Centre to centre distance.
[x1] BASIC SETTING FORCES

SPB BELT SECTION
Small Pulley Diameter:
112 to 160mm (4.4 to 6.3in) 4.0kgf (8.8lbf)
170 to 224mm (6.7 to 8.8in) 5.1kgf (11.2lbf)
236 to 355mm (9.3 to 14.0in) 6.3kgf (13.9lbf)
Over 355mm (14in) 6.6kgf (14.6lbf)
SPC BELT SECTION
224 to 250mm (8.8 to 9.8in) 7.1kgf (15.7lbf)
265 to 355mm (10.4 to 14in) 9.4kgf (20.7lbf)
Over 375mm (14.8in) 12kgf (26.5lbf)
[x1.25] BASIC SETTING FORCES

If recommended for new belts
SPB BELT SECTION
112 to 160mm (4.4 to 6.3in) 5.1kgf (11.2lbf)
170 to 224mm (6.7 to 8.8in) 6.3kgf (13.9lbf)
236 to 355mm (9.3 to 14.0in) 7.9kgf (17.4lbf)
Over 355mm (14in) 8.3kgf (18.3lbf)
SPC BELT SECTION
224 to 250mm (8.8 to 9.8in) 8.9kgf (19.6lbf)
265 to 355mm (10.4 to 14in) 11.8kgf (26lbf)
Over 375mm (14.8in) 15kgf (33.1lbf)
Maintenance 9
(4) Replacement of Vee Belts
NOTICE
The Vee belts must be of the same type, size, and number to those originally fitted and specified.
nn WARNING
Entanglement hazard. Risk of trapping parts of the body.
PROCEDURE
1. Before fitting new belts, check the pulley grooves are free from score marks or sharp edges.
Also check the grooves for wear. Ensure the pulleys are tight on their shafts.
2. If replacement of the belts is necessary due to premature failure, the cause should be
investigated and rectified before fitted new belts. Ref: Section 10 (Vee Belt Troubleshooting).
3. The drive centre distance must be reduced prior to installation so that new belts can be fitted
without the use of force.
4. Under no circumstance must belts be prised into the grooves as belts and pulley grooves
can be damaged by using sharp tools to stretch the belts over the pulley rim.
5. The procedure for fitting new belts is generally the same as described for belt adjustment
except it is necessary to slacken off the drive enough to remove the old belts and fit the new
without damage. It may also be necessary to remove more of the guarding to gain access.

9 Maintenance
9.16 Electrical Maintenance
(1) Prior to Welding
NOTICE
Before any welding work can be carried out at this machine a number of electrical components
must be disconnected to prevent potential damage.
PROCEDURE
1. Switch off the machine and implement the lockout procedure.
2. Remove both of the plugs (Items 1, Ref: Figure 9.65) on the control panel..
OMA00579
Figure 9.65 - Radio Control Receiver In Main Control Panel
3. Proceed to the engine compartment.

4. Disconnect the ground negative [-] battery cable on the batteries.
5. Disconnect the two ECU‘s (Items 1, Ref: Figure 9.66).
1
OMA00076
Figure 9.66 - Scania Engine ECU Plugs

Maintenance 9
(2) Safely Remove and Install the Battery
nn WARNING
Do wear protective eye wear, clothing and gloves.
Do not expose the battery to flame, sparks, or incendiary devices, including cigarettes.
Do not lay tools across the top of the battery. A conductive metal might touch both terminals
simultaneously causing a short, sparks, or a potential explosion.
NOTICE
Never give your key to anyone else and where more than one person is working on the equipment
they must fit their lock also.
Dumping the battery will be a hazard to the environment. Dispose of the battery by special
disposal or at a recycling centre
When purchasing a new battery, confirm that the negative and positive terminal posts are on the
same side of the battery as your old one.
PROCEDURE
1. Turn off the Engine at Starter Panel and remove key. Lock the Panel and put the key in a
safe place.
2. Rotate the Switch (Item 1,) from the “ON” position (Item 2) to the “OFF” position (Item 3).
Ref: Figure 9.67
2 “ON” 3 “OFF”
1
OMA00078
3. Fit your LOCK-OUT-HASP (Item 4, Ref: Figure 9.68) and your UNIQUE PADLOCK (Item
5, Ref: Figure 9.68) on the Main Power Isolator and keep the key to make sure no one can
remove your lock and turn the power back on (ONE PERSON – ONE LOCK - ONE KEY ).

9 Maintenance
OMA00079
Figure 9.68 - Isolator Switch “OFF“ Locked
4. Raise the engine inspection door (Item 6, Ref: Figure 9.69).
OMA00080
Figure 9.69 - Engine Inspection Door
5. The battery terminals are labeled + (red/positive) and – (black/negative). Disconnect the
negative terminal first (Item 7) and flex the cable away from the battery. Next disconnect the
positive terminal (Item 8). Ref: Figure 9.70.
8
7
9
10
11
9
OMA00081
Figure 9.70 - Fitted Battery

Maintenance 9
6. Finally disconnect the top clamp that holds the battery down by removing bolts (Items 9) and
clamp (Item 10). Ref: Figure 9.70.
7. Lift the battery straight up and out by holding it at opposite corners. As the battery weighs
101.4 pounds (46 kg) or more and should be lifted out with extreme care by 2 operators. Do
not tip or drop the battery. Many newer batteries are made with strap handles (Items 11,
Ref: Figure 9.70).
8. Clean the battery cables, pan and clamp. If there is corrosion present (white powder),
neutralize it with a mixture of baking soda and water using an old toothbrush.
9. Carefully lower the new battery into place. Make sure it is sitting flat in the battery pan, and
not on the lip.
10. Position the top clamp (Item 10) into place and secure the battery by tightening down the
bolts (Items 9). Ref: Figure 9.70.
11. Reconnect the positive terminal first (Item 8). Next reconnect the negative terminal (Item 7).
The battery terminals are labeled + (red/positive) and - (black/negative). Ref: Figure 9.70.

9 Maintenance
9.17 Hydraulic Ram Maintenance

nn DANGER
As part of the finish process in our chrome rod manufacturing a natural lubricant is rolled into the
surface. To prolong the life of hydraulic cylinder we recommend that any cylinder exposed (i.e.
Item 1, Ref: Figure 9.71) for more than one week should have the rod coated with a good quality
water resistant grease.
OMA00082
Figure 9.71 - Exposed Hydraulic Ram Chrome Rod (Illustration purposes only)

Troubleshooting 10
Table of Content
10 Troubleshooting........................................................................................ 10-2
10.1 General Troubleshooting...............................................................................10-3
10.2 Engine Troubleshooting................................................................................10-4
(1) Accessing Diagnostic Data.......................................................................10-4
(a) Viewing the Engine Information Screen...............................................10-5
(2) Viewing SPN and FMI Codes...................................................................10-7
(3) SPN and FMI Explanations......................................................................10-9
(a) FMI Code Explanations (Fault type identifier (FMI)).........................10-9

(b) SPN Code Explanations (Engine Fault Codes).................................10-10
10.3 Machine Troubleshooting............................................................................10-14
(1) Machine diagnostic fault list....................................................................10-14
(a) Machine Fault Icons...........................................................................10-15
10.4 Hydraulics System Troubleshooting............................................................10-16
10.5 Urea Troubleshooting..................................................................................10-18
(1) Urea Faults/Indication.............................................................................10-18
(a) Urea indication status table................................................................10-19
(2) SCR Faults / Indication ..........................................................................10-20
(a) SCR indication status table................................................................10-21
10.6 Vee Belt Troubleshooting............................................................................10-22

10 Troubleshooting
10 Troubleshooting
NOTICE
The diagnostic codes may alert the operator to conditions that may damage the machines
components. Never ignore a Machine fault if one occurs. Always investigate thoroughly or if in
doubt contact your Terex supplier.
Procedure to Address the Occurrence of Codes

Whenever a diagnostic code occurs, try to note all operating conditions of the engine. It is especially
critical to take note of the operating conditions for intermittent codes. This information provides
the technicians with the operating conditions at the time of the intermittent code. This will enhance
the technician’s ability to produce the code again. This will also enhance the technician’s ability
to diagnose the problem. The codes are recorded in the ECM and the codes may be recovered
with the electronic service tool.
Diagnostic Code and Event Code Chart

The charts on the following pages are provided in order to help determine the action that
should be taken if a particular diagnostic code is active. The current operating conditions
will determine the reaction of the operator to the codes. As an example, only intermittent
service codes that are a persistent problem should be serviced.

Troubleshooting 10
10.1 General Troubleshooting
Fault Possible Cause Procedure

Machine Stops Overload through discharge Clear machine, adjust setting
setting too low
Packing in crushing chamber Clear discharge chute
Build up in discharge chute Clear blockage, check chute
Power supply/ drive motor failure Check power supply/ drive motor,
see manufacturer’s literature
Broken vee belt(s) Replace belt(s)
Erratic movement of Air in hydraulic system Bleed system / check for leaks
hydraulic cylinder(s) Hydraulic system filter(s) blocked Replace
Crusher motor stops Over current due to voltage drop Check the transformer capacity
Over current due to overload Suitable feed amount ?
Uniform feeding ?
No packing ?
Insufficient oil supply?
Damaged bearing ?
Machine overloaded?
Interlock operation Deteriorated pump performance
or lack of oil ?
Return oil temperature too high?

10 Troubleshooting
10.2 Engine Troubleshooting
(1) Accessing Diagnostic Data
NOTICE
The control panel screen will automatically display all active faults.
PROCEDURE
1. On the Main Menu Screen select the Information Icon (Item 8). Ref: Figure 10.1.
1 8
2 7
3 4 5 6 OMA00311
2. Press enter F6 (Item 6) or the scroll button (Item 3). Ref: Figure 10.1.
»»The Information Display screen will appear. Ref: Figure 10.2.
1 10
2 9
3 8
4 5 6 7 OMA00366
3. On the Information Screen select the Caution icon (Item 2, Ref: Figure 10.2) any machine
faults will now be displayed.

Troubleshooting 10
(a) Viewing the Engine Information Screen
PROCEDURE
1. On the Main Menu Screen select the Information Icon (Item 8). Ref: Figure 10.3.
1 8
2 7
3 4 5 6 OMA00311
2. Press enter F6 (Item 6) or the scroll button (Item 3). Ref: Figure 10.3.
»»The Information Display screen will appear. Ref: Figure 10.4.
1 10
2 9
3 8
4 5 6 7 OMA00366
3. On the Information Screen select the Engine Icon (Item 8, Ref: Figure 10.4).
»»The Engine Information Screen will now be shown. Ref: Figure 10.5.

10 Troubleshooting
13 12 11
1 10
9
2
4 7
5 6 OMA00320
Figure 10.5 - Engine Information Screen
Engine Information
1 Coolant Temperature
2 Fuel Level
3 Urea Level
4 Engine Hours
5 Engine Diagnostics
6 Fuel Heater
7 Percentage Load on the Engine
8 Engine Speed
9 Fuel Consumption
10 Battery Voltage
11 Oil Pressure
12 Inlet Pressure
13 Intake Manifold Temperature

Troubleshooting 10
(2) Viewing SPN and FMI Codes
PROCEDURE
1. On the Information Screen select the Engine Icon (Item 8). Ref: Figure 10.6.
1 10
2 9
3 8
4 5 6 7 OMA00366
Figure 10.6 - Information Screen
2. Press enter F6 (Item 7) or press the scroll button (Item 4).

»»The Engine Information Screen will display. Ref: Figure 10.7.
2
1 OMA00367
Figure 10.7 - Engine Information Display Screen
3. Press the F2 button (Item 1). Ref: Figure 10.7.

»»The Fault screen (Ref: Figure 10.8) will display. On this screen SPN and FMI codes can be viewed.

10 Troubleshooting
1 2 3 OMA00321
Figure 10.8 - SPN and FMI Screen
4. If there is more than one fault logged on the display screen use the F4 & F5 buttons (Items
1 & 2) to scroll through the faults. Ref: Figure 10.8.

Troubleshooting 10
(3) SPN and FMI Explanations
NOTICE
Fault codes generated in the CAN network are sent via CAN message DM 1. This document
describes how to interpret these fault codes from the DM 1 message.
Abbreviation Explanation
SPN Suspect Parameter Number
FMI Failure Mode Identifiers
(a) FMI Code Explanations (Fault type identifier (FMI))
Code Explanation
0 Data valid but above normal operational range (that is, engine
overheating)
1 Data valid but below normal operational range (that is, engine oil
pressure too low)
2 Data erratic, intermittent, or incorrect
3 Voltage above normal or shorted high
4 Voltage below normal or shorted low
5 Current below normal or open circuit
6 Current above normal or grounded circuit
7 Mechanical system not responding properly
8 Abnormal frequency, pulse width, or pending
9 Abnormal update rate
10 Abnormal rate of change
11 Failure mode not identifiable
12 Bad intelligent device or component
13 Out of calibration
14 Special instructions
15 Reserved for future assignment by the SAE subcommittee

10 Troubleshooting
(b) SPN Code Explanations (Engine Fault Codes)
SPN SPN Name SPN Explanation FMI a

51 Engine Throttle The position of the valve used to regulate 0,1,2,3,4,5
Position the supply of a fluid, usually air or fuel/air
mixture, to an engine.
94 Engine Fuel Gauge pressure of fuel in system as 0
Delivery Pressure delivered from supply pump to the injection
pump.
98 Engine Oil Level Ratio of current volume of engine sump oil 2,3,4
to maximum required volume.
100 Engine Oil Gauge pressure of oil in engine lubrication 0,1,2,3,4
Pressure system as provided by oil pump.
102 Engine Intake The gauge pressure measurement of the air 0,1,2,3,5
Manifold #1 intake manifold.
Pressure
105 Engine Intake Temperature of precombustion air found 0,2,3,4
Manifold 1 in intake manifold number 1 of engine air
Temperature supply system.
107 Engine Air Filter Change in engine air system pressure, 1
1 Differential measured across the filter, due to the filter
Pressure and any accumulation of solid foreign matter
on or in the filter.
108 Barometric Absolute air pressure of the atmosphere. 2,3,4
Pressure
110 Engine Coolant Temperature of liquid found in engine 0,1,2,3,4
Temperature cooling system.
111 Engine Coolant Ratio of volume of liquid found in engine 1,3,4
Level cooling system to total cooling system
volume.
156 Engine Injector The gauge pressure of fuel in the timing 0,1,2,3,4
Timing Rail 1 rail delivered from the supply pump to the
Pressure injector timing inlet.
167 Charging System Electrical potential measured at the 2,5,6
Potential (Voltage) charging system output. The charging
system may be any device charging
the batteries. This includes alternators,
generators, solid state charger and other
charging devices.
168 Battery Potential / This parameter measures the first source of 0,1
Power Input 1 battery potential as measured at the input of
the ECM/actuator etc. Coming from one or
more batteries, irrespective of the distance
between the component and the batter
171 Ambient Air Temperature of air surrounding vehicle. 0,1,2
Temperature
190 Engine Speed Actual engine speed which is calculated 0,2
over a minimum crankshaft angle of 720º
divided by the number of cylinders.

Troubleshooting 10
559 Accelerator Pedal Switch signal which indicates whether 2

Kick down Switch the accelerator pedal kick down switch is
opened or closed.
590 Engine Idle Status signal which indicates the current 2
Shutdown Timer mode of operation of the idle shutdown
State timer system.
636 Engine Position 2,3,4,5
Sensor
651 Engine Injector 5,6,7
Cylinder #01
Cylinder #02
Cylinder #03
Cylinder #04
Cylinder #05
Cylinder #06
Cylinder #07
Cylinder #08
677 Engine Starter Activates the starter 0,2,3,4,5,7,8
Motor Relay
986 Requested Percent Fan speed as a ratio of the actual fan drive 2,3,4,5,7
Fan Speed (current speed) to the fully engaged fan
drive (maximum fan speed).
1110 Engine Protection Status signal which indicates whether or not 2
System has the engine protection system has shutdown
Shutdown Engine the engine
1239 Engine Fuel Status signal which indicates fuel leakage in 7
Leakage 1 the fuel rail of the engine. Location can be
either before or after the fuel pump.
1322 Engine Misfire for When a misfire occurs in any one of the 7
Multiple Cylinders cylinders.
1323 Engine Misfire Engine misfire detected in cylinder 7
Cylinder #1
Cylinder #2
Cylinder #3
Cylinder #4
Cylinder #5

10 Troubleshooting

Cylinder #6
Cylinder #7
Cylinder #8
1442 Engine Fuel Valve The position of a gaseous fuel valve that is 2,3,
1 Position metering the fuel flow to the engine.
1483 Source Address of The source address of the SAE J1939 2
Controlling Device device currently controlling the engine.
for Engine Control
1632 Engine Torque Torque limit rating described in the current 2
Limit Feature record.
1639 Fan Speed The speed of the fan associated with engine 4
coolant system.
1761 After treatment 1 A special catalyst uses a chemical reagent 0,1,3,6,8
SCR Catalyst Tank to reach legal requirement for NOX
Level emissions. This parameter indicates the
reagent level within that catalyst tank.
2797 Engine Injector A first collection of fuel injector circuits that 2,3,4
Group 1 are grouped together.
2798 Engine Injector A second collection of fuel injector circuits 2,3,4
Group 2 that are grouped together.
3031 After treatment 1 Temperature of the reagent in the storage 0,1,3,6
SCR Catalyst Tank tank.
Temperature
3226 After treatment 1 The amount of combined NO and NO2 in 2,3,5,6
Outlet NOx the exhaust entering the after treatment
system measured by a NOx sensor at
the after treatment outlet, represented in
NOx molecule parts per million non-NOx
molecules in exhaust bank 1.
3241 After treatment The reading from the exhaust gas 2,3,5,6
1 Exhaust Gas temperature sensor located farthest
Temperature 1 upstream in the after treatment system in
exhaust bank 1.
3360 After treatment 1 The catalyst tank controller has the ability 2
SCR Catalyst Tank to read attributes of the catalyst reagent
Controller such as the catalyst reagent level, catalyst
reagent temperature and catalyst reagent
quality.
3361 After treatment The catalyst dosing unit is a device that 2,3,4,6
1 SCR Catalyst mixes the catalyst reagent and air, and
Dosing Unit delivers a metered quantity of this mixture to
the exhaust stream.
3363 After treatment 1 Percentage of heating applied to the 2,3,5,6
SCR Catalyst Tank catalyst tank heater.
Heater

Troubleshooting 10
4090 NOx limits Indicates that On-Board Diagnostics has 0,2

exceeded, root determined that the limits for NOx in the
cause unknown exhaust stream have been exceeded, but
the root cause cannot be determined by the
OBD system.
4095 NOx limits Indicates that On-Board Diagnostics has 2
exceeded due determined that the limits for NOx in the
to Interrupted exhaust stream have been exceeded due to
Reagent Dosing an Interruption in reagent dosing activity.
4096 NOx limits Indicates that On-Board Diagnostics has 2
exceeded due to determined that the limits for NOx in the
Empty Reagent exhaust stream have been exceeded due to
Tank the reagent tank being empty.
4334 After treatment The SCR dosing reagent absolute pressure 0,1,2,3,6
1 SCR Dosing (measured closest to dosing valve) for after
Reagent Absolute treatment system 1 (exhaust bank 1).
Pressure
4337 After treatment The SCR dosing reagent temperature 2,3,6
1 SCR Dosing (measured closest to dosing valve) for after
Reagent treatment system 1 (exhaust bank 1).
Temperature
4341 After treatment Used to identify the applicable J1939-73 2,3,5,6
1 SCR Catalyst FMI detected in the SCR catalyst reagent
Reagent Line line heater 1, by the manufacturer’s control
Heater 1 software in exhaust bank 1.
Preliminary FMI
4374 After treatment Rotational speed of the motor driving a 0,1,2,3,5,6
1 SCR Catalyst pump for reagent used in an after treatment
Reagent Pump system.
Motor Speed
a. Possible FMIs, for an explanation of the code see the table under the heading fault type
identifier.

10 Troubleshooting
10.3 Machine Troubleshooting
NOTICE
The diagnostic codes may alert the operator to conditions that may damage the machines
components. Never ignore a Machine fault if one occurs. Always investigate thoroughly or if in
doubt contact your Terex Plant supplier.
(1) Machine diagnostic fault list
Table 10.1 - Plant Fault Codes

Code Description Code Description
00 No active faults 17 PT Tech coil fault
01 Communication with PLC lost 18 PT Tech fault
02 Emergency stop 19 Cylinder high fault
03 Radio stop fault 20 Umbilical stop
04 Engine fault 21 Cylinder low fault
05 Crusher start fault 22 Air filter restriction
06 Hydraulic oil low 23 Urea Alarm
07 J1939 communication lost with PT 24 SCR alarm
Tech Clutch
08 Low fuel level 25 Tracking inhibit
09 Product conveyor under speed 26 PLC error
10 Hydraulic oil temperature fault 27 N/A
11 Hydraulic oil temperature high 28 N/A
12 N/A 29 N/A
13 Clutch pressure low 30 Node 1 error
14 Feeder cut out 31 Clutch comms error
15 Clutch pressure sensor fault 32 Engine comms error
16 PT Tech clutch lock out

Troubleshooting 10
(a) Machine Fault Icons
OMA00368
Figure 10.9 - Machine Fault Icons

10 Troubleshooting
10.4 Hydraulics System Troubleshooting

Fault Possible Cause Procedure
The pump doesn’t start Electrical fault Check the thermal relay
connection and motor, fuses &
connections
Rotating direction error Check the rotating direction and
reconnect
Insufficient quantity of oil in the Refill oil
tank.
Pump seized Check that pump shaft rotates, fit
replacement if faulty
The pump starts but Clogged suction side piping Clean the piping and carry out
no pressure and flushing
discharge occur Clogged suction side filter Remove and clean
Air mixed from the suction side Re-tighten the coupling screw.
Replace the piping
Oil viscosity too high Check for the specified brand
Defective or damaged pump and Check and replace
coupling
Relief valve setting failure Contact Terex
Pump noise Air mixed from the suction side Clean the piping and carry out
flushing
Clogged air breather Disassemble and clean
Sound in the relief valve Disassemble
Clean or replace the spring
nozzle
High oil viscosity Check for the specified brand

Troubleshooting 10
Irregular motion of the Air mixed in the cylinder Check the piping, hose and
cylinder coupling
After checking and repair,
remove air
Filters blocked Replace
Downward adjustment Unseated unloader valve Replace valve
possible - system Solenoid operated vent valve Replace valve
will not build up or unseated
maintain pressure
Directional control valve Check operation of solenoid,
inoperative replace if necessary
Check for possible sticking
spool on valve, dismantle, clean
and replace parts or complete
assembly
Dirt in relief valve Screw the adjuster out a few
turns then in again to the original
setting
This will dislodge dirt under the
ball seat
If no response, remove unit,
dismantle and clean, particularly
jet.
Replace in system.
Faulty relief valve Check valve spring, renew as
necessary
External leakages Make visual inspection
Tighten connections
Renew pipes, hoses or couplings
as necessary
Mechanical failure of the crusher Check to see if any object
touches the machine
Insufficient oil quantity Check the oil level gauge
Refill as necessary
Downward adjustment One or both quick release Inspect, replace as required
not possible - high couplings faulty
pressure build-up Directional control valve ‘jammed Check operation of valve,
occurs half open dismantle, clean, replace parts or
complete valve as necessary
Mechanical blockage on crusher Investigate crusher

10 Troubleshooting
10.5 Urea Troubleshooting
NOTICE
It is recommended to use Adblue - din70070 Diesel Exhaust Fluid (DEF), if using a different
supplier ensure that the DEF complies with this standard.
If flushing or cleaning urea associated parts do not use diesel or any other cleaning fluids. Use
only clean water or urea to carry out the procedure.
(1) Urea Faults/Indication
NOTICE
The Urea tank and integrated controller monitor the level, and condition of the Urea. Urea level
is critical to the correct operation of the SCR system and the reduction of exhaust emissions.
If the Urea level begins to fall critically low, action will be taken by the engine and the machine
control systems to shut down crushing and de-rate the engine (if the low level condition is serious
enough, or remains for a sustained time period)
Urea level indicators have been implemented on the Main Menu, and in addition on running pages
and engine information pages, and are identifiable by the standard Urea level indicator symbol
At any point in time, all low Urea imposed conditions will be released when the tank level is refilled
above 20% and machine power is cycled. NOTE – ignoring Urea level conditions will result in the
engine beginning to impose SCR fault conditions as detailed previously, as the physical lack of
Urea in the system will mean the NOX emissions increase above the allowable limits.

Troubleshooting 10
(a) Urea indication status table
SYMBOL STATE CONDITION & ACTION

Fixed LEVEL 1 Urea CONDITION
Symbol • Urea tank has determined that there is less
than 20% Urea remaining
• No action is taken by the machine / engine
systems
• Operator should ideally fill up Urea at the
next available opportunity to avoid shutdown
Flashing LEVEL 2 Urea CONDITION
Symbol • Urea tank has determined that there is less
(1/2 Hz) than 10% Urea remaining in the tank
• The machine has performed a controlled
shutdown of crushing actions
• Crushing action will be inhibited until level
is determined as being >20%
• Engine speed will be de-rated & limited if
the condition remains for a sustained period
• Operator should fill up Urea level to >20%
and cycle machine power
Flashing LEVEL 3 Urea CONDITION
Symbol • Urea tank has determined that either in no
(2 Hz) Urea left (level =0%)
• Machine has performed a controlled
shutdown & inhibit of crushing action.
• Engine will revert to a de-rate idle speed
• Operator should fill up Urea level to >20%
and cycle machine power

10 Troubleshooting
(2) SCR Faults / Indication
NOTICE
The SCR system controls the injection of Urea into the exhaust system, where the Urea
decomposes to ammonia and reacts to reduce the nitrous oxides. This process is controlled
and monitored by both the engine and the SCR ECU units. Urea level indicators have been
implemented on the Main Menu, and in addition on running pages and engine information pages,
and are identifiable by the standard Urea level indicator symbol.
Any faults arising from the dosing of Urea / the subsequent inability of the system to produce
acceptable levels of NOX will have varying affects on machine and engine performance; and
ultimately result in a de-rate condition where crushing is shut down and the machine cannot be
throttled above idle.
If an SCR fault condition occurs it will be indicated by the arrival of a fault message on the display;
in addition to this message the standard SCR fault indicator has been adopted and will be displayed
on main menu, running screens and the engine information page on the machine interface screen.
The fault conditions have varying levels of severity, and will be released when the fault has been
taken care of and the SCR system can detect that the issue has been resolved. NOTE If torque
has reached a low level, the system will not be able to auto detect that the issue is resolved, and
a service technician will be required to release the condition; it is advisable that action is taken
early to resolve any SCR fault condition, so that the engine does not reach this level of lockout.

Troubleshooting 10
(a) SCR indication status table
SYMBOL STATE CONDITION & ACTION

Fixed LEVEL 1 SCR CONDITION
Symbol • Engine has determined a ‘NOX’ failure; the
dosing of Urea to the exhaust is not capable
of keeping the emissions within required
levels.
shutdown & inhibit of crushing operation
• Tracking at any engine speed in unaffected.
Flashing LEVEL 2 SCR CONDITION
Symbol • Engine has reverted to an active torque
(1/2 Hz) limit due to the inability to reduce ‘NOX’
emissions.
• Tracking at any engine speed in unaffected
Flashing LEVEL 3 SCR CONDITION
Symbol • Engine has reverted to an active speed
(2 Hz) limit due to the inability to reduce ‘NOX’
emissions.
• Engine will revert to a de-rate idle speed
• Tracking at de-rated engine speed only

10 Troubleshooting
10.6 Vee Belt Troubleshooting

Small Cracks on V-belt side and Base
Generally caused by shortage of belt tension but excessive heat and/or chemical fumes can also
give same failure.
Vee Belt Swelling or Softening
Caused by excessive contamination by oil, certain cutting fluids or rubber solvent.
Whipping During Running
Usually caused by incorrect tensioning, principally on long centre drives. If a slightly higher [or
lower] tension does not cure the problem there may be a critical vibration frequency in the system
which requires rectification. Consult your local Powerscreen® dealer or Powerscreen® Technical
Support department.

Storage 11
Table of Content
11 Storage.......................................................................................................11-2

Premiertrak 400/R400 Page
11 Storage
11 Storage
On receipt of the machine and the separate lubrication and hydraulic equipment carry out a careful
inspection and immediately report any component damage or loss. Conduct a careful visual
check of the machine and check all the separate loose items against the equipment delivery note.
The equipment should be stored in a dry, well-ventilated area free of excessive dust. All openings
should be sealed to prevent the ingress of dirt or moisture.
If the machinery cannot be stored indoors it must be sheeted over and made thoroughly
weatherproof to avoid deterioration.
Contact Powerscreen for advice on any situation wherever storage or inactivity is in excess of
that reasonably to be expected or where a possibly hostile environment exists, as the defects
liability warranty may be affected.

Page Premiertrak 400/R400
Glossary of Terms 12
12 Glossary of Terms
Small Cracks on Vee-belt side and Base - Generally caused by shortage of belt tension but
excessive heat and/or chemical fumes can also give same failure.
Vee Belt Swelling or Softening - Caused by excessive contamination by oil, certain cutting
fluids or rubber solvent.
Vee belts Whipping During Running - Usually caused by incorrect tensioning, principally on
long centre drives. If a slightly higher [or lower] tension does not cure the problem there may be
a critical vibration frequency in the system which requires rectification.
Packing/ Caking - Congealed lumps in the product usually due to an excessive percentage of
fines in the feed.
Wearing parts - Components subject to wear from the stone being crushed. Mainly the blow bars.

12 Glossary of Terms

Page 12-2 Premirtrak 400/R400
Appendix
13 Appendix
Appendix A EC Declaration of Conformity
Appendix B Warranty
Appendix C Schematics

Appendix

Appendix A
Appendix A EC Declaration of Conformity

This machine is in conformity with the provisions of the EC Machinery Directive 06/42/EC together
with appropriate EN Harmonised Standards and National BS Standards and Specifications.
A Declaration of Incorporation certificate is applicable to each machine. The original copy of the
certificate is sent out with the machine.
The following page shows an example of a Declaration of Incorporation certificate and the
information which should be included in it.
Each item of information on the example is numbered and the list of explanations below refer to
the corresponding numbered items on the example.
1 Full name and address of the manufacturer of the machine.
2 The name of the person authorised to compile the technical file.
3 The address of the person authorised to compile the technical file.
4 The function of the machine.
5 The model or type of the machine.
6 Serial number or pin number of the machine.
7 Commercial name of the machine.
8 Manufacturers declaration of conformity to the Machinery Directive 2006/42/EC.
9 Manufacturers declaration of conformity to the EMC Directive 2004/108/EC.
10 The place where the machine was issued from.
11 The date on which the machine was issued.
12 Identification of the person empowered to sign on behalf of the manufacturer.

Premiertrak 400/R400 Page A-1
Appendix A
Example
Original EC Declaration of Conformity

2006/42/EC ‘Machinery Directive’
Manufacturer: Terex Powerscreen

200 Coalisland Road, 1
Dungannon
Co. Tyrone
BT71 4DR
United Kingdom
Name of person authorised to compile the Technical File 2

Address of person authorised to compile the Technical file Terex GB Limited (address as above)
3
Machine Function: Mobile Crusher 4
Model / Type: 5
E
Serial / PIN number: 6
PL
Commercial Name: 7
Terex GB Limited hereby declare that the above piece of industrial equipment has been
AM
designed and manufactured to comply with the relevant provisions of the Machinery Directive
2006/42/EC. 8
Terex GB Limited hereby declare that the above of industrial equipment has been designed
and manufactured to comply with the EMC Directive 2004/108/EC. 9
EX
Place of issue: Dungannon, United Kingdom. 10

Date of issue: AUGUST 2011 11
Empowered signatory: 12

Page A-2 Premiertrak 400/R400
Appendix B
Appendix B Warranty
The following page shows an example of the warranty information. The original copy of the
warranty is sent out with the machine.

Premiertrak 400/R400 Page B-1
Appendix B
LIMITED PRODUCT WARRANTY

Terex GB Ltd. trading as Terex Mobile Processing Equipment warrants its new Equipment to be free of defects in material or workmanship for a period of (i) 12 months from the date the Equipment is first placed into service
whether such Equipment is sold, rented or leased or (ii) 2000 hours of use, whichever first occurs, provided that in no event shall this warranty extend beyond a period of two years of the date of shipment from the factory; provided
that the Buyer or the end-user sends Seller written notice of the defect within (30) days of its discovery and establishes to the Seller’s satisfaction that: (i) the Equipment has been maintained and operated within the limits of rated
and normal usage, and there have been no alterations to it; and (ii) the defect did not result in any manner from the intentional or negligent action or inaction by Buyer or the end-user or any of their respective agents or employees
or any person using it (iii) a new machine registration certificate has been completed, signed and delivered to Seller within thirty (30) days of the Equipment’s “in -service” date. If requested by Seller, Buyer must return the defective
Equipment to Seller’s manufacturing facility , or other location designated by Seller, for inspection, and if Buyer cannot establish that conditions (1) (i) and (1) (ii) above have been met, then this warranty shall not cover the alleged
defect.
Subject to the Buyer establishing that conditions (1)(i) and 1(ii) above have been met, Seller warrants all Critical Components (as defined herein) to be free, under normal use and service, of any defects in manufacture or materials
for a period of: (1) twenty four (24) months from the date of commissioning, (2) 4000 hours of use, or (3) Thirty Six (36) months the date of shipment from the factory, whichever occurs first. For the purposes of this warranty, Critical
Components shall mean:
Cone machines :- Main frame, Upper frame Countershaft and Housing, Drive pulley Drive Pinion and Gear, Eccentric, Wedge Ring (Excluding Pads)
Jaw Machines: - Mainframe including Cross Beam, Eccentric Shaft, Jaw Stock, Toggle Beam, Flywheels.
Impactor Machines: - Rotor, Main shaft, Crusher Body and Drive Pulley.
Screen Boxes; - Screen Box Welded Assembly, Screen Box Sub frame, Main Shaft.
Seller’s obligation and liability under this warranty is expressly limited to, at Seller’s sole option, repairing or replacin g, with new or remanufactured parts or components, any part, which appears to Seller upon inspection to have
been defective in material or workmanship. Such parts shall be provided at no cost to the owner, FCA Seller’s parts facility . If requested by Seller, components or parts for which a warranty claim is made shall be returned to Seller
at a location designated by Seller. All components and parts replaced under this limited product warranty become the property of Seller.
This warranty shall be null and void if parts (including wear parts) other than genuine OEM Seller parts are used in the Equipment.
Accessories, assemblies and components included in the Equipment, which are not manufactured by Seller, are subject to the warranty of their respective manufacturers. Normal maintenance, adjustments, or maintenance/wear
parts, including without limitation friction plates, glass, clutch and brake linings, filters, wire rope and paint, are not covered by this warranty and are the sole maintenance responsibility of Buyer.
SELLER MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, AND MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
E
No employee or representative is authorised to modify this warranty unless such modification is made in writing and signed by an authorized officer of Seller.
Seller’s obligation under this warranty shall not include duty, taxes, environmental fees, including without limitation, disp
direct, indirect, incidental, or consequential damages.
osal or handling of tires, batteries, petrochemical items, or any other charges whatsoever, or any liability for
PL
Improper maintenance, improper use, abuse, improper storage, operation beyond rated capacity, operation after discovery of defective or worn parts, accident, sabotage or alteration or repair of the Equipment by persons not
authorized by Seller shall render this warranty null and void. Seller reserves the right to inspect the installation of the product and review maintenance procedures to determine if the failure was due to improper maintenance,
improper use, abuse, improper storage, operation beyond rated capacity, operation after discovery of defective or worn parts, or alteration or repair of the Equipment by persons not authorized by Seller.
Parts Warranty: Seller warrants the parts ordered from the Seller’s parts department to be free of defect in material or workmanship for ei ther (1) a period of 12 months after date of shipment from the factory or (2) 2000 hrs of use
or (3) the balance of the remaining new equipment warranty, whichever occurs first. With respect to parts ordered from the Seller’s parts department for Equipment that is no longer covered under this limited p roduct warranty due
to lapse of time or usage in excess of 4,000 hours of Critical Components, Seller warrants such parts to be free of defect in material or workmanship for a period of either 12 months after date of shipment from the factory or 2000
hrs of use, whichever occurs first.
NO TRANSFERABILITY OF WARRANTY: This warranty is limited to the original purchaser or original end-user if sold to a distributor, and is not assignable or otherwise transferable without the written agreement of Seller. Please
contact your local distributor for additional details if needed.
M
ITEMS NOT COVERED BY SELLER WARRANTY
The following items are NOT covered under the Seller Warranty (the following list is not exhaustive):
1. Items sold by any individual, corporation, partnership or any other organization or legal entity that is not an authorized Seller distributor.
2. Components which are not manufactured by Seller are not covered by Seller’s warranty. Such components are covered only by the warranty that is provided by the manufacturer of such components. Such
components may include, but are not limited to, chassis, engines, air compressors, batteries, tires, customer supplied products.
3. Replacement of assemblies: Seller has the option to repair or replace any defective part or assembly. It is Seller’s policy to refuse claims for the replacement of a complete assembly that is field repairable by
the replacement or repair of defective part(s) within the assembly.
4. Normal Operational Maintenance Services and Wear Parts: Maintenance services and wear parts are excluded from warranty claims. Maintenance services and wear parts not covered include, but are not
SA
limited to, such items as: seals, gaskets, hoses, friction plates, glass, clutch and brake linings, filters, wire rope, exterior coatings, proper tightening of bolts, nuts and fittings, adding or replacing of fluids, filter, breathers, belts,
nozzles, adjustments of any kind, services supplies such as hand cleaners, towels and lubricants, inspections, diagnostic time, travel time.
5. Transportation cost and/ or damage: Any damage caused by carrier handling is a transportation claim and should be filed immediately with the respective carrier.
6. Deterioration: Repairs, work required or parts exposed as the result of age, storage, weathering, lack of use, demonstration use, or use for transportation of corrosive chemicals.
7. Secondary Failures: Should the owner or operator continue to operate a machine after it has been noted that a failure has occurred, Seller will not be responsible under the warranty for resultant damage to
other parts due to that continued operation.
8. Workmanship of Others: Seller does not accept responsibility for improper installation or labor costs or costs of any kind from personnel other than authorized Seller distributor personnel.
9. Stop and Go Warranty: Seller does not recognize “Stop and Go” warr anties.
10. Incidental or Consequential Damage: SELLER SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND, INCLUDING, BUT NOT LIMITED TO, LOST
PROFITS, LOSS OF PRODUCTION, INCREASED OVERHEAD, LOSS OF BUSINESS OPPORTUNITY, DELAYS IN PRODUCTION, COSTS OF REPLACEMENT COMPONENTS AND INCREASED COSTS OF
OPERATION THAT MAY ARISE FROM THE BREACH OF THIS WARRANTY. Customer’s sole remedy shall be limited to (at Seller’s sole option) repair or replacement of the defective part.
THIS WARRANTY IS EXPRESSLY IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES, REPRESENTATIONS AND CONDITIONS, EXPRESS OR IMPLIED AND ALL OTHER STATUTORY, CONTRACTUAL,
TORTIOUS AND COMMON LAW OBLIGATIONS OR LIABILITY ON SELLER'S PART ARE HEREBY EXPRESSLY EXCLUDED TO THE MAXIMUM EXTENT PERMITTED BY LAW. THERE ARE NO WARRANTIES THAT
EXTEND BEYOND THE LIMITED WARRANTY CONTAINED HEREIN. Seller neither assumes nor authorizes any other person to assume for Seller any other liability in connection with the sale of Seller’s Equipment. This
warranty shall not apply to any of Seller's Equipment or any part thereof which has been subject to misuse, alteration, abuse, negligence, accident, acts of God or sabotage. No action by any party shall operate to extend or revive
this limited warranty without the prior written consent of Seller. In the event that any provision of this warranty is held unenforceable for any reason, the remaining provisions shall remain in full force and effect.
IN THE EVENT OF ANY BREACH OF THE WARRANTY BY SELLER, SELLER'S LIABILITY SHALL BE LIMITED EXCLUSIVELY TO THE REMEDIES (AT SELLER’S SOLE OPTION) OF REPAIR OR REPLACEME NT OF
ANY DEFECTIVE EQUIPMENT COVERED BY THE WARRANTY. IN NO EVENT SHALL SELLER, OR ANY SUBSIDIARY OR DIVISION THEREOF BE LIABLE FOR INDIRECT OR CONSEQUENTIAL DAMAGES OR
LOSSES RESULTING FROM ANY BREACH OF WARRANTY, REPRESENTATION OR CONDITION, EXPRESS OR IMPLIED, OR ANY OTHER TERMS OF THIS WARRANTY, OR ANY BREACH OF ANY DUTY OR
OBLIGATION IMPOSED BY STATUTE, CONTRACT, TORT OR COMMON LAW OR OTHERWISE (WHETHER OR NOT CAUSED BY THE NEGLIGENCE OF THE SELLER, ITS EMPLOYEES, AGENTS OR OTHERWISE),
INCLUDING, WITHOUT LIMITATION, LOSS OF USE, LOST PROFITS OR REVENUES, LABOUR OR EMPLOYMENT COSTS, LOSS OF USE OF OTHER EQUIPMENT, DOWNTIME OR HIRE CHARGES, THIRD PARTY
REPAIRS, IMPROPER PERFORMANCE OR WORK, LOSS OF SERVICE OF PERSONNEL, LOSS OF CONTRACT OR OPPORTUNITY AND PENALTIES OF ANY KIND, OR FAILURE OF EQUIPMENT TO COMPLY
WITH ANY APPLICABLE LAWS. THE SELLER’S LIABILI TY TO THE BUYER SHALL NOT IN ANY EVENT EXCEED THE PURCHASE PRICE OF THE EQUIPMENT, PROVIDED THAT NOTHING CONTAINED IN THIS
LIMITED PRODUCT WARRANTY SHALL OPERATE TO EXCLUDE THE SELLER’S LIABILITY FOR DEA TH OR PERSONAL INJURY.
Rev 2 June 2010

Page B-2 Premiertrak 400/R400
Appendix C
Table of Content
Appendix C Schematics.............................................................................C-3
(1) XA/XR400S Electrical Schematics............................................................ C-3
(2) XA/XR400S Pre-Screen Electrical Schematics......................................... C-4
(3) Hydraulic Schematics................................................................................ C-5

Premiertrak 400/R400 Page C-1
Appendix C

Page C-2 Premiertrak 400/R400
Appendix C
Appendix C Schematics
(1) XA/XR400S Electrical Schematics

1 2 3 4 5 6 7 8 9 10 11 12
Company / customer Terex
Project description 60501529 - XAR400S T4 SP
drawing number 60501529_Mk03b
Project name 60501529_Hawk_T4_SP_Mk03b
Manufactured by Westbury Control Systems Ltd
Created on 28/02/2012
Edit date 13/11/2012 by AV Number of pages 19
Revision description Date By This drawing is copyright Unit 5 Wylam Court,
and must not be reproduced Project Description == = PLANT
Stephenson Ind. Est.
without written permission from
Coalville, Leicestershire UK.
60501529 - XAR400S T4 SP ++ +
Westbury Control Systems Ltd
LE67 3HE Page Description
Drg No. 60501529_Mk03b
Approved by Tel:+44 (0)1530 510751 Fax:+44 (0)1530 510756 Title page / cover sheet Project Total
Approved date Email: Design@Westbury-uk.com Drawn by AV Date started 19/10/2012 Date last modified 19/10/2012 Pages 19 Page 1 of 19
1 2 3 4 5 6 7 8 9 10 11 12
Table of contents Column X: An automatically generated page was edited
Page Page description Date Edited by X

=PLANT/1 Title page / cover sheet 19/10/2012 AV
=PLANT/2 Table of contents : =PLANT/1 - =PLANT/19 13/11/2012 AV
=PLANT/3 ENGINE SCHEMATIC 19/10/2012 AV
=PLANT/4 INCOMING POWER & POWER CB'S 19/10/2012 AV
=PLANT/5 EMERGENCY STOPS 19/10/2012 AV
=PLANT/6 SCREEN & PLC 19/10/2012 AV
=PLANT/7 RADIO & UMBILICAL 19/10/2012 AV
=PLANT/8 OPERATOR PANEL, SPEEDWHEEL & ALARMS 19/10/2012 AV
=PLANT/9 SENSORS & INTERNAL OUTPUTS 19/10/2012 AV
=PLANT/10 OUTPUTS TO REAR VALVE BANK 19/10/2012 AV
=PLANT/11 PTECH CLUTCH CONTROL 19/10/2012 AV
=PLANT/12 PLUG LAYOUT 13/11/2012 AV
=PLANT/13 Terminal Layout 19/10/2012 AV
=PLANT/14 Panel Door Layout 19/10/2012 AV
=PLANT/15 Panel Door - Fitted 13/11/2012 AV
=PLANT/16 Panel side Layout 19/10/2012 AV
=PLANT/17 WCSGP22SP_REV a 19/10/2012 AV
=PLANT/18 PLANT ITEMS 19/10/2012 AV
=PLANT/19 PLANT ITEMS 19/10/2012 AV

without written permission from 60501529 - XAR400S T4 SP
Westbury Control Systems Ltd Coalville, Leicestershire UK. ++ +
Drg No. 60501529_Mk03b
Approved by Tel:+44 (0)1530 510751 Fax:+44 (0)1530 510756 Table of contents : =PLANT/1 - =PLANT/19 Project Total
1 2 3 4 5 6 7 8 9 10 11 12
D
D
HE
HE
ITC
TC
WI
SW
NS
UN
LO
I
TU
H
TT
TT
TT
39
39
AT
NR
NR
BA
-BA
-BA
J19
J19
+B
IG
IG
+
1
6
F1 F2 F3 F4 F5 F6
20A 20A 20A SP 10A SP
STARTER
MOTOR
FUEL HEATER
FL1 1
30A
FHR
2
M
ISOLATOR D
FUEL SENSOR
A
C
CLUTCH OIL
OIL COOL OIL TEMP OIL LEV CONV R/L JAWS O/C CONV RUN L/H TRACK AIR FILT PURGE
A B 1 2 1 2 1 2 E 1 2 E 1 2 3 1 2 3 4 1 2 1 2
SCANIA ENGINE
+ENG-XS
PIN31
PIN14
PIN13
PIN19
PIN20
PIN10
PIN11
PIN12
PIN26
PIN27
PIN28
PIN29
PIN25
PIN24
PIN22
PIN21
PIN32
PIN15
PIN2
PIN1
PIN5
PIN4
PIN8
PIN6
PIN7
PIN3
PIN9
+WE-XP
4.7 / -RED/BLU_ENG_24V
4.6 / -OIL_COOLER
4.1 / -RED_WHT_24V
4.2 / -RED_WHT_24V_1
4.1 / -BLK_0V
4.2 / -BLK_0V_1
9.9 / -GRN_HYD_OIL_TEMP
-ORN/BLK_FUEL_HEATER
-E_STOP_NEG
9.5 / -PUR_FUEL_LEVEL
4.5 / -ORN_SWITCHED_POS
9.2 / -ORN/RED_OIL_LEVEL_POS
9.5 / -BLU_OIL_LEVEL
-J1939_HI
-J1939_LO
-J1939_SCRN
-YEL_ENG_ENABLE
9.7 / -BRN_PROD_CONV_UP
9.8 / -BLU/ORN_PROD_CONV_DWN
-JAW_OPEN_CLOSE_CYL_A
-JAW_OPEN_CLOSE_CYL_B
-YEL/BRN_PROD_CONV_SIG
-YEL/BLU_PROD_CONV_POS
10.4 / -BRN/WHI_LH_TRACK_SIG
10.4 / -BLU/WHI_LH_TRACK_POS
-BLU/BLK_AIR_FILTER_REST
-BRN_CLUTCH_OIL_PURGE
9.3 /
9.2 /
9.3 /
4.6 /
4.7 /
9.4 /
9.4 /
9.9 /
9.8 /
9.7 /
9.6 /
9.10 /
Red writing (pin 14 and pin 12) should be 1.5 mm male pins
FL1 added, Fuse ratings changed and wiring changed. 28/05/12 A.V without written permission from
60501529 - XAR400S T4 SP ++ +
Drg No. 60501529_Mk03b
Approved by Tel:+44 (0)1530 510751 Fax:+44 (0)1530 510756 ENGINE SCHEMATIC Project Total
1 2 3 4 5 6 7 8 9 10 11 12
60
SUPPLY / 11.2
62
1 -X3 62 1 1 1 1 1 1
-Q10 -Q11 -Q12 -Q13 -Q14 -Q15 -Q16
6A B 2 16A B 2 10A B 2 1A B 2 4A C 2 4A B 2 6A B 2
61
5
66
77
80
23
81
0
13 23 13 13 33
+DOOR OFF ON START
30 -K11 -K11 -K1 -K10 -K11
-S1 50A
/5.2 14 /5.2 24 /9.12 14 /4.2 14 /5.2 34
15/54
64
73
21
62
63
14 24
78
79
-X2 62 -K13 -K13 -X3 23 81 21
/9.10 11 /9.10 21
1
74
65
-Q17
-G1 2A B 2
LOAD DUMP
-X2 63 65 74
LINK LINK LINK

A1 A1
-K10 -K2
A2 A2
0V / 5.1
13 14 /4.7 14 11 /4.7
12
11
60
60
-K2
-X1 60 0 60 0 67 55 68 75 69 /4.5 12 14
70 71
5
82
67
55
61
68
75
69
70
71
80
23
81
21
21
+PNL-XP 1 4 5 8 30 7 6 2 14 12
+WE-XS 1 4 5 8 7 6 2 14 12
6.1 / PDM
6.2 / VBBO
ES_SUPPLY
PT_SUPPLY
7.2 / INPUTS
3.3 / BLK_0V
PLC_SUPPLY
UMB_SUPPLY
E_STOP_NEG
3.4 / BLK_0V_1
RADIO_SUPPLY
5.2 /
11.2 /
6.2 /
3.2 / OIL_COOLER
7.7 /
3.5 /
6.2 /
3.3 / RED_WHT_24V
6.11 / -ENGINE_CRANK
3.3 / RED_WHT_24V_1
3.7 / YEL_ENG_ENABLE
ORN_SWITCHED_POS
3.4 / RED/BLU_ENG_24V
3.5 /

Drg No. 60501529_Mk03b
Approved by Tel:+44 (0)1530 510751 Fax:+44 (0)1530 510756 INCOMING POWER & POWER CB'S Project Total
1 2 3 4 5 6 7 8 9 10 11 12
-UMB_STOP_SND / 7.7
-UMB_STOP_RTN / 7.9
+OS/S -S1 +OS/B -S1

ES_SUPPLY / 4.8
1 2 1 2
1 2 1 2
+W1-CAB BRN WHI BLK BLU +W2-CAB BRN WHI BLK BLU
+W1-XP 1 2 4 3 +W2-XP 1 2 4 3
+XRA-XS 1 2 4 3 +W2-XS 1 2 4 3
+XRA-XP A8 A6 A5 A7
+DOOR -S2
+PNL-XRA A8 A6 A5 A7
1 2 93A
-X1 93A 83A 86 96
1 2 83A
80
90
93
83
-K11 A1 S11 S21 S52

+N/FRNT -S1 +BTM/PLAT -S1 +PLTFRM -S1
E/STOP RELAY
1 2 1 2 1 2
A2 S34 S22 S12
1 2 1 2 1 2
100
99
89
0
+W5-CAB BRN WHI BLK BLU +W4-CAB BRN WHI BLK BLU +W3-CAB BRN WHI BLK BLU
+W5-XP 1 2 4 3 +W4-XP 1 2 4 3 +W3-XP 1 2 4 3
31
-K13 +XLA-XS 1 2 4 3 1 2 4 3 1 2 4 3
/9.10 32
+XLA-XP A8 A6 A5 A7
+PNL-XLA A8 A6 A5 A7
-X1 99 89 86 96
13 14 /4.5
23 24 /4.6
33 34 /4.10
4.12 / 0V 0V / 6.1
PLUG & PLAY KIT ADDED 05.03.2009 ST without written permission from
60501529 - XAR400S T4 SP ++ +
Drg No. 60501529_Mk03b
Approved by Tel:+44 (0)1530 510751 Fax:+44 (0)1530 510756 EMERGENCY STOPS Project Total
4.11 /
4.9 /
5.12 / 0V
1
+DOOR-A10
4.12 /
-X1
-X1
VIO GRY 61
GND VBB+ PDM / 4.4
0
-VBBO
-RADIO_SUPPLY
PLC_SUPPLY
61
WHT/GRY WHT/YEL
GND SWITCHED VBB+
0
23
5
21
23
RED
SWITCHED GND
0
2
120Ω
-R1
BLK GRN
SWITCHED GND CAN1 H
0
14
GRY/PNK RED/BLU
RS232 RxD CAN1 L
32
WHT/GRN BRN/GRN
RS232 TxD CAN2 H
PDM SCREEN
120Ω
-R17
Revision description
BRN YEL/BRN
SHIELD CAN2 L
0
3
GRY/BRN YEL
ETHERNET TxD+ ETHERNET RxD+
TXD+ RXD+
PNK WHT
ETHERNET TxD- ETHERNET RxD-
TXD- RXD-
-A11
4
23
01 GND S VBB S 23
23
Date
5
15 GND 0 VBB O 05
5
By
34
12 GND A
5
VBB R 34
5
-X1
06 24
06 RxD TEST 24
6
24
0V
Approved by
LINK
Approved date
07
07 TxD
7
33
33 GND
-X1
This drawing is copyright

33
6
and must not be reproduced

14
23
CAN1 H 14
32
13 ERROR CAN1 L 32
44
9.10 / ENGINE_ENABLE 44 Q10 J1939_SCRN / 9.3
120R
-R11
PLC
SCN
45 26
7
9.11 / RADIO_TRACK_ENABLE 45 Q11 CAN H 26 J1939_HI / 9.3
LE67 3HE
Email: Design@Westbury-uk.com
26
26
46 25
9.11 / UMBILICAL_TRACK_ENABLE 46 Q12 CAN L 25 J1939_LO / 9.2
25
25
Unit 5 Wylam Court,

47

9.10 / -AIR_FILTER_REST 47 I13 CAN_H_PT / 11.2
26
Tel:+44 (0)1530 510751 Fax:+44 (0)1530 510756

36

9.6 / PRODUCT_CONV_SPEED 36 Q20 CAN_L_PT / 11.2
25
54 8
10.9 / FEEDER_SPEED 54 Q21 I00 08 FEEDER_SPEED_REF / 8.3
8
17 27
Drawn by AV
9.6 / PRODUCT_CONV_ON 17 Q22 I01 27 JAW_PRESSURE / 8.10
53 9
SCREEN & PLC

10.11 / FEEDER_ON 53 Q23 I02 09 UMB_SOUNDER / 7.9
Page Description
39 28
Project Description
10.1 / BEACON 39 Q30 I03 28 RADIO_SOUNDER / 7.4
3 10
10.3 / SOUNDER 03 Q31 I04 10 FUEL_LEVEL / 9.5
9
60501529 - XAR400S T4 SP
40 29
9.7 / PRODUCT_CONV_RAISE 40 Q32 I05 29 HYD_OIL_TEMP / 9.9
22 11
22 Q33 I06 11
Date started 28/02/2012

9.8 / PRODUCT_CONV_LOWER FEEDER_ON/OFF / 7.4
41 30
9.4 / FUEL_HEATER 41 Q34 I07 30 RADIO_STOP / 7.3
42 20
9.4 / CLUTCH_OIL_PURGE 42 Q35 I14 20 SPEED_WHEEL / 8.6
43 2
10
9.12 / OIL_COOLER_SW 43 Q36 I15 02 DUMP_SIGNAL / 8.11

4 21 E_STOP_HEALTHY
10.8 / 04_DIVERTER_VALVE 04 Q37 I16 21
21
48 38
10.7 / 48 Q40 I17 38
Date last modified 19/10/2012

DIRT_CONV_ON UMBILICAL_STOP / 7.9
49 19
9.8 / CYLINDER_A 49 Q41 I24 19 OIL_LEVEL / 9.5
++
==
31 55
Pages 19
9.9 / CYLINDER_B 31 Q42 I25 55 ENGINE_CRANK / 4.4
Project Total
11
50 18
10.2 / LEFT_TRACK_DIVERT 50 Q43 I26 18 FEEDER_START / 8.2
21
51 37
10.3 / RIGHT_TRACK_DIVERT 51 Q44 I27 37 FEEDER_STOP / 8.2
+
52
10.12 / 52_DUMP_VALVE 52 Q45
= PLANT
16
Drg No. 60501529_Mk03b

10.8 / DIRT_CONV_RAISE 16 Q46
12
35
10.9 / DIRT_CONV_LOWER 35 Q47
Page 6 of 19
0V / 7.2
-RADIO_SUPPLY / 7.2
1 2 3 4 5 6 7 8 9 10 11 12
81
4.10 / INPUTS INPUTS / 8.1
21
6.11 / -RADIO_SUPPLY 83
5.3 / -UMB_STOP_SND
82
4.10 / UMB_SUPPLY
-X1 82 83 81
+PLT-XR RED BRN ORG WHT
+RADIO-U1 +UMB-U1
RED +24VDC
BRN RADIO STOP
ORG ENGINE STOP
WHT FEEDER ON/OFF
C1 +24VDC
C2 UMB STOP
C6 ENGINE STOP
RADIO 16 WAY
UMBILICAL
CONNECTOR
WHT FEEDER ON/OFF
GRN OUTPUT VALVE1
BLU OUTPUT VALVE2
C9 OUTPUT VALVE1
C5 OUTPUT VALVE2
GRY SOUND ALARM
ORG ENGINE STOP
YEL VALVE POWER
C4 SOUND ALARM
C8 VALVE POWER
BRN RADIO STOP
C7 ENGINE STOP
C3 UMB STOP
BLK 0VDC
G/Y 0VDC
+PNL-XR BLK BRN ORG WHT GRY YEL GRN BLU
-X2 30 11 28 0 90 38 9 104 105 106
GRN
BLU
104
105
106
YEL
30
11
28
90
38
9
6.9 / RADIO_SOUNDER
6.8 / -UMB_SOUNDER
-RADIO_STOP
6.9 / FEEDER_ON/OFF
10.4 / -RADIO_TRK_PWR
-RADIO_TRK_VALVE1
-RADIO_TRK_VALVE2
-UMB_STOP_RTN
-UMBILICAL_STOP
10.6 / -UMB_TRK_PWR
-UMB_TRK_VALVE1
-UMB_TRK_VALVE2
6.10 /
5.2 /
6.10 /
10.6 /
10.7 /
10.4 /
10.5 /
0
6.12 / 0V 0V / 8.1
60501529 - XAR400S T4 SP ++ +
Drg No. 60501529_Mk03b
Approved by Tel:+44 (0)1530 510751 Fax:+44 (0)1530 510756 RADIO & UMBILICAL Project Total
1 2 3 4 5 6 7 8 9 10 11 12
81
-X1 81 81 81
+PNL-XLA B2 C1 +PNL-XRA C1
+XLA-XP B2 C1 +XRA-XP C1
+XLA-XS P1
+OP-XP P1 +XRA-XS 1
C1 -S1
1
3 1 -B1
1 4 PRESSURE
+
-S1 -S2 -R1 SWITCH +
4 2 P
2 -
-
C4 C5 C2 C3
3 2 4
=ELEC_PACK+OP_PANEL
=ELEC_PACK+PROD_CONV
+OP-XP P4 P5 P2 P3 P6
=ELECTRIC_PACK+CRUSHER
+XRA-XS 3 2 4
+XLA-XS P4 P5 P2 P3 P6
+XLA-XP B5 B6 B3 B4 B7 C4 C2 +XRA-XP C3 C2 C4
+PNL-XLA B5 B6 B3 B4 B7 C4 C2 +PNL-XRA C3 C2 C4
-X1 18 37 8 0 0 0 20 0 27 2
8
2
18
37
20
27
FEEDER_STOP
-JAW_PRESSURE
-FEEDER_START
6.11 /
6.10 / -DUMP_SIGNAL
6.10 / -SPEED_WHEEL
6.8 /
6.11 /
6.8 / -FEEDER_SPEED_REF
A1
-K12
A2
0
7.12 / 0V 0V / 9.1
11 14 /10.12

PLUG & PLAY KIT ADDED 05.03.2009 ST without written permission from 60501529 - XAR400S T4 SP
Drg No. 60501529_Mk03b
Approved by Tel:+44 (0)1530 510751 Fax:+44 (0)1530 510756 OPERATOR PANEL, SPEEDWHEEL & ALARMS Project Total
1 2 3 4 5 6 7 8 9 10 11 12
-UMBILICAL_TRACK_ENABLE / 6.7
81
8.12 / INPUTS
-PRODUCT_CONV_LOWER / 6.9
-PRODUCT_CONV_SPEED / 6.8
-PRODUCT_CONV_RAISE / 6.9
-RADIO_TRACK_ENABLE / 6.7
-PRODUCT_CONV_ON / 6.8
CLUTCH_OIL_PURGE / 6.10
OIL_COOLER_SW / 6.10
AIR_FILTER_REST / 6.7
-ENGINE_ENABLE / 6.7
-HYD_OIL_TEMP / 6.9
FUEL_HEATER / 6.10
-CYLINDER_A / 6.11
-CYLINDER_B / 6.11
J1939_SCRN / 6.7
FUEL_LEVEL / 6.9
OIL_LEVEL / 6.11
J1939_LO / 6.7
J1939_HI / 6.7
25
26
41
42
10
19
17
36
40
22
49
31
29
47
44
45
46
43
-X2 36 107
-R14
107
10k
+
-R13 -C10
1k 1uF
81 25 26 SCN 41 42 10 19 17 0 107 40 22 49 31 29 47
+PNL-XP 3 9 10 11 13 15 19 20 24 25 26 27 28 29 31 32
+WE-XS 3 9 10 11 13 15 19 20 24 25 26 27 28 29 31 32
3.6 / ORN/RED_OIL_LEVEL_POS
3.6 / J1939_LO
3.6 / J1939_HI
3.6 / J1939_SCRN
ORN/BLK_FUEL_HEATER
BRN_CLUTCH_OIL_PURGE
3.5 / PUR_FUEL_LEVEL
JAW_OPEN_CLOSE_CYL_A
JAW_OPEN_CLOSE_CYL_B
3.4 / GRN_HYD_OIL_TEMP
3.4 /
3.11 /
3.8 /
3.8 /
3.9 /
3.9 /
3.11 /
A1 A1 A1 A1
-K13 -K14 -K15 -K1
A2 A2 A2 A2
0
8.12 / 0V 0V / 10.1
14 11 /4.5 11 14 /10.411 14 /10.613 14 /4.6
24 21 /4.6 21 24 /10.421 24 /10.6
31 32 /5.2 31 34 /10.531 34 /10.7
60501529 - XAR400S T4 SP ++ +
Drg No. 60501529_Mk03b
Approved by Tel:+44 (0)1530 510751 Fax:+44 (0)1530 510756 SENSORS & INTERNAL OUTPUTS Project Total
1 2 3 4 5 6 7 8 9 10 11 12
/ 6.10
-BEACON / 6.9
-LEFT_TRACK_DIVERT / 6.11
-SOUNDER / 6.9
-RADIO_TRK_PWR / 7.5
-RADIO_TRK_VALVE1 / 7.5
-UMB_TRK_PWR / 7.10
-UMB_TRK_VALVE1 / 7.10
-DIRT_CONV_ON / 6.10
04_DIVERTER_VALVE
-DIRT_CONV_RAISE / 6.12
-DIRT_CONV_LOWER / 6.12
-FEEDER_SPEED / 6.8
-FEEDER_ON / 6.8
52_DUMP_VALVE / 6.12
-RIGHT_TRACK_DIVERT / 6.11
3
4
39
48
16
35
54
53
52
104
105
106
YEL
BLU
GRN
50
51
-X1 39 3A 3 3B
50 51 11 21 31 11 21 31
+PNL-XRA A3 W17 A2 -K14 -K14 -K14 -K15 -K15 -K15 -X2 54 112
W16
BLK BLK /9.11 14/9.11 24/9.11 34 /9.11 14/9.11 24/9.11 34
-R16
109 10k
+XRA-XP A3 4 4 A2
11
110
+ -K12
-R15 -C11 /8.11 14
112
108 1k 1uF
+XRA-XS P5 P5
52
111
P5 P5 108 109 108 110 48 4 16 35 0 112 53 111 52

-XP
1 1
+PNL-XRA B2 B3 A4 C6 B7 B8 B6 B5 C8
USE TERMINAL 111
FOR DUMP VALVE
CONNECTION IF MACHINE
2 2 IS TO BE IN HR MODE
+ + +XRA-XP B2 B3 A2 C6 B7 B8 B6 B5 C8
-H1 -H1
BEACON - SOUNDER -
+OS_BEACON
+OS_SOUNDER
1 1 2 1
2 1 1 2 1
-Y1 -Y2 -Y3 -Y5 -Y1
O/S TRACK 3 4 3 4
VALVE
-Y4
+R_VLVS
E 2 PE 2
+CRUSHER
-XP P6 P6
3 3
+XRA-XS P6 BLU BLU P6
W16 W17
0
+XRA-XP A1 C7 A9 C9
0 0
A1 C7 A9 C9
+PNL-XRA
0 0 0
-X1 0
0 0
9.12 / 0V 0V / 11.1

Drg No. 60501529_Mk03b
Approved by Tel:+44 (0)1530 510751 Fax:+44 (0)1530 510756 OUTPUTS TO REAR VALVE BANK Project Total
1 2 3 4 5 6 7 8 9 10 11 12
PT TECH CLUTCH
26
6.7 / -CAN_H_PT CONTROLLER
25
(Optional - Not usually fitted)
6.8 / CAN_L_PT
4.11 / -PT_SUPPLY
21 -R12
120Ω
60
4.12 / -SUPPLY
A B C
1 2
0
-F1 60
5A 21 0 25 26 600 601 602
600
601
602
BLU BLU GRY BLU BLU BLU BLU BLU
21
25
26
+
1 2 3 4 5 6 7 8
+PNL-XSPT
+PT_TECH_LOOM
-X1 1 2 3 4 5 6 7 8
GREEN "B" CAN1
YELLOW "A" CAN1
WHITE SHIELD
BLACK SHIELD
8 WAY ILME PLUG
YELLOW
BLACK
GREY
RED
-X6 1 2 -X7 1 2
PWM COIL CLUTCH ON/OFF
PURPLE
GREEN
BLACK
BLACK
-X5 1 2 3 -X4 2 1 4
WHITE
BLACK
BLACK
SCRN
INPUT SPEED PICKUP
RED
RED
PT TECH CLUTCH
PRESSURE TRANSDUCER
BARE METAL SHIELD

BARE SHIELD DRAIN
YELLOW "A" CAN1

GREEN "B" CAN1
BLACK SHIELD
BLACK SHIELD
WHITE SHIELD
RED SHIELD
ORANGE
YELLOW
PURPLE
WHITE
BLACK
GREEN
BLACK
GREY
RED
RED
-X2 1 2 3 4 5 6 7 8 9 10 11 12 -X3 1 2 3 4 5 6 7 8 9 10 11 12
0 12 Way Grey Plug 12 Way Black Plug
0
10.12 / -0V
60501529 - XAR400S T4 SP ++ +
Drg No. 60501529_Mk03b
Approved by Tel:+44 (0)1530 510751 Fax:+44 (0)1530 510756 PTECH CLUTCH CONTROL Project Total
Appendix C
(2) XA/XR400S Pre-Screen Electrical Schematics

Page C-4 Premiertrak 400/R400
1 2 3 4 5 6 7 8 9 10 11 12
Company / customer TEREX
Project description 60501662 - X400S T4 SP Pre Screen
drawing number 60501662_MK01c
Project name 60501662_X400S_T4_MK01c
Manufactured by Westbury Control Systems Ltd.
Created on 26/08/2008
Edit date 23/05/2012 by samtongue Number of pages 20
60501662 - X400S T4 SP Pre Screen ++ +
Drg No. 60501662_MK01c
Approved by Tel:+44 (0)1530 510751 Fax:+44 (0)1530 510756 Title page / cover sheet Project Total
1 2 3 4 5 6 7 8 9 10 11 12
Table of contents Column X: An automatically generated page was edited
Page Page description Date Edited by X

=PLANT/1 Title page / cover sheet 10/05/2012 AV X
=PLANT/2 Table of contents : =PLANT/1 - =PLANT/20 10/05/2012 AV
=PLANT/3 ENGINE SCHEMATIC 10/05/2012 AV
=PLANT/4 INCOMING POWER & POWER CB'S 10/05/2012 AV
=PLANT/5 EMERGENCY STOPS 10/05/2012 AV
=PLANT/6 SCREEN & PLC 10/05/2012 AV
=PLANT/7 NODE IO 10/05/2012 AV
=PLANT/8 RADIO & UMBILICAL 10/05/2012 AV
=PLANT/9 OPERATOR PANEL, SPEEDWHEEL & ALARMS 10/05/2012 AV
=PLANT/10 SENSORS & INTERNAL OUTPUTS 10/05/2012 AV
=PLANT/11 OUTPUTS TO REAR VALVE BANK 10/05/2012 AV
=PLANT/12 PTECH CLUTCH CONTROL 10/05/2012 AV
=PLANT/13 PreScreen cables 10/05/2012 AV
=PLANT/14 Ignition Label 10/05/2012 AV
=PLANT/15 PLUG LAYOUT 10/05/2012 AV
=PLANT/16 Terminal Layout 10/05/2012 AV
=PLANT/17 Panel Door Layout 10/05/2012 AV
=PLANT/18 Panel side Layout 10/05/2012 AV
=PLANT/19 WCSGP22SP_REV a 10/05/2012 AV
=PLANT/20 Panel Door - Fitted 10/05/2012 AV

without written permission from 60501662 - X400S T4 SP Pre Screen
Drg No. 60501662_MK01c
Approved by Tel:+44 (0)1530 510751 Fax:+44 (0)1530 510756 Table of contents : =PLANT/1 - =PLANT/20 Project Total
Approved date Email: Design@Westbury-uk.com Drawn by samtongue Date started 10/05/2012 Date last modified 23/05/2012 Pages 20 Page 2 of 20
ISOLATOR
Red writing (pin 14 and pin 12) should be 1.5 mm male pins
SCANIA ENGINE
1
STARTER
MOTOR
+ENG-XS
M
+WE-XP
2
20A
OIL COOL
A
4.6 / -OIL_COOLER
PIN2
20A
3
4.1 / -RED_WHT_24V
15A
PIN1
4.2 / -RED_WHT_24V_1
PIN5
4.1 / -BLK_0V
10A
PIN4
OIL TEMP
1
4.2 / -BLK_0V_1
PIN8
10A
2
10.9 / -GRN_HYD_OIL_TEMP
4
PIN31
Date
4.7 / -RED/BLU_ENG_24V
PIN14
SP
10.4 / -ORN/BLK_FUEL_HEATER
PIN13
4.6 / -E_STOP_NEG
PIN6 FHR
1
By
10.5 / -PUR_FUEL_LEVEL +B
PIN19 AT
2 TU
-BA NS
5
TT WI
3 TC
Approved date
Approved by
HE
IG
4.5 / -ORN_SWITCHED_POS D
PIN7 NR
4
1
+
OIL LEV
10.2 / -ORN/RED_OIL_LEVEL_POS BA
PIN3
5 TT
UN
2
10.5 / -BLU_OIL_LEVEL -BA SW

PIN20
6 TT ITC
10.3 / -J1939_HI J19 HE
39 D
6
PIN10
7
J19 H I
10.2 / -J1939_LO
Tel:+44 (0)1530 510751 Fax:+44 (0)1530 510756
PIN9 39
8 LO
10.3 / -J1939_SCRN
PIN11
4.7 / -YEL_ENG_ENABLE
PIN12
LE67 3HE
Unit 5 Wylam Court,
1
1
7
CONV R/L
IG
PIN26 NR
2
2
PIN27
3
E
4
Drawn by AV
ENGINE SCHEMATIC
Page Description
60501662 - X400S T4 SP Pre Screen
Project Description
-JAW_OPEN_CLOSE_CYL_A
JAWS O/C
10.8 / 5
PIN28
8
2
10.9 / -JAW_OPEN_CLOSE_CYL_B 6
PIN29
E
CONV RUN
10.7 / -YEL/BRN_PROD_CONV_SIG
PIN25
2
10.6 / -YEL/BLU_PROD_CONV_POS
9
PIN24
3
L/H TRACK
PIN22
2
PIN21
10
3
4
YEL/WHI_LH_TRACK_ERROR
PIN23
AIR FILT
Pages 20
Project Total
Drg No. 60501662_MK01c
++
==
1
2
10.10 / -BLU/BLK_AIR_FILTER_REST
PIN32
11
Page 3 of 20
CLUTCH OIL
1
10.4 / -BRN_CLUTCH_OIL_PURGE
PURGE
+
= PLANT
PIN15
2
12
C
FUEL SENSOR FUEL HEATER

1 2 3 4 5 6 7 8 9 10 11 12
SUPPLY / 12.2
62
1 -X3 62 1 1 1 1 1 1
-Q10 -Q11 -Q12 -Q13 -Q14 -Q15 -Q16
6A B 2 16A B 2 10A B 2 1A B 2 4A C 2 4A B 2 6A B 2
61
5
66
77
80
23
81
0
13 23 13 13 33
+DOOR OFF ON START
30 -K11 -K11 -K1 -K10 -K11
-S1 50A
/5.2 14 /5.2 24 /10.12 14 /4.2 14 /5.2 34
15/54
64
73
21
62
63
14 24
78
79
-X2 62 -K13 -K13 -X3 23 81 21
/10.10 11 /10.10 21
1
74
65
-Q17
-G1 2A B 2
LOAD DUMP
-X2 63 65 74
LINK LINK LINK

A1 A1
-K10 -K2
A2 A2
0V / 5.1
14 11 /4.7
12
11
13 14 /4.7
23 24 -K2
-X1 60 0 60 0 67 55 68 75 69 /4.5 12 14
33 34
43 44 70 71
5
82
67
55
61
68
75
69
70
71
80
23
81
21
21
+PNL-XP 1 4 5 8 30 7 6 2 14 12
+WE-XS 1 4 5 8 30 7 6 2 14 12
6.1 / PDM
6.2 / VBBO
ES_SUPPLY
PT_SUPPLY
3.3 / BLK_0V
8.2 / INPUTS
PLC_SUPPLY
UMB_SUPPLY
E_STOP_NEG
3.4 / BLK_0V_1
RADIO_SUPPLY
5.2 /
12.2 /
6.2 /
3.2 / OIL_COOLER
3.5 /
8.5 /
6.2 /
3.3 / RED_WHT_24V
6.11 / -ENGINE_CRANK
3.3 / RED_WHT_24V_1
3.7 / YEL_ENG_ENABLE
ORN_SWITCHED_POS
3.4 / RED/BLU_ENG_24V
3.5 /

Drg No. 60501662_MK01c
Approved by Tel:+44 (0)1530 510751 Fax:+44 (0)1530 510756 INCOMING POWER & POWER CB'S Project Total
1 2 3 4 5 6 7 8 9 10 11 12
-UMB_STOP_SND / 8.5
-UMB_STOP_RTN / 8.6
+OS/S -S1 +OS/B -S1

ES_SUPPLY / 4.8
1 2 1 2
1 2 1 2
+W1-CAB BRN WHI BLK BLU +W2-CAB BRN WHI BLK BLU
+W1-XP 1 2 4 3 +W2-XP 1 2 4 3
+XRA-XS 1 2 4 3 +W2-XS 1 2 4 3
+XRA-XP A8 A6 A5 A7
+DOOR -S2
+PNL-XRA A8 A6 A5 A7
1 2 93A
-X1 93A 83A 86 96
1 2 83A
80
90
93
83
-K11 A1 S11 S21 S52

+N/FRNT -S1 +BTM/PLAT -S1 +PLTFRM -S1
E/STOP RELAY
1 2 1 2 1 2
A2 S34 S22 S12
1 2 1 2 1 2
100
99
89
0
+W5-CAB BRN WHI BLK BLU +W4-CAB BRN WHI BLK BLU +W3-CAB BRN WHI BLK BLU
+W5-XP 1 2 4 3 +W4-XP 1 2 4 3 +W3-XP 1 2 4 3
31
-K13 +XLA-XS 1 2 4 3 1 2 4 3 1 2 4 3
/10.10 32
+XLA-XP A8 A6 A5 A7
+PNL-XLA A8 A6 A5 A7
-X1 99 89 86 96
13 14 /4.5
23 24 /4.6
33 34 /4.10
4.12 / 0V 0V / 6.1
60501662 - X400S T4 SP Pre Screen ++ +
Drg No. 60501662_MK01c
Approved by Tel:+44 (0)1530 510751 Fax:+44 (0)1530 510756 EMERGENCY STOPS Project Total
4.11 /
4.9 /
5.12 / 0V
1
+DOOR-A10
4.12 /
-X1
-X1
VIO GRY 61
GND VBB+ PDM / 4.4
0
61
-VBBO
-RADIO_SUPPLY
PLC_SUPPLY
WHT/GRY WHT/YEL
GND SWITCHED VBB+
0
23
5
21
23
RED
SWITCHED GND
0
2
120Ω
-R1
BLK GRN
SWITCHED GND CAN1 H
0
14
GRY/PNK RED/BLU
RS232 RxD CAN1 L
32
WHT/GRN BRN/GRN
RS232 TxD CAN2 H
PDM SCREEN
120Ω
-R17
BRN YEL/BRN
SHIELD CAN2 L
0
3
GRY/BRN YEL
ETHERNET TxD+ ETHERNET RxD+
TXD+ RXD+
PNK WHT
ETHERNET TxD- ETHERNET RxD-
TXD- RXD-
-A11
4
23
01 GND S VBB S 23
Date
-X1
5
15 GND 0 VBB O 05
5
By
34
12 GND A
5
VBB R 34
5
-X1
06 24
06 RxD TEST 24
6
24
0V
Approved by
LINK
Approved date
07
07 TxD
7
33
23
33 GND

33
6

14
CAN1 H 14 CAN1_H / 7.2
14
32
13 ERROR CAN1 L 32 CAN1_L / 7.2
32
44
10.10 / ENGINE_ENABLE 44 Q10 J1939_SCRN / 10.3
120R
-R11
PLC
SCN
45 26
7
10.11 / RADIO_TRACK_ENABLE 45 Q11 CAN H 26 J1939_HI / 10.3
LE67 3HE
26
26
46 25
10.11 / UMBILICAL_TRACK_ENABLE 46 Q12 CAN L 25 J1939_LO / 10.2
25
25
Unit 5 Wylam Court,

47

10.10 / -AIR_FILTER_REST 47 I13 CAN_H_PT / 12.2
26
Tel:+44 (0)1530 510751 Fax:+44 (0)1530 510756

36

10.6 / PRODUCT_CONV_SPEED 36 Q20 CAN_L_PT / 12.2
25
54 8
11.9 / FEEDER_SPEED 54 Q21 I00 08 FEEDER_SPEED_REF / 9.3
8
17 27
Drawn by AV
10.6 / PRODUCT_CONV_ON 17 Q22 I01 27 JAW_PRESSURE / 9.10
53 9
SCREEN & PLC

11.10 / FEEDER_ON 53 Q23 I02 09 UMB_SOUNDER / 8.7
Page Description
39 28
Project Description
11.1 / BEACON 39 Q30 I03 28 RADIO_SOUNDER / 8.3
3 10
11.4 / DIRT_CONV_DIVERT 03 Q31 I04 10 FUEL_LEVEL / 10.5
9
40 29
10.7 / PRODUCT_CONV_RAISE 40 Q32 I05 29 HYD_OIL_TEMP / 10.9
22
22 Q33 I06 11

10.8 / PRODUCT_CONV_LOWER

41 30
10.4 / FUEL_HEATER 41 Q34 I07 30 RADIO_STOP / 8.2
42 20
10.4 / CLUTCH_OIL_PURGE 42 Q35 I14 20 SPEED_WHEEL / 9.6
43 2
10
10.12 / OIL_COOLER_SW 43 Q36 I15 02 DUMP_SIGNAL / 9.11

04 21 E_STOP_HEALTHY
11.8 / DIVERTER_VALVE 04 Q37 I16 21
21
48 38
11.7 / 48 Q40 I17 38

DIRT_CONV/PRE_SCREEN_RUN UMBILICAL_STOP / 8.6
49 19
10.8 / CYLINDER_A 49 Q41 I24 19 OIL_LEVEL / 10.5
++
==
31 55
Pages 20
10.9 / CYLINDER_B 31 Q42 I25 55 ENGINE_CRANK / 4.4
Project Total
11
21
23
50 18
11.2 / LEFT_TRACK_DIVERT 50 Q43 I26 18 FEEDER_START / 9.2
51 37
11.3 / RIGHT_TRACK_DIVERT 51 Q44 I27 37 FEEDER_STOP / 9.2
+
52
11.11 / DUMP_VALVE 52 Q45
= PLANT
DIRT_CONV/HOPPER_BANK 16
Drg No. 60501662_MK01c

11.9 / 16 Q46
(DEFLECTOR_RAISE)
12
35
11.9 / DEFLECTOR_LOWER 35 Q47
Page 6 of 20
0V / 7.2
PLC_SUPPLY / 7.2
-RADIO_SUPPLY / 8.2
1 2 3 4 5 6 7 8 9 10 11 12
23
6.11 / PLC_SUPPLY
14
6.6 / CAN1_H
32
6.6 / CAN1_L
207_RADIO_PROD_CONV / 8.10
206_RADIO_PROD_CONV / 8.9
203_RADIO_FEEDER / 8.11
SPEED_DOWN
SPEED_UP
ON_OFF
LOWER
RAISE
-X1 23
203
204
205
206
207
-A5
10
11
12
10
11
12
1
5
CAN H
CAN L
IN10
IN11
IN12
IN13
IN14
+UB
+UB
+UB
+UB
+UB
+UB
+UB
+UB
+UB
+UB
+UB
+UB
+UB
IN1
IN2
IN3
IN4
IN5
IN6
IN9
X1 X3
OUT15
OUT16
OUT7
OUT8
GND
GND
GND
GND
GND
GND
GND
GND
GND
13
14
15
16
17
18
13
14
15
16
17
18
2
301
302
-X1 301A 301 301B -X1 0

+PNL-XRA A2
PRE_SCREEN_DIVERT
+XRA-XP A2
P5
=ELEC_PACK+OS_SOUNDER
P5
+
11.3 /
-H1
SOUNDER -
P6
P6
XRA_0V / 11.1
0
6.12 / -0V -0V / 8.2
60501662 - X400S T4 SP Pre Screen ++ +
Drg No. 60501662_MK01c
Approved by Tel:+44 (0)1530 510751 Fax:+44 (0)1530 510756 NODE IO Project Total
6.11 /
1
7.12 / 0V
4.10 / INPUTS
-RADIO_SUPPLY
+RADIO-U10
+PNL-XR
+PLT-XR
BLK 0VDC RED +24VDC

0
2
21
81
BLK
RED
-X2
30
6.10 / -RADIO_STOP BRN RADIO STOP BRN RADIO STOP
30
BRN
BRN
ORG ENGINE STOP ORG ENGINE STOP

ORG
ORG
WHT FEEDER ON/OFF WHT FEEDER ON/OFF

3
WHT
WHT
28
6.9 / RADIO_SOUNDER GRY SOUND ALARM
28
GRY
YEL
11.5 / -RADIO_TRK_PWR YEL VALVE POWER
YEL
GRN
11.5 / -RADIO_TRK_VALVE1 GRN OUTPUT VALVE1
4
CONNECTOR
5.3 /
RADIO 16 WAY
GRN
4.10 /
BLU
Date
11.5 / -RADIO_TRK_VALVE2 BLU OUTPUT VALVE2

BLU
By
UMB_SUPPLY
-UMB_STOP_SND
5
82
83
+UMB-U11
Approved by
Approved date
-X1
G/Y 0VDC C1 +24VDC

0
82

6

90
5.2 / -UMB_STOP_RTN C3 UMB STOP C2 UMB STOP
90
83
38
6.10 / -UMBILICAL_STOP C7 ENGINE STOP C6 ENGINE STOP
38
81
9
6.8 / -UMB_SOUNDER C4 SOUND ALARM
9
7
LE67 3HE
104
11.6 / -UMB_TRK_PWR C8 VALVE POWER
104
Unit 5 Wylam Court,

105

11.6 / -UMB_TRK_VALVE1 C9 OUTPUT VALVE1
UMBILICAL
105
Tel:+44 (0)1530 510751 Fax:+44 (0)1530 510756

106
11.7 / -UMB_TRK_VALVE2 C5 OUTPUT VALVE2
106
8
Drawn by AV
Page Description
Project Description
RADIO & UMBILICAL

+RADIO-U12
9
+PNL-XR2
+PNL-XR2
206
7.5 / -206_RADIO_PROD_CONV_LOWER GRY BUTTON 5-1 WHT BUTTON 5-2
206

GRY
WHI

207
7.5 / -207_RADIO_PROD_CONV_RAISE BLK BUTTON 6-1 BRN BUTTON 6-2
BLK
207
BRN
GRN BUTTON 7-1

10
GRN
ORG BUTTON 7-2
ORG

205
7.5 / -205_RADIO_FEEDERSPEED_DOWN PUR BUTTON 8-1
205
PUR
++
==
204
Pages 20
7.4 / -204_RADIO_FEEDERSPEED_UP YEL BUTTON 8-2
Project Total
11
YEL
204
CONNECTOR
RADIO 10 WAY
203
7.3 / -203_RADIO_FEEDERON_OFF RED BUTTON 10-2
203
RED
+
BLU RADIO SIGNAL OK
= PLANT
BLU
Drg No. 60501662_MK01c

12
Page 8 of 20
0V / 9.1
INPUTS / 9.1
1 2 3 4 5 6 7 8 9 10 11 12
81
-X1 81 81 81
+PNL-XLA B2 C1 +PNL-XRA C1
+XLA-XP B2 C1 +XRA-XP C1
+XLA-XS P1
+OP-XP P1 +XRA-XS
=ELEC_PACK+PROD_CONV
=ELECTRIC_PACK+CRUSHER
=ELEC_PACK+OP_PANEL
C1 -S1
1
3 1 -B1
1 4 PRESSURE
-S1 -S2 -R1
+
SWITCH +
4 2
2 - P
-
C4 C5 C2 C3
3 2 4
+OP-XP P4 P5 P2 P3 P6
+XRA-XS 3 2 4
+XLA-XS P4 P5 P2 P3 P6
+XLA-XP B5 B6 B3 B4 B7 C4 C2 +XRA-XP C3 C2 C4
+PNL-XLA B5 B6 B3 B4 B7 C4 C2 +PNL-XRA C3 C2 C4
-X1 18 37 8 0 0 0 20 0 27 2
18
37
20
27
8
2
6.10 / -SPEED_WHEEL
-JAW_PRESSURE
6.10 / -DUMP_SIGNAL
-FEEDER_START
FEEDER_STOP
6.8 / -FEEDER_SPEED_REF
6.11 /
6.8 /
6.11 /
A1
-K12
A2
0
8.12 / 0V 0V / 10.1
11 14 /11.11
60501662 - X400S T4 SP Pre Screen ++ +
Drg No. 60501662_MK01c
Approved by Tel:+44 (0)1530 510751 Fax:+44 (0)1530 510756 OPERATOR PANEL, SPEEDWHEEL & ALARMS Project Total
1 2 3 4 5 6 7 8 9 10 11 12
81
9.12 / INPUTS
J1939_LO / 6.7
J1939_HI / 6.7
J1939_SCRN / 6.7
FUEL_HEATER / 6.10
CLUTCH_OIL_PURGE / 6.10
FUEL_LEVEL / 6.9
OIL_LEVEL / 6.11
-PRODUCT_CONV_ON / 6.8
-PRODUCT_CONV_SPEED / 6.8
-PRODUCT_CONV_RAISE / 6.9
-PRODUCT_CONV_LOWER / 6.9
-CYLINDER_A / 6.11
-CYLINDER_B / 6.11
-HYD_OIL_TEMP / 6.9
AIR_FILTER_REST / 6.7
-ENGINE_ENABLE / 6.7
-RADIO_TRACK_ENABLE / 6.7
-UMBILICAL_TRACK_ENABLE / 6.7
OIL_COOLER_SW / 6.10
25
26
41
42
10
19
17
36
40
22
49
31
29
47
44
45
46
43
-X2 36 107
-R14
107
10k
+
-R13 -C10
1k 1uF
81 25 26 SCN 41 42 10 19 17 -X2 0 107 -X1 40 22 49 31 29 47
+PNL-XP 3 9 10 11 13 15 19 20 24 25 26 27 28 29 31 32
+WE-XS 3 9 10 11 13 15 19 20 24 25 26 27 28 29 31 32
3.6 / J1939_HI
3.6 / J1939_LO
3.6 / J1939_SCRN
3.5 / PUR_FUEL_LEVEL
ORN/BLK_FUEL_HEATER
3.4 / GRN_HYD_OIL_TEMP
JAW_OPEN_CLOSE_CYL_B
BRN_CLUTCH_OIL_PURGE
JAW_OPEN_CLOSE_CYL_A
3.4 /
3.8 /
3.8 /
3.6 / ORN/RED_OIL_LEVEL_POS
3.11 /
3.9 /
3.9 / A1 A1 A1 A1
3.11 /
-K13 -K14 -K15 -K1

A2 A2 A2 A2
0
9.12 / 0V 0V / 11.1
14 11 /4.5 11 14 /11.511 14 /11.613 14 /4.6
24 21 /4.6 21 24 /11.521 24 /11.6
31 32 /5.2 31 34 /11.531 34 /11.7

Drg No. 60501662_MK01c
Approved by Tel:+44 (0)1530 510751 Fax:+44 (0)1530 510756 SENSORS & INTERNAL OUTPUTS Project Total
1 2 3 4 5 6 7 8 9 10 11 12
-DIRT_CONV/PRE_SCREEN_RUN / 6.10
DIRT_CONV/HOPPER_BANK / 6.12
-RIGHT_TRACK_DIVERT / 6.11
-LEFT_TRACK_DIVERT / 6.11
-PRE_SCREEN_DIVERT / 7.3
-DEFLECTOR_LOWER / 6.12
-DIRT_CONV_DIVERT / 6.9
/ 6.10
-RADIO_TRK_PWR / 8.4
(DEFLECTOR_RAISE)
-UMB_TRK_PWR / 8.7
-FEEDER_SPEED / 6.8
DUMP_VALVE / 6.12
DIVERTER_VALVE
-FEEDER_ON / 6.8
-BEACON / 6.9
302
104
105
106
GRN
BLU
YEL
39
50
51
48
35
16
54
53
52
3
4
-X1 39 50 51 16 3
11 21 31 11 21 31
+PNL +PNL +PNL +PNL +PNL
A3 BLK BLK BLK BLK -K14 -K14 -K14 -K15 -K15 -K15 -X2 54 112
-XRA -W16 -W17 -W18 -W19 /10.11 /10.11
14 /10.11
24 34 /10.11 /10.11
14 /10.11
24 34
-R16
+XRA +W16 +W17 +W18 +W19 109 10k
A3 4 4 4 4
-XP -XP -XP -XP -XP 11
/13.8 /13.8 110
+ -K12
112
-R15 -C11 /9.11 14
+XRA 108 1k 1uF
P5
-XS
111
52
112 53
-XP P5 1 1 1 1 108 109 108 110 48 4 35 16 0 111 52
=ELEC_PACK+OS_BEACON
+PNL USE TERMINAL 111

B2 B3 A4 C6 B8 B7 B6 B5 C8
-XRA FOR DUMP VALVE
CONNECTION IF MACHINE
IS TO BE IN HR MODE
2 2 2 2
+
+XRA B2 B3 A4 C6 B8 B7 B6 B5 C8
-H1 -XP
=ELEC_PACK+CRUSHER
=ELEC_PACK+R_VLVS
BEACON -
1 1 1 2 1 1
2 1 2
-Y2 -Y3 -Y4 -Y1
+W16 +W17 +W18 +W19 -Y1 -Y5
-XP P6 3 3 3 3 O/S TRACK VALVE 3 E 2 E 3 2
-XP -XP -XP -XP
/13.8 /13.8
+XRA P6
+PNL BLU
+PNL BLU
+PNL BLU
+PNL BLU
-XS -W16 -W17 -W18 -W19
0
7.4 / XRA_0V
+XRA-XP A1 C7 A9 C9
0 0 0 0
C7
+PNL-XRA A1 A9 C9
0 0 0
-X1 0
0 0
10.12 / 0V 0V / 12.1
60501662 - X400S T4 SP Pre Screen ++ +
Drg No. 60501662_MK01c
Approved by Tel:+44 (0)1530 510751 Fax:+44 (0)1530 510756 OUTPUTS TO REAR VALVE BANK Project Total
1 2 3 4 5 6 7 8 9 10 11 12
26
6.7 / -CAN_H_PT
25 PT TECH CLUTCH
6.8 / CAN_L_PT
CONTROLLER
21
4.11 / -PT_SUPPLY (Optional - Not usually fitted)
60
4.12 / -SUPPLY
-R12
120Ω
A B C
1 2
-F1 60
5A 34 0 25 26 600 601
+PNL-XSPT 1 2 3 4 5 6 7 8
+PT_TECH_LOOM
-X1 1 2 3 4 5 6 7 8
8 WAY ILME PLUG
RED
GREY
BLACK
YELLOW
BLACK SHIELD
WHITE SHIELD
GREEN "B" CAN1

YELLOW "A" CAN1
-X6 1 2 -X7 1 2
PWM COIL CLUTCH ON/OFF
BLACK
BLACK
GREEN
PURPLE
-X5 1 2 3 -X4 2 1 4
INPUT SPEED PICKUP
RED
RED
PT TECH CLUTCH
SCRN
BLACK
BLACK
WHITE
PRESSURE TRANSDUCER
RED
RED
GREY
BLACK
WHITE
BLACK
GREEN
PURPLE
ORANGE
YELLOW
RED SHIELD
BLACK SHIELD
BLACK SHIELD
WHITE SHIELD
GREEN "B" CAN1
YELLOW "A" CAN1
BARE SHIELD DRAIN

BARE METAL SHIELD
-X2 1 2 3 4 5 6 7 8 9 10 11 12 -X3 1 2 3 4 5 6 7 8 9 10 11 12
0 12 Way Grey Plug 12 Way Black Plug
0
11.12 / -0V

Drg No. 60501662_MK01c
Approved by Tel:+44 (0)1530 510751 Fax:+44 (0)1530 510756 PTECH CLUTCH CONTROL Project Total
1 2 3 4 5 6 7 8 9 10 11 12
+W18-XS
7.5 m +W18-XP
+W18-XS +W18-XP
3 1 BRN BRN 4
1 2
Pe
2 BLU BLU 3
-W18
/13.5 Pre Screen Divert /13.8
2x1.00 mm²
+W19-XS
5m +W19-XP
+W19-XS +W19-XP
3 1 BRN BRN 4
1 2
Pe
2 BLU BLU 3
-W19
/13.5 Dirt Conveyor Divert /13.8
2x1.00 mm²
60501662 - X400S T4 SP Pre Screen ++ +
Drg No. 60501662_MK01c
Approved by Tel:+44 (0)1530 510751 Fax:+44 (0)1530 510756 PreScreen cables Project Total
Appendix C
(3) Hydraulic Schematics

www.powerscreen.com
Powerscreen, 200 Coalisland Road, Dungannon, Co.Tyrone, BT71 4DR, Northern Ireland.
Tel: +44 (0) 28 8771 8500, Fax: +44 (0) 28 8774 7231, E-mail: sales@powerscreen.com
Printed in the UK

Premiertrak 400 - R400 (T4) Operations Manual Revision 1.0 (En)

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Premiertrak 400 - R400 (T4) Operations Manual Revision 1.0 (En)

Încărcat de

Drepturi de autor:

Formate disponibile

Premiertrak 400/R400 (T4)

SUBJECT TO CHANGE WITHOUT PRIOR NOTICE

Issue Date: 30-Nov-2012

Operations Manual Revision 1.0 30-11-2012

Intentionally Left Blank

30-11-2012 Revision 1.0 Operations Manual

Operations Manual Revision 1.0 30-11-2012

3.5 Machine Components...................................................................................3-13

30-11-2012 Revision 1.0 Operations Manual

6 Initial Setup and Adjustments................................................................... 6-2

Operations Manual Revision 1.0 30-11-2012

(1) Diesel Engine.............................................................................................9-6

30-11-2012 Revision 1.0 Operations Manual

(c) Changing Pressure Filters...................................................................9-30

Operations Manual Revision 1.0 30-11-2012

(a) FMI Code Explanations (Fault type identifier (FMI)).........................10-9

30-11-2012 Revision 1.0 Operations Manual

Operations Manual Revision 1.0 30-11-2012

1.1 Notes to the Operations Manual

(2) Optional Equipment

30-11-2012 Revision 1.0 Operations Manual

1.2 Safety Information

(1) Safety Warning Symbol

(2) ANSI Hazard Classification System

(3) California Proposition 65 Warnings

Operations Manual Revision 1.0 30-11-2012

1.3 Intended Use

1.4 Prohibited Use

1.5 Declaration of Conformity

30-11-2012 Revision 1.0 Operations Manual

Operations Manual Revision 1.0 30-11-2012

2.1 General Safety

(1) Safety Warning Symbol

(2) ANSI Hazard Classification System

30-11-2012 Revision 1.0 Operations Manual

(3) Description of Safety Symbols

Table 2.1 - Description of Safety Symbols

Stay sufficient distances from electrical power lines.

Stay clear of conveyor.

Install covers and guards before operation.

Turn machine off and remove the key.

Read and understand operations manual before using equipment.

Use cardboard or wood to check for leaks.

Operations Manual Revision 1.0 30-11-2012

Falling material hazard

Stay clear of hopper during operation.

Do not climb onto the machine.

Use personnel lift to reach high places.

Check tyre pressures prior to transport.

Connect and check braking system.

Keep hands clear of openings.

Hand entanglement in pulley/ winch

Keep hands clear of moving components

30-11-2012 Revision 1.0 Operations Manual

Wear hearing personal protective equipment.

Keep open flame away.

Flying Material Hazard

Wear eye personal protective equipment

Stay clear of moving conveyors.

Unauthorized persons prohibited.

Flying Material Hazard

Operations Manual Revision 1.0 30-11-2012

Do not stand on machine while in operation.