684 Operations Manual Revision 3.0 (En) PDF

® 684
MOBILE SCREEN
Operations Manual
SUBJECT TO CHANGE WITHOUT PRIOR NOTICE
Original Instructions
© TEREX GB Ltd
Issue Date: 25-April-2015

Language: English (en)
Revision No.: 3.0
®
Terex MPE,
Drumquin Road,
Omagh, Co. Tyrone,
N. Ireland, BT78 5PN
+44 (0) 2882 418700
+44 (0) 28 87 244294
Email: sales@terex.com
www.terex.com
Record of Revisions
Record of Revisions
Revision
Number Reason for Change Date
1.0 New machine designed and released June 2011
1.1 All decals updated and new decals added. Images and 24-Feb-2012
procedures updated in line with machine changes.
2.0 General updates made to complete manual with information 22-May-2012
from engineering and Tier 4 information added. Tipping grid
remote option also controls vibrating grid if fitted.
2.1 2 deck screenbox information added. 12-Dec-2012
Double deck vibrating grid and extended 4th product
conveyor transport and setup procedure updated.
2.2 Maitenance section updated. Information added on engine 02-Oct-2014
oil (Tier 4) and hydraulic oil change intervals.
Tie down points section added, along with various other
general updates carried out.
Perkins Tier 3 Constant Speed information added.
3.0 CAT 4.4 82kW Tier 4 Final Update. 25-April-2015
Fines Conveyor folding procedures updated
Operations Manual Revision 3.0 25-April-2015

684 Page 1
Record of Revisions
Intentionally Left Blank
25-April-2015 Revision 3.0 Operations Manual

Page 2 684
Table of Content
Table of Content
Record of Revisions ..............................................................................................1
1 Introduction ................................................................................................ 1-2
1.1 Notes to the Operations Manual.....................................................................1-2
(1) Units...........................................................................................................1-2
(2) Optional Equipment ...................................................................................1-3
1.2 Safety Information ..........................................................................................1-3
(1) Safety Alert Symbol ...................................................................................1-3
(2) ANSI Hazard Classification System ..........................................................1-3
(3) California Proposition 65 Warnings ...........................................................1-4
1.3 Intended Use ..................................................................................................1-4
1.4 Prohibited Use ................................................................................................1-4
1.5 Declaration of Conformity ...............................................................................1-4
1.6 Warranty .........................................................................................................1-4
1.7 Copyright ........................................................................................................1-5
1.8 Bulletin Distribution and Compliance..............................................................1-5
2 Safety .......................................................................................................... 2-2
2.1 General Safety ...............................................................................................2-2
(3) Description of Safety Symbols ...................................................................2-4
2.2 Positions of Safety Signs on the Machine ......................................................2-9
2.3 Personal Safety ............................................................................................2-15
(1) Personal Protective Equipment ...............................................................2-15
2.4 Work Area Safety .........................................................................................2-16
(1) General Work Area Guidelines ................................................................2-16
(a) Safety Warnings and Labels ...............................................................2-16
(b) Modifications .......................................................................................2-16
(2) Transportation Safety ..............................................................................2-17
(3) Operation Safety ......................................................................................2-18
(4) Hydraulic and Pneumatic Safety .............................................................2-19
(5) Electrical Safety .......................................................................................2-20
(6) Maintenance Safety .................................................................................2-21
(7) Gas, Dust, Steam, Smoke .......................................................................2-23
(8) Hazardous Substances ...........................................................................2-23
(9) Noise Levels ............................................................................................2-23
2.5 Emergency Stop Locations ..........................................................................2-24
3 Technical Data ............................................................................................ 3-2
3.1 General Information........................................................................................3-2
(1) Machine Weights .......................................................................................3-2
3.2 Machine Component Specifications ...............................................................3-2
(1) Engine .......................................................................................................3-2
(a) Tier 3 .....................................................................................................3-2
(b) Tier 4 .....................................................................................................3-2

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(2) Screen .......................................................................................................3-2

(3) Tracks ........................................................................................................3-2
(4) Hopper and Belt Feeder ............................................................................3-3
(5) Product Conveyors ....................................................................................3-3
(6) Vibrating Grid .............................................................................................3-3
(7) Hydraulic Pressures...................................................................................3-3
(8) Tank Capacities .........................................................................................3-3
(9) Options ......................................................................................................3-4
3.3 Dimensions.....................................................................................................3-5
(1) Working Range Diagrams..........................................................................3-5
(2) Transport Diagrams ...................................................................................3-7
3.4 Noise Levels - dB(A) ......................................................................................3-8
4 Machine Description.................................................................................. 4-2
(1) Machine Description and Intended Operation ...........................................4-2
(2) Machine References ..................................................................................4-2
4.2 Machine Components ....................................................................................4-3
4.3 Control and Display Elements ........................................................................4-4
(1) MCU300 Control panel ..............................................................................4-4
(2) Tracking .....................................................................................................4-6
4.4 Pictorial Decal Descriptions............................................................................4-8
(1) Machine Operations Decals ......................................................................4-8
(2) Machine Information Decals ....................................................................4-14
5 Transportation............................................................................................ 5-2
5.1 Prior to Transportation ....................................................................................5-2
5.2 Putting the Machine into the Transport Position .............................................5-4
(1) Stopping the Machine ................................................................................5-4
(2) Setting the Remote Grid to the Transport Position ....................................5-5
(a) Manual Operation of Remote Grid ........................................................5-5
(b) Radio Operation of Remote Grid ..........................................................5-5
(3) Lowering the Vibrating Grid to the Transport Position (Optional) ..............5-7
(4) Placing the Transfer Conveyor into the Transport Position
and Removing the Transfer Conveyor Chute (3 Deck Only)...............................5-7
(5) Removing Walkway Access Steps from the Working Position ..................5-8
(6) Folding in the Screen Walkway .................................................................5-9
(7) Fold In the Extended 4th Product Conveyor (Option) ..............................5-10
(8) Folding the 4th Product Conveyor into the Transport Position
(3 Deck Only) .................................................................................................... 5-11
(9) Folding in the Side Conveyors .................................................................5-13
(10) Lowering the 4th Product Conveyor Angle (3 Deck Only) .......................5-14
(11) Folding Extended 4th Product Conveyor
(Double Deck Vibrating Grid Option) ................................................................5-15
(12) Lower and Fold in the Fines Conveyor ....................................................5-16
(13) Lowering the Screenbox and Main Conveyor ..........................................5-17
(14) Raising the Support Legs ........................................................................5-18

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Table of Content
5.3 Loading the Machine to the Low Loading Trailer (Track Machine) ...............5-19
(1) Ready for Transport .................................................................................5-20
(2) Prior to Haulage .......................................................................................5-20
6 Initial Setup and Adjustments .................................................................. 6-2
6.1 Initial Inspection..............................................................................................6-2
6.2 Machine Location Considerations ..................................................................6-2
6.3 Measures Before Setup..................................................................................6-3
6.4 Measures After Long Term Standstill..............................................................6-3
6.5 Putting the Machine into the Working Position ...............................................6-4
(1) Lowering the Support Legs ........................................................................6-4
(2) Raising the Screenbox and Main Conveyor ..............................................6-5
(3) Raise and Fold out the Fines Conveyor ....................................................6-7
(4) Raising the 4th Product Conveyor Angle (3 Deck Only) ............................6-8
(5) Opening Out the Side Conveyors ............................................................6-10
(6) Moving the 4th Product Conveyor into the Working Position
(3 Deck Only) .................................................................................................... 6-11
(7) Opening Out the Extended 4th Product Conveyor (Option) ....................6-13
(8) Fitting the Screen Walkway .....................................................................6-14
(9) Removing Walkway Access Steps from the Transport Position ..............6-15
(10) Moving the Transfer Conveyor in Working Position and
Fitting the Transfer Conveyor Chute (3 Deck Only) ..........................................6-16
(11) Raising Vibrating Grid to Working Position (Optional) .............................6-16
(12) Setting Remote Grid to Working Position ................................................6-17
(a) Manual Operation of Remote Grid ......................................................6-17
(b) Radio Operation of Remote Grid ........................................................6-17
7 Standard Operating Procedures .............................................................. 7-2
7.1 Pre-Operating Checks ....................................................................................7-2
7.2 Initial Startup ..................................................................................................7-3
7.3 Start Up ..........................................................................................................7-4
(1) Starting the Engine (Tier 3)........................................................................7-5
(a) No Faults on Display Screen ................................................................7-5
(b) Active Fault on Display screen ..............................................................7-6
(2) Starting the Engine (Tier 4 and Tier 3 Constant Speed) ............................7-9
(a) No Faults on the Display Screen ..........................................................7-9
(b) Active Fault on the Display screen ......................................................7-13
(c) CAT Fault Indicator Lamps..................................................................7-18
7.4 Standard Operation ......................................................................................7-20
(1) Changing the Machine Setting ................................................................7-20
(2) Operating the Machine ............................................................................7-21
(a) 3 Deck Machine Operation .................................................................7-21
(b) 2 Deck Machine Operation .................................................................7-22
(3) Screening ................................................................................................7-23
(4) Conveyor Speed Control .........................................................................7-24
7.5 Manoeuvring.................................................................................................7-25
(a) Undercarriage .....................................................................................7-25

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(1) Manual Tracking Information ...................................................................7-26

(2) Manual Tracking Umbilical .......................................................................7-26
(3) Tracking the Machine ..............................................................................7-27
(a) Manual tracking Handset ....................................................................7-29
(b) Radio Control Handset (Optional) .......................................................7-30
(c) Fast Tracking - Constant Speed Engine .............................................7-32
7.6 Shut Down ....................................................................................................7-33
(1) Stopping the Machine (3 Deck Machine) .................................................7-33
8 Emergency Operating Procedures........................................................... 8-2
8.1 Lockout and Tagout ........................................................................................8-2
(1) Before Carrying out any Work on the Machine ..........................................8-2
(2) After Carrying out any Work on the Machine .............................................8-4
8.2 Emergency Stop .............................................................................................8-4
8.3 Restarting after Emergency Stop ...................................................................8-6
8.4 Testing Emergency Stops...............................................................................8-6
9 Maintenance ............................................................................................... 9-4
9.2 Non Scheduled Maintenance .........................................................................9-5
(1) Hydraulic System .......................................................................................9-5
(a) Hydraulic Rams .....................................................................................9-5
(b) Hydraulic Fluids ....................................................................................9-5
(2) Filtration .....................................................................................................9-6
(a) Air Breather ...........................................................................................9-6
(b) Suction Line Breather ...........................................................................9-6
(c) Return Line Filter ..................................................................................9-6
(3) Oil Tank Pipes and Fittings ........................................................................9-6
(4) Tracks ........................................................................................................9-6
9.3 Maintenance Schedules .................................................................................9-7
(1) Regular Servicing ......................................................................................9-7
(2) Daily, Weekly and Monthly Checks............................................................9-7
(a) Daily Checks .........................................................................................9-8
(b) Weekly Checks .....................................................................................9-8
(c) Monthly Checks ....................................................................................9-8
(3) Daily or 10 Hour Maintenance Schedule ...................................................9-9
(a) General Maintenance ............................................................................9-9
(b) Conveyor Maintenance .........................................................................9-9
(c) Screen Maintenance .............................................................................9-9
(d) Hydraulic System Maintenance ............................................................9-9
(e) Track Maintenance................................................................................9-9
(f) Twin Deck Vibrating Grid Maintenance (If Fitted)................................9-10
(4) Weekly or 50 Hour Maintenance Schedule .............................................9-10
(a) General Maintenance ..........................................................................9-10
(b) Screen Unit Maintenance ....................................................................9-10
(c) Conveyor Maintenance .......................................................................9-10
(5) Monthly or 250 Hour Maintenance Schedule .......................................... 9-11
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Table of Content
(a)
General Maintenance .......................................................................... 9-11
(b)
Track Maintenance.............................................................................. 9-11
(c)
Belt Feeder Maintenance .................................................................... 9-11
(6) 2 Monthly or 500 Hour Maintenance Schedule ....................................... 9-11
(a) General Maintenance .......................................................................... 9-11
(7) 4 Monthly or 1000 Hour Maintenance Schedule ..................................... 9-11
(a) Track Maintenance.............................................................................. 9-11
(b) Belt Feeder Maintenance .................................................................... 9-11
9.4 Engine Maintenance Schedules ...................................................................9-12
(1) Tier 4 Engine Maintenance Schedules ....................................................9-12
(a) When Required ...................................................................................9-12
(b) Daily ....................................................................................................9-12
(c) Weekly ................................................................................................9-12
(d) Every 50 Service Hours or Monthly ....................................................9-12
(e) Every 250 Service Hours ....................................................................9-13
(f) Every 500 Service Hours ....................................................................9-13
(g) Every 500 Service Hours or 1 Year .....................................................9-13
(h) Every 1000 Service Hours ..................................................................9-13
(i) Every 1500 Service Hours ..................................................................9-13
(j) Every 2000 Service Hours ..................................................................9-13
(k) Every 3000 Service Hours ..................................................................9-14
(l) Every 3000 Service Hours or 2 Years .................................................9-14
(m) Every 4000 Service Hours ..................................................................9-14
(n) Every 6000 Service Hours or 3 Years .................................................9-14
(o) Every 12000 Service Hours or 6 Years ...............................................9-14
(a) General Maintenance when Required ................................................9-15
(b) Daily or 10 Hour Engine Maintenance ................................................9-15
(c) 50 Hour or Weekly Engine Maintenance.............................................9-15
(d) 250 Hour Engine Maintenance ...........................................................9-15
(e) 500 Hour Engine Maintenance ...........................................................9-16
(f) 1000 Hour Engine Maintenance .........................................................9-16
(g) 2000 Hour or Annually Engine Maintenance.......................................9-16
(h) 3000 Hour or 2 Year Engine Maintenance ..........................................9-17
9.5 Lubrication ....................................................................................................9-18
(1) Recommended Lubricants .......................................................................9-18
(2) Recommended Lubricants and Capacities ..............................................9-19
(3) Lubrication Points ....................................................................................9-19
(4) Greasing Schedule ..................................................................................9-21
9.6 Maintenance Procedures .............................................................................9-22
(1) Engine Maintenance ................................................................................9-22
(a) Check Fuel Level and Topup...............................................................9-22
(b) Check Engine Oil ................................................................................9-23
(c) Change Engine Oil and Filter ..............................................................9-23

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Table of Content
(d)Check and Replace Air Cleaner Elements ..........................................9-24

(e)Check and Replace Water Trap ..........................................................9-25
(f)Topping Up Engine Coolant Level .......................................................9-26
(2) Fuel System .............................................................................................9-27
(a) Check and Replace Fuel Filters ..........................................................9-27
(b) Draining Water from the Fuel System .................................................9-27
(c) Check Fuel Level and Top-up .............................................................9-28
(d) Fuel System Prime (Tier 3 CAT4.4 83KW Mechanical Engines) ........9-29
(3) Hydraulic Maintenance ............................................................................9-31
(a) Checking and Refilling Hydraulic Fluid ...............................................9-31
(b) Changing Hydraulic Fluid ....................................................................9-32
(c) Changing Suction Filters .....................................................................9-32
(d) Changing Return Line Filter ................................................................9-33
(4) Electrical Maintenance ............................................................................9-34
(a) Battery Removal and Installation ........................................................9-34
(b) Removal and Installation of Fuses ......................................................9-36
(5) Adjusting the Belt Feeder Scraper ...........................................................9-36
(6) Conveyor Maintenance ............................................................................9-37
(a) Changing the Feed Conveyor Gearbox Oil .........................................9-37
(b) Check and Clean Conveyor Belts .......................................................9-38
(c) Tensioning Conveyor Belts .................................................................9-39
(d) Aligning Conveyor Belts ......................................................................9-40
(7) Track Maintenance ..................................................................................9-40
(a) Measuring Track Tension ....................................................................9-40
(b) Adjusting Track Tension ......................................................................9-42
(c) Refilling the Track Gearbox Oil ...........................................................9-43
(d) Cleaning the Tracks ............................................................................9-44
(e) Changing Track Gearbox Oil ...............................................................9-45
(8) Screen Unit Maintenance ........................................................................9-46
(a) Moving Main Conveyor and Screenbox for Maintenance ...................9-46
(b) Raising Screenbox for Maintenance (Option Only) .............................9-48
(c) Changing the Top and Bottom Deck Screen Mesh .............................9-49
(d) Changing the Middle Deck Screen Cloth (3 Deck Only) .....................9-50
10 Troubleshooting....................................................................................... 10-2
10.1 No Response from any Hydraulic System....................................................10-2
10.2 Machine Operating Slowly with No External Oil Leaks ................................10-2
10.3 Excessive Noise from Hydraulic Pump ........................................................10-2
10.4 Vibrating Grid Not Working ...........................................................................10-3
10.5 Vibrating Grid will not Start ...........................................................................10-3
10.6 Tracks will not Operate .................................................................................10-3
10.7 Belt Feeder not Working when Conveyor is Running...................................10-3
10.8 Screeching Noise when Conveyor is Running .............................................10-4
10.9 Conveyor Belt Not Running ..........................................................................10-4
10.10 Conveyor Belt Tends to Run Back if Stopped with a Load on the Belt .........10-4
10.11 Conveyor Belt Not Tracking Correctly ..........................................................10-4
10.12 Reject Grid will not Hinge .............................................................................10-5

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10.13 Speed Screen Wire Breaking Prematurely...................................................10-5

10.14 Meshes Breaking Prematurely .....................................................................10-5
10.15 Vibrating Grid and Screen Bearings Fail Prematurely..................................10-5
10.16 Engine Fails to Start .....................................................................................10-6
10.17 Belt Stops Under Load .................................................................................10-6
10.18 Engine Stops ................................................................................................10-6
10.19 Conveyor Belts Running Out of Line ............................................................10-6
11 Glossary of Terms ....................................................................................11-1
Appendix A EC Declaration of Conformity ..............................................A-1
Appendix B Warranty ................................................................................B-1
Appendix C Schematics ............................................................................C-1
(1) Tier 3 Schematics ..................................................................................... C-1
(2) Tier 4 Schematics ..................................................................................... C-3
Appendix D Engine Fault Codes ..............................................................D-1

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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 ...................................................................................1-3
1.2 Safety Information ..........................................................................................1-3
(3) California Proposition 65 Warnings ...........................................................1-4
1.3 Intended Use ..................................................................................................1-4
1.4 Prohibited Use ................................................................................................1-4
1.5 Declaration of Conformity ...............................................................................1-4
1.6 Warranty .........................................................................................................1-4
1.7 Copyright ........................................................................................................1-5
1.8 Bulletin Distribution and Compliance..............................................................1-5

684 Page 1-1
1 introduction
1 Introduction
1.1 Notes to the Operations Manual

These operating instructions assume that the machine will only be operated by authorized, trained
and specially instructed personnel.
Read this manual carefully to learn how to operate and service your machine correctly. 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.
Follow all applicable safety regulations and recommendations in this manual as appropriate to
your machine and the situation/conditions prevailing at the time.
Included with this manual is a disc which contains the original language version of this manual
which is English.
There is a separate engine manufacturer’s manual which should also be read and understood
prior to any operation or maintenance of the machine.
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.
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 plant 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 plant 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
If you need any information or advice regarding your machine, you can contact:-
TEREX MPE
Drumquin Road
Omagh, Co. Tyrone,
BT78 5PN
Telephone: +44 (0) 2882 418700
(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.
25-April-2015 Revision3.0 Operations Manual

Page 1-2 684
Introduction 1
(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 information 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.
1.2 Safety Information
(1) Safety Alert Symbol
The safety alert symbol is used on safety signs and throughout this manual to alert you to potential
personal injury hazards. Obey all messages that follow this symbol to avoid injury or death. For
more information related to machine safety, please refer to the safety section of the manual
(Chapter 2).
(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.
 DANGER
This indicates a hazardous situation which, if not avoided, will result in death or serious injury.
The safety alert symbol is shown with this danger classification.
 WARNING
This indicates a hazardous situation which, if not avoided, could result in death or serious injury.
 CAUTION
This indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
This indicates a message related to property damage. The safety alert symbol is not shown with
this danger classification.
All hazards associated with each procedure will be listed before each procedure as described
above.

684 Page 1-3
1 introduction
(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.
1.3 Intended Use

This product and its approved attachments are designed to be used in Material Processing
applications, such as crushing, screening and recycling. 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 2006/42/EC together
with appropriate EN Harmonised Standards and National BS Standards and Specifications.
A Declaration of Conformity certificate is applicable to each machine. Refer to Appendix A for
an example of a Declaration of Conformity certificate. The original copy of the certificate is sent
out with the machine.
1.6 Warranty
Refer to Appendix B for an example of the warranty.

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Introduction 1
1.7 Copyright
The copyright of this Manual is reserved by Terex.
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.
Terex® MPE is a registered trademark for portable screening plant manufactured by Terex® MPE.
The right is reserved to alter any details contained in this manual without notice. Copyright 2012.
Terex MPE
Drumquin Road
Omagh
Co. Tyrone,
BT78 5PN
Telephone: +44 (0) 2882 418700
To order additional copies contact your local Terex Dealer.
1.8 Bulletin Distribution and Compliance

Safety of product users is of paramount importance to Terex MPE. Various bulletins are used by
Terex MPE to communicate important safety and product information to dealers and machine
owners. The information contained in bulletins is tied to specific machines using the machine
model and serial numbers. Disribution of bulletins is based on the most current owner on record
along with their associated dealer, so it is important to register your machine and keep your
contact information up to date.
To provide for the safety of personnel and the reliable continued operation of your machine, be
sure to comply with actions indicated in all safety and product notices.

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1 introduction

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Safety 2
Table of Content
2 Safety .......................................................................................................... 2-2
2.1 General Safety ...............................................................................................2-2
(3) Description of Safety Symbols ...................................................................2-4
2.2 Positions of Safety Signs on the Machine ......................................................2-9
2.3 Personal Safety ............................................................................................2-15
(1) Personal Protective Equipment ...............................................................2-15
2.4 Work Area Safety .........................................................................................2-16
(1) General Work Area Guidelines ................................................................2-16
(a) Safety Warnings and Labels ...............................................................2-16
(b) Modifications .......................................................................................2-16
(2) Transportation Safety ..............................................................................2-17
(3) Operation Safety ......................................................................................2-18
(4) Hydraulic and Pneumatic Safety .............................................................2-19
(5) Electrical Safety .......................................................................................2-20
(6) Maintenance Safety .................................................................................2-21
(7) Gas, Dust, Steam, Smoke .......................................................................2-23
(8) Hazardous Substances ...........................................................................2-23
(9) Noise Levels ............................................................................................2-23
2.5 Emergency Stop Locations ..........................................................................2-24

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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
plant/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.
The environment in which the machine will operate contains inherent risks to health and
safety which the operator must take steps to guard against. Dangers from overhead conveyor
discharges, overspill material, vehicle movements, etcetera, as well as other site related hazards
must be anticipated. Avoid these by carrying out risk assessments before the machine is put into
operation to ensure appropriate exclusion zone measures are put in place and site personnel
safety awareness training has been undertaken.
2.1 General Safety

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

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Safety 2
(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.
 DANGER
This indicates a hazardous situation which, if not avoided, will result in death or serious injury.
 WARNING
This indicates a hazardous situation which, if not avoided, could result in death or serious injury.
 CAUTION
This indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
This indicates a message related to property damage. The safety alert symbol is not shown with
this danger classification.

684 Page 2-3
2 Safety
(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.

Page 2-4 684
Safety 2
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

684 Page 2-5
2 Safety
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.

Page 2-6 684
Safety 2
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.

684 Page 2-7
2 Safety
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.

Page 2-8 684
Safety 2
2.2 Positions of Safety Signs on the Machine

Table 2.2 lists the safety signs that are on the machine.
Table 2.2 - Safety Signs

Sign
Item ISO ANSI
1
1502- IO
1507- IO

684 Page 2-9
2 Safety
Sign
Item ISO ANSI
4
1515- IO
1508- IO

Page 2-10 684
Safety 2
Sign
Item ISO ANSI
7
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
2
1
1522- IO

684 Page 2-11
2 Safety
Sign
Item ISO ANSI
10
11
1506- IO
Figure 2.1 and Figure 2.2 show the positions of these safety signs on the machine.

Page 2-12 684
Safety 2
DUN00028
2 3
2 2 3
1
4
5
2 6
6
4 10 9 8 7
1 5
2 3
2 11
Figure 2.1 - Safety Sign Positions Side View

684 Page 2-13
2 Safety
DUN00029
1
2 11
2
6
5
3 11
1
Figure 2.2 - Safety Sign Positions End View

Page 2-14 684
Safety 2
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.

684 Page 2-15
2 Safety
2.4 Work Area Safety
(1) General Work Area Guidelines

Operators must have received specific training in all operating and service tasks as required for
the safe operation and service of the machine. Operators must know the location and correct
operation of all controls and safety features such as remote stop buttons and isolator switches.
Operators must be aware of all moving parts on the machine.
Keep the work area as neat and as clean as practical. Keep your equipment clean and free of
dirt and grease so it can be checked for loose, cracked or broken parts. Replace defective parts
as soon as they are discovered.
The guards provided are designed and manufactured to ensure so far as reasonably practicable
that the machinery and plant 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.
Walkways should only be used when the machine is turned off, unless to perform specific
maintenance procedures which require the machine to be operational. In this instance, only suitable
trained and authorised personnel equipped with the correct PPE should be allowed access and
the machine must be running empty and cleared of all material beforehand.
Always check that walkways and handrails are fully secured in place before using. Do not smoke
or allow smoking near flammable fuels or solvents. Use non flammable solvents for cleaning parts
and equipment. Know where fire extinguishers and other fire suppression equipment are located
and learn how to use them.
Always use hoisting equipment for heavy loads. Regularly check hooks, cables, shackles and
chains for stretch and wear. Never overload hoists, cranes or other lifting devices.
Avoid electrical and static sparks and any open flame while handling, storing, moving or pouring
fuels, electrolytes for batteries, hydraulic fluids or coolants.
(a) 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.
(b) 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.

Page 2-16 684
Safety 2
(2) 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.
The machine is remote controlled and may start without notice. Stay clear of the machine. The
machine must be loaded and transported only in accordance with the operating instructions.
For manoeuvring the machine, observe the prescribed transport position, admissible speed and
itinerary. Use only appropriate means of transport and lifting equipment and where applicable
of adequate capacity. The re-commissioning procedure must be strictly in accordance with the
operating instructions. Before travelling with the machine, check that the braking and any signalling
and lighting systems are fully functional. Before setting the machine in motion always check that
the accessories have been safely stowed away.
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
• 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.

684 Page 2-17
2 Safety
(3) 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. Study all safety signs on your machine.
It is emphasized that all safety aspects are checked before starting the machinery.
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. NEVER leave the machine unattended
whilst it is in operation.
Before starting, walk completely around the machine. Make sure no one is under it, on it or close
to it. Let other workers and bystanders know you are starting up and do not start until everyone
is clear of the machine.
Before moving the machine, ensure that everyone is clear from the surrounding area and that the
warning siren and beacon and the tracking umbilical Machine Stop button are operating correctly
Make certain enough ventilation is present to run engines safely. Do not start an engine in an
enclosed space without properly vented exhaust. Exhaust fumes from gasoline or diesel engines
can kill.
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.
Be alert and watch for pinch points, closing mechanisms, and falling parts when working on or
around any machinery. Keep hands and tools clear. 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. During
operation, do not climb onto, over or under moving conveyor belts and rollers. Always use ladders,
steps and walkways when mounting and dismounting.
Hole alignment on mechanical supports must be checked and secured with pins provided and
in accordance with safety signs.
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.
Never check the tension of ‘V’ belts, drive chains and conveyors when machine is running.
DO check frequently the stability of the machine. The chassis SHOULD NOT have undue vibration
during operation.
After each day’s operation, always run the machine dry; never leave material in the beltfeeder
on conveyor belts or screenbox. Starting a machine with a full load will cause strain problems in
your machine.

Page 2-18 684
Safety 2
(4) 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. Never disable or alter any hydraulic
circuit or component without consulting with Terex.
Relieve all pressure in the hydraulic system by returning all controls to the neutral position. 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.
Check for leaks in tanks or tubing with flashlights or other proper equipment. Never use an open
flame to check for leaks. 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 if this occurs. Wear personal protective equipment including goggles and gloves.
Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Splashed
oil may cause injury and fire. Repair any 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.
Do not exceed safe limits. Never set a pressure relief valve to a pressure higher than that set
at the factory.
For questions concerning accumulators, which are pressure-containment vessels, contact your
Terex distributor. Malfunctioning valves or poor maintenance practices can result in build-up of
extremely high hydraulic and/or pneumatic pressures inside the accumulator.

684 Page 2-19
2 Safety
(5) Electrical Safety

The electrical mode of operation on the electric hydraulic machines operates at 380-415 Volts
AC, 50/60Hz.
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 and regulations.
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. If machine is electric-hydraulic or direct
electric drive, the ‘mains’ electrical supply to the machine should always be isolated by unplugging/
uncoupling the ‘mains’ power socket. It is recommended that an earth leakage safety switch be
fitted in the supply line to the power point on site. Special care should be taken to ensure that
earth wires are correctly connected.
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.
Always disconnect battery leads before carrying out any maintenance to the electrical system or
servicing the engine. Never short across the starter terminals of a battery as this can cause a
fire and could also damage the electrical system. If welding is to be carried out on the machine,
it is essential that the powerpack is isolated.
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.
Diesel engine exhaust emissions contain products of combustion which may be harmful to your
health. Always operate the machine in a well ventilated area and if operating in an enclosed
area, vent the emissions outside. Do not touch any part of the engine or exhaust system. Allow
the engine and exhaust to cool before performing any repair or maintenance.

Page 2-20 684
Safety 2
Never fill the fuel tank with the engine running, while smoking or when near an open flame. Never
overfill the tank or spill fuel. If fuel is spilled, clean it up immediately.
(6) Maintenance Safety

Understand the service procedures 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.
Whenever maintenance or service is being carried out a minimum of two (2) persons should be
present at all times. NEVER WORK ALONE.
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.
Never attempt repairs or adjustments to the machine while it is running unless specified to do so.
Before carrying out any maintenance, relieve all hydraulic pressure by returning the controls to
the neutral position and secure all hydraulically operated attachments with pins provided.
Disconnect the 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.
Remove only guards or covers that provide access. Wipe away any excess grease and oil.
Never leave guards off or access doors open when unattended. Keep bystanders away if access
doors are open.
When working beneath raised equipment, always use blocks, jack-stands or other rigid and stable
supports. 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.
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.
When working at height make sure you take all necessary precautions in line with local regulations
and use approved PPE, safety harnesses and work platforms. If you are not aware of working
at height requirements speak to your manager before starting any work.
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. The gap between the idler
roller and the guard must be renewed. Contact your local Terex dealer to obtain an approved
replacement.
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.

684 Page 2-21
2 Safety
When the machine is completely shutdown for maintenance and repair work, it must be secured
against inadvertent starting by:
• Switching off the engine and removing the ignition key or isolating 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 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 equipment.
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.
Always use an EN/ANSI approved safety harness when reaching any points 2 m (7ft) 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 marshaller 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.
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.
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. Recheck all fluid
levels before releasing machine for operation.

Page 2-22 684
Safety 2
(7) 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.
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.
(8) 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. Store hazardous materials in restricted
access areas and mark them clearly.
(9) 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.

684 Page 2-23
2 Safety
2.5 Emergency Stop Locations

Emergency stops are located at both the left hand side and right hand side of the machine,
Ref: Figure 2.3 to Figure 2.5.
1 2
DUN00026
Figure 2.3 - Emergency Stop Positions Left Side
5 4
DUN00027
Figure 2.4 - Emergency Stop Positions Right Side
DUN00140
Figure 2.5 - Emergency Stop Position (item 1) Front

Page 2-24 684
Technical Data 3
Table of Content
3 Technical Data ............................................................................................ 3-2
(1) Machine Weights .......................................................................................3-2
3.2 Machine Component Specifications ...............................................................3-2
(1) Engine .......................................................................................................3-2
(a) Tier 3 .....................................................................................................3-2
(b) Tier 4 .....................................................................................................3-2
(2) Screen .......................................................................................................3-2
(3) Tracks ........................................................................................................3-2
(4) Hopper and Belt Feeder ............................................................................3-3
(5) Product Conveyors ....................................................................................3-3
(6) Vibrating Grid .............................................................................................3-3
(7) Hydraulic Pressures...................................................................................3-3
(8) Tank Capacities .........................................................................................3-3
(9) Options ......................................................................................................3-4
3.3 Dimensions.....................................................................................................3-5
(1) Working Range Diagrams..........................................................................3-5
(2) Transport Diagrams ...................................................................................3-7
3.4 Noise Levels ...................................................................................................3-8

684 Page 3-1
3 Technical Data
3 Technical Data
3.1 General Information

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 machine 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.
Machine: Mobile Screen
Type: 684
(1) Machine Weights

Total Weight Approximate - 3 Deck Machine: 30500 kg (67240 lbs)
Total Weight Approximate - 2 Deck Machine: 28750 kg (63380 lbs)
3.2 Machine Component Specifications
(1) Engine
(a) Tier 3
Standard Tier 3 machines are powered by a CAT 4.4 water cooled diesel engine output 83 kW
(110hp) coupled to hydraulic pumps. Fitted at ground level in a purpose built compartment. It is
situated next to the hydraulic tank providing easy access to all filters and gauges.
Engine speed is 2200 rpm.
(b) Tier 4
Tier 4 machines are powered by a Caterpillar C4.4 Tier 4F - 4 cylinder diesel engine developing
82kW (110 Hp) @ 2200 RPM.
(2) Screen
The screen is available in both 2 Deck and 3 Deck options. The decks are designed with
dimensions 4.3 metres (14’) long by 1.7 metres (5’7”) wide. Screenbox features include heavy
duty bearings and springs, crash box fitted with wear plates and interchangeable mesh design
for quick and efficient fitting. The bottom deck is also hydraulic tensioned. The screenbox is
surrounded by an access catwalk.
Screen speed is 950 rpm.
(3) Tracks
The machine is mounted on and driven by a high specification tracked undercarriage fitted with
transmittal gearboxes with integrated brake and over centre valve. The movement of the machine
is controlled by two alternative methods either by a hand-held radio control transmitter or a hand
held control connected to the receiver by a wander lead.

Page 3-2 684
Technical Data 3
(4) Hopper and Belt Feeder

The Loading Hopper fitted beneath the grid area is designed with a 8m³ (10.5yd³) capacity and
tapered sides for greater efficiency. The variable speed belt feeder fitted with a 1200mm (47”)
wide belt has a speed of 0-16m/min. Driven by hydraulic gearbox the belt feeder can handle the
most difficult material with maximum efficiency.
(5) Product Conveyors

The Fines, Middle grade and Oversize conveyors can be hydraulically folded from the transport
to working positions from their control panels at ground level providing easy access and vision
to each conveyor. A unique feature of each conveyor is their built in variable speed which is
controlled from a central location.
Speed
Conveyor Metres per minute Feet per minute
Belt feeder (Variable Speed) 0-16 0-53
Main Conveyor 92 302
Fines discharge conveyor 92 302
Side discharge conveyors (Variable Speed) 0-80 0-263
(6) Vibrating Grid

The Vibrating grid with loading dimensions 3.7m (12-2”) x 1.9m (6-2”) is designed with split level
scalping grizzly to achieve higher screening efficiency. The grid is fitted with interchangeable
cassettes for desired bar spacing. Cassettes are also interchangeable with heavy duty mesh or
punch plate depending on application. The grid is supported on spring mounts giving excellent
support to the vibrating system.
(7) Hydraulic Pressures

Pressure
Hydraulic Pressure Bar Psi
Maximum working pressure on tracks 245 3550
Maximum working pressure on rest of 205 2500
machine
Pressure rating on Hydraulic 3/8” 330 4800
Hoses 1/2” 275 4000
3/4” 215 3125
(8) Tank Capacities

Capacity
Tank Liters US Gal
Diesel tank 324 86
Hydraulic tank (Tier 3) 500 132
Hydraulic tank (Tier 4) 450 118

684 Page 3-3
3 Technical Data
(9) Options
The following is a list of optional equipment which is available for the machine.
1 Double deck vibrating grid
• Loading dimensions 3.7m (12-2”) x 1.9m (6-2”)
• Split level scalping grizzly to achieve higher screening efficiency. The grid is fitted with
• Interchangeable cassettes for desired bar spacing. Cassettes are also interchangeable
with heavy duty mesh or punch plate depending on application.
• Supported on spring mounts giving excellent support to the vibrating system.
2 Radio control handset
3 Hopper bypass feed chute
4 Dust Covers on Conveyors

Page 3-4 684
Technical Data 3
3.3 Dimensions
(1) Working Range Diagrams
16980 (55’-9’’)
Figure 3.1 - Working Range Plan View

684 Page 3-5
3 Technical Data
18470 (60’-7’’)
4850 (15’-11’’)
4270 (14’-0’’)
4370 (16’-2’’)
3510 (13’-4’’)
2350 (9’-7’’)
Figure 3.2 - Working Range Dimensions Side
5250 (18’-1’’)
4850 (15’-11’’)
4760 (17’-5’’)
Figure 3.3 - Working Range Dimensions End

Page 3-6 684
Technical Data 3
(2) Transport Diagrams
3490 (11’-5’’)
17200 (56’-6’’)

684 Page 3-7
3 Technical Data
3.4 Noise Levels - dB(A)

Noise levels for the Terex® MPE 684 (running on empty)
72.2dB
75.3dB
79.3dB
77.6dB
82.8dB
80.5dB
86.2dB
82.8dB
87.3dB
94.5dB
82.6dB
78.4dB
97.6dB
85.2dB
81.2dB
87.7dB
87.6dB
82.4dB
86.5dB
78.8dB
82.0dB
1m (3’-3’’)
5m (16’-4’’)
83.2dB
10m (32’-8’’)
81.6dB
76.9dB
Figure 3.4 - Noise Levels

Page 3-8 684
Machine Description 4
Table of Content
4 Machine Description.................................................................................. 4-2
(1) Machine Description and Intended Operation ...........................................4-2
(2) Machine References ..................................................................................4-2
4.2 Machine Components ....................................................................................4-3
4.3 Control and Display Elements ........................................................................4-4
(1) MCU300 Control panel ..............................................................................4-4
(2) Tracking .....................................................................................................4-6
4.4 Pictorial Decal Descriptions............................................................................4-8
(1) Machine Operations Decals ......................................................................4-8
(2) Machine Information Decals ....................................................................4-14

684 Page 4-1
4 Machine Description
(1) Machine Description and Intended Operation

This machine and its approved attachments have been designed to be used in Materials Processing
screening applications. Use of this product in any other way is prohibited and contrary to its
intended use
(2) Machine References

When using this operations manual, at all times the right hand and left hand references are viewed
from the feeder end of the machine. The rear of the machine is situated at the feeder end of the
machine, Ref: Figure 4.1.
DUN00024
Figure 4.1 - Machine Overview
1 Left hand side

2 Front
3 Right hand side
4 Rear

Page 4-2 684
4.2 Machine Components

The following sections identify the main components of the machine and the term with which they
are referred to in this manual.
1 2 3
11
4
10
6
7
8
DUN00025
Figure 4.2 - Machine Components
1 Middle grade conveyor

2 Main conveyor
3 Fines conveyor
4 Walkway
5 Oversize minus conveyor
6 Transfer conveyor
7 Tracks
8 Power unit
9 Feeder unit
10 Remote tipping grid (standard)
11 4th product conveyor (3 deck only)

684 Page 4-3
4.3 Control and Display Elements
(1) MCU300 Control panel

The main hydraulic control panel, fitted at ground level, has all the controls centrally located. This
allows the operator to quickly and easily optimize production preventing unnecessary downtime.
Controls for the folding discharge conveyors are strategically positioned at 2 points beside these
conveyors to allow clear vision when raising and lowering them into position. There is a display
screen on the control which indicates the current state of the machine.
O I
3
DUN00149
Figure 4.3 - Control Panel
1 Display screen
2 Ignition switch
3 Pre-heat button (Tier 3) / Throttle switch (Tier 4) / Two-speed tracking switch (Tier 3 Constant
Speed)
When the ignition switch is turned to the ON position the home screen is displayed on the control
panel display screen, Ref: Figure 4.4.
Figure 4.4 - Home Screen (No faults)
If there are active faults these will be displayed on the home screen. The total engine run hours
are displayed in the centre of the home screen. The software version is displayed on the bottom
centre of the home screen. The first number states the screen (display) version and the second
number indicates the PLC version, example: v1.1.
Refer to Section 7.4 for more information on the operation of the MCU300 Control Panel.

Page 4-4 684
An indicator light on the control panel display screen will illuminate red when a machine fault
occurs. The light or lights which illuminate will depend on the fault, Ref: Table 4.1.
Table 4.1 - Display Screen Fault Codes

Indicator Fault Code Indicates
FC001 Emergency stop engaged
FC002 Low hydraulic oil level
FC003 Low coolant level
FC004 High engine temperature
FC005 Air filter element restricted
FC006 Fuel contamination
FC007 Low oil pressure
FC008 Machine run failure
FC009 Alternator failure
FC010 Communication loss
The control panel also displays an engine fault screen (Figure 4.5) if there is a problem with the
engine.
Figure 4.5 - Engine Fault Screen
Refer to the table in Appendix D for a list of the engine fault codes. Refer to the engine
manufacturer’s manual or your local dealer for more information.

684 Page 4-5
(2) Tracking
(i) Manual Tracking System

Figure 4.6 below shows the manual tracking umbilical layout.
1 2
3 4
5 6
7 0 I 8
TEREX R
9
DUN00004
Figure 4.6 - Tracking Umbilical Layout
Table 4.2 below gives a description of each button on the tracking umbilical shown above.
Table 4.2 - Tracking Umbilical Layout

ID Description
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

Page 4-6 684
(ii) Radio Tracking System

Figure 4.7 below shows the Radio Tracking Transmitter Layout.
1 2
3 4
5
0 I 6
7 8
9 START START 0
TEREX R
DUN00008
Figure 4.7 - Radio Tracking Transmitter Layout
Table 4.3 below gives a description of each button on the radio tracking transmitter shown above.
Table 4.3 - Radio Tracking Transmitter Layout

ID Description
5 Stop Tracks
6 Start Tracks
7 Unused
8 Unused
9 Radio Start Button 1
0 Radio Start Button 2

684 Page 4-7
4.4 Pictorial Decal Descriptions

Pictorial decals have been placed on the machine to ensure that the machine is correctly operated
and maintained. Operations decals describe the operations of levers on the machine. Information
decals give details about how to correctly operate and maintain the machine.
(1) Machine Operations Decals

Each operation decal is placed on the machine beside the corresponding lever or control. The
following table gives a short explanation of each operation decal used on the machine. The up
arrow in the decals indicates moving the lever forward or up. The circle in the decals indicates
the neutral position. The down arrow in the decals indicates moving the lever back or down. The
pictorial decals contain an image of a component or of the machine with a shaded component.
This indicates the part of the machine and the operation that the lever controls.
Table 4.4 - Machine Operation Decals

Decal Component Explanation
Left hand side
conveyor Fold in

Neutral

Fold out

Transfer
conveyor Slide out

Neutral

Slide in

4th product

Neutral

Fold out


Page 4-8 684

4th product
conveyor Lower

Neutral

Raise

4th product
conveyor slider Lower

frame
Neutral

Raise

Main conveyor
and screenbox Lower

Neutral

Raise

Main conveyor
and screenbox Slide back

Neutral

Slide forward

Screenbox valve
Start

Neutral

Stop


684 Page 4-9

Right hand side

Neutral

Fold out

Tail conveyor
Lower

Neutral

Raise

Tail conveyor
Fold out

Neutral

Fold in

4th product
conveyor Lower

extended section
Neutral

Raise

Feeder gate
valve Start

Neutral

Stop


Page 4-10 684

Tracks, main
conveyor Start main conveyor and transfer conveyor

and transfer
conveyor
Neutral

Engage tracks

Hopper support
legs Lower hopper legs

Neutral

Raise hopper legs


Tracks, belt
feeder and Start belt feeder and 4th product conveyor

4th product
conveyor
Neutral

Engage tracks

Side conveyors Turn flow control valve anti-clockwise

to increase speed of the right hand side
conveyor and decrease the speed of the left
hand side conveyor.
Turn flow control valve clockwise to decrease
speed of the right hand side conveyor and
increase the speed of the left hand side
conveyor.
4th product
conveyor Turn flow control valve anti-clockwise to
increase speed of the 4th product conveyor.

speed of the 4th product conveyor.
39-1470
Transfer
conveyor Turn flow control valve anti-clockwise to
increase speed of the transfer conveyor.

speed of the transfer conveyor.
39-1474

684 Page 4-11

Vibrating Grid
Lower vibrating grid

Neutral

Raise vibrating grid


Grid
Lift grid / Start grid


Neutral

Belt feeder
speed of belt feeder.
Turn flow control valve anti-clockwise to

increase speed of belt feeder.
Side conveyors
Start side conveyors


Neutral

Screen and fines

conveyor
Start screen and fines conveyor

Neutral


Page 4-12 684

Screen
Increase screen tension

Neutral

39-1172-0
Decrease screen tension

Tracking/ Insert the tracking umbilical into this socket to

operation socket track the machine.
Insert the dummy plug into this socket to
operate the machine.
Insert the tracking umbilical or dummy plug

into this socket when not in use. This socket
39-1380-0
is for storage purposes only.

684 Page 4-13
(2) Machine Information Decals
Table 4.5 - Machine Information Decals

Decal Description
Maximum screen speed.
Ensure frame arms are free from foreign body/

stone build up. Check on a regular basis. Refer
to operations manual.
Ensure tracks are tied down correctly.
Do not elevate with pins in position.

Remove pins prior to elevation.
Remove pins before elevation of side conveyors.

Page 4-14 684
Decal Description
Recommended hydraulic oil - ISO 46.
Ensure transport pins and chains are secure.
Switch off machine and disconnect battery

terminals and remote unit prior to welding.
Diesel oil only.
Lubrication point.

684 Page 4-15
Decal Description
Transfer conveyor and chute

Remove the transfer chute before moving the
2 transfer conveyor into the transport position.
1
39-1450-0
If the fuel supply is interrupted (e.g. fuel level low,

water trap maintenance or burst hose) the engine
60 3 mins should be primed for 3 minutes before startup
by turning the ignition key to the on position as
45 15
shown.
30
10200282
Use ultra low sulphur fuel only.

(Tier 4 engines)
S
10200276
The fines conveyor must be unfolded before the

screen is raised to the working position.
The screen must be lowered to the transport
position before the fines conveyor is folded to the
transport position.

Page 4-16 684
Transportation 5
Table of Content
5 Transportation............................................................................................ 5-2
5.1 Prior to Transportation ....................................................................................5-2
5.2 Putting the Machine into the Transport Position .............................................5-4
(1) Stopping the Machine ................................................................................5-4
(2) Setting the Remote Grid to the Transport Position ....................................5-5
(a) Manual Operation of Remote Grid ........................................................5-5
(b) Radio Operation of Remote Grid ..........................................................5-5
(3) Lowering the Vibrating Grid to the Transport Position (Optional) ..............5-7
(4) Placing the Transfer Conveyor into the Transport Position and
Removing the Transfer Conveyor Chute (3 Deck Only)......................................5-7
(5) Removing Walkway Access Steps from the Working Position ..................5-8
(6) Folding in the Screen Walkway .................................................................5-9
(7) Fold In the Extended 4th Product Conveyor (Option) ..............................5-10
(8) Folding the 4th Product Conveyor into the
Transport Position (3 Deck Only) ...................................................................... 5-11
(9) Folding in the Side Conveyors .................................................................5-13
(10) Lowering the 4th Product Conveyor Angle (3 Deck Only) .......................5-14
(11) Folding Extended 4th Product Conveyor
(Double Deck Vibrating Grid Option) ................................................................5-15
(12) Lowering the Fines Conveyor ..................................................................5-16
(13) Lowering the Screenbox and Main Conveyor ..........................................5-17
(14) Folding Fines Conveyor ...........................................................................5-18
(15) Raising the Support Legs ........................................................................5-20
5.3 Loading the Machine to the Low Loading Trailer (Track Machine) ...............5-21
(1) Ready for Transport .................................................................................5-22
(2) Prior to Haulage .......................................................................................5-22

684 Page 5-1
5 Transportation
5 Transportation
5.1 Prior to Transportation
 CAUTION
Prior to transportation always check the machine for loose or damaged components. Ensure
all loose items are carefully stowed and secured if these are to be transported on the machine.
Fasten all loose parts, replace missing items or make repairs as found necessary to ensure that
all components are safely secured during transportation.
Check that the travelling dimensions and weight of the machine will be within the regulation limits.
NOTICE
When transporting the machine, it is the responsibility of the haulage contractor to safely secure
it to the transporter.
Before transporting the machine, observe the prescribed transport position, admissible speed and
itinerary. The manufacturer/supplier will not be liable for damage caused by improper disassembly.
Dangers from overhead cables, moving conveyors etc., as well as other site related hazards must
be anticipated. Avoid these by carrying out risk assessments before the machine is put into the
transport position.
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.
The machine is remote controlled and may start without notice. Stay clear of the machine. The
machine must be loaded and transported only in accordance with the operating instructions.
For manoeuvring the machine, observe the prescribed transport position, admissible speed and
itinerary. Use only appropriate means of transport and lifting equipment and where applicable
of adequate capacity. The re-commissioning procedure must be strictly in accordance with the
operating instructions. Before travelling with the machine, check that the braking and any signalling
and lighting systems are fully functional. Before setting the machine in motion always check that
the accessories have been safely stowed away.
On wheeled machine:
Ensure wheel nuts are torqued between 500 to 550 ft.lb (69 to 76 kg.m) prior to transport. Recheck
the wheel nut torque every 150 miles (200km).
Connect and check the braking system.

Page 5-2 684
Transportation 5
Check your tires for:-

• correct pressure
• cuts or bulges
• nails or spikes
• uneven or excessive wear
• 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.

684 Page 5-3
5 Transportation
5.2 Putting the Machine into the Transport Position
 WARNING
Nip Point Hazard.
Nip points exist where rams and moving assemblies exist. Stay clear of all moving sub assemblies
on the machine.
NOTICE
Before folding out conveyors, ensure there is adequate space for the conveyors to fold out and
for material stockpiles. The machine must be unfolded and setup in the correct sequence to
prevent damage.
Do not raise or lower any part of the machine with securing pins in position. Ensure all pins are
removed prior to starting the machine and raising or lowing machine components.
Use the control levers in a smooth and controlled manner. Do not rush or jerk the controls.
Refer to Section 4.4 for descriptions of operational decals.
(1) Stopping the Machine
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 7.6.
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.

Page 5-4 684
Transportation 5
(2) Setting the Remote Grid to the Transport Position
(a) Manual Operation of Remote Grid
PROCEDURE
1. Start the engine, Ref: Section 7.2(1).
2. Move up the control valve lever to activate the tipping/vibrating grid solenoid.
3. Push and hold the toggle switch (item 1) on the radio tipping/vibrating grid receiver in the up
position to activate the ‘grid up’ solenoid, Ref: Figure 5.1.
4. Push and hold the toggle switch on the radio tipping/vibrating grid receiver in the down
position to activate the ‘grid down’ solenoid.
Figure 5.1 - Radio Tipping/Vibrating Grid Receiver
(b) Radio Operation of Remote Grid

Pre-stored programmed sequence
PROCEDURE
1. Start the engine.
3. Press and hold the ‘On/ Off’ button (I) for 2 seconds, Ref: Figure 5.2.
» The status LED will illuminate red.
4. Press the Start / Stop button (S).
» The ‘grid up’ solenoid will energise for a programmed time. Once this time has elapsed, the ‘grid
down’ solenoid will energise for a programmed time.
5. Press the Start / Stop button (S) during the sequence to pause the sequence.
6. Press the Start / Stop button (S) to continue the sequence.

684 Page 5-5
5 Transportation
Figure 5.2 - Radio Tipping/Vibrating Grid Transmitter
Sequence override buttons
PROCEDURE
1. Start the engine, Ref: Chapter 7.
4. Press the ‘up arrow’ to energise the ‘grid up’ solenoid.
5. Press the ‘down arrow’ to energise the ‘grid down’ solenoid.
Set a new programmed sequence
PROCEDURE
1. Start the engine,
3. Press and hold the program button (P).
4. Continue to hold the Program button pressed for the duration of the programming sequence.
7. Press and hold the ‘UP’ button.
» This will energise the ‘grid up’ solenoid and cause the grid to rise. The status LED will flicker.
8. When the grid is at the required height, release the ‘UP’ button, keeping the Program button
(P) pressed.
9. Press and hold the ‘DOWN’ button.
» This will energise the ‘grid down’ solenoid and cause the grid to lower. The status LED will flicker.
10. When the grid is almost fully down, release the ‘DOWN’ button.
11. Release the program button (P).
» This sequence is now stored.
12. Press the Start / Stop button (S) to activate the programmed sequence.

Page 5-6 684
Transportation 5
(3) Lowering the Vibrating Grid to the Transport Position (Optional)

The vibrating grid can be operated by manually operating the vibrating grid control lever or by
using the grid remote option as detailed above.
 DANGER
Fall Hazard. Do not climb onto working or moving machinery. Use suitable lifting equipment
when working at a height. Do not work under unsupported equipment.
 WARNING
Hazardous nip and crush points. Keep clear of folding equipment. Switch off, tag out and lock
out before working at the machine.
PROCEDURE
1. Operate the control lever at the main hydraulic control panel to lower the vibrating grid.
2. Fit the pins into the holes provided in the telescopic legs on either side of grid to hold the
position. Use the same hole on either side to keep the grid level.
(4) Placing the Transfer Conveyor into the Transport Position and Removing
the Transfer Conveyor Chute (3 Deck Only)
 DANGER
 WARNING
PROCEDURE
1. Remove the transfer conveyor chute.
2. Operate the control lever to move the transfer conveyor into the transport position.

684 Page 5-7
5 Transportation
(5) Removing Walkway Access Steps from the Working Position
 DANGER
 WARNING
PROCEDURE
1. Remove pins, Ref: Figure 5.3 (items 1 and 2).
2
DUN00042
Figure 5.3 - Access Steps in Working Position
2. Lift and rotate the access steps from the support hooks.
DUN00038
Figure 5.4 - Access Steps in Transport Position
3. Insert pins to hold the ladders in the transport position, Ref: Figure 5.4.

Page 5-8 684
Transportation 5
(6) Folding in the Screen Walkway
 DANGER
Fall Hazard. Do not climb onto working or moving machinery. Use a suitable platform when
working at a height. Only use lifting equipment capable of lifting the parts. When using lifting
equipment, do so at a slow and steady pace. NEVER work under suspended loads. Ensure the
front hand rail is safely supported before any nuts or bolts are removed.
 WARNING
PROCEDURE
1. Attach lifting chains to the front walkway.
2. Remove the wedges (item 1) holding the front handrail end sections in the working position,
and rotate into the transport position, Ref: Figure 5.5.
DUN00142
Figure 5.5 - Walkway Working Position
3. Remove bolts and rotate the floor section upwards to fit into the transport position.
4. Rotate the walkway frame into the transport position.
5. Insert bolts along the side of each walkway to hold in the transport position, Ref: Figure 5.6.
1
DUN00044
Figure 5.6 - Walkway Transport Position
6. Repeat this procedure for the walkway on the other side of the machine.

684 Page 5-9
5 Transportation
(7) Fold In the Extended 4th Product Conveyor (Option)
 WARNING
Fall Hazard. Removing and inserting the pins from the 4th product conveyor extended section
will require working at a height. Follow the working at a height regulations. Use suitable lifting
equipment.
Do not work under or near unsupported equipment.
Hazardous nip and crush points. Keep clear of folding conveyors.
PROCEDURE
1. Remove the pins (items 1) holding the 4th product conveyor extended section in the working
position, Ref: Figure 5.7.
DUN00172
Figure 5.7 - 4th Product Conveyor Extended Section Pins
2. Raise the control lever to fold the 4th product conveyor extended section in to the transport
Figure 5.8 - 4th Product Conveyor Extended Section Control Lever Decal
3. Reinsert the pins to hold the 4th product conveyor extended section in the transport position.

Page 5-10 684
Transportation 5
(8) Folding the 4th Product Conveyor into the Transport Position (3 Deck Only)
 WARNING
Fall Hazard. Pinning the height of discharge and chain securing will require working at a height.
Follow the working at a height regulations. Use suitable lifting equipment.
PROCEDURE
1. Remove the pin (item 1) from the telescopic stay securing the 4th product conveyor in the
working position, Ref: Figure 5.9
DUN00146
Figure 5.9 - 4th Product Conveyor Telescopic Stay
2. Remove pins (item 2) holding the 4th product conveyor in the working position, Ref: Figure
5.10.
3. Move the 4th product lever up to fold in the 4th product conveyor.
4. Remove the pins (item 1) from the 4th product slider frame telescopic, Ref: Figure 5.10.
1 DUN00045
Figure 5.10 - 4th Product Slider Frame Pins
5. Move the 4th product slider frame lever down to raise the slider frame on the 4th product
conveyor.
6. Make sure that the conveyor angle is raised in the air.

684 Page 5-11
5 Transportation
7. Move the 4th product conveyor lever up to lower the 4th product conveyor into the transport
position.
8. Insert pins to secure the conveyor in the transport position.

Page 5-12 684
Transportation 5
(9) Folding in the Side Conveyors

This procedure must be carried out for both the left hand side and right hand side conveyors.
 WARNING
Hazardous nip and crush points. Ensure there is no obstructions before folding in the conveyors.
Keep clear of folding conveyors.
PROCEDURE
1. Remove the feedboot extensions (item 2) from the sockets, Ref: Figure 5.11.
2
1
DUN00046
Figure 5.11 - Side Conveyor Pins
2. Remove the pins (item 1) from both sides of the side conveyor telescopics, Ref: Figure 5.11.
3. Fold down slider pads.
4. Move the side conveyor lever up to fold in the side conveyor.
5. Insert pins (item 1) into the side conveyors to hold in the transport position, Ref: Figure 5.12.
1
DUN00047
Figure 5.12 - Side Conveyor Transport Position
6. Insert feedboot extensions into their transport location (position 2) and secure with fixing
bolt, Ref: Figure 5.12.
7. Repeat steps 1 to 4 for the other side conveyor.

684 Page 5-13
5 Transportation
(10) Lowering the 4th Product Conveyor Angle (3 Deck Only)
 WARNING
PROCEDURE
1. Insert the transport bracket (item 2) between the two cleats on the feeder and secure with
pins, Ref: Figure 5.13.
2. Remove the pins (item 1) from the 4th product conveyor, Ref: Figure 5.13.
DUN00048-1
Figure 5.13 - 4th Product Conveyor Raised
3. Move the 4th product conveyor lever up to lower the angle of 4th product conveyor level with
the tipping grid and resting on the transport bracket, Ref: Figure 5.14.
DUN00037
Figure 5.14 - 4th Product Conveyor Lowered
4. Reinsert pins (item 1) into the 4th product conveyor, Ref: Figure 5.14.

Page 5-14 684
Transportation 5
(11) Folding Extended 4th Product Conveyor (Double Deck Vibrating Grid
Option)
NOTICE
If the double deck vibrating grid is fitted, the standard transport bracket must be fitted to the
outside of the cleat on the feeder and the extended 4th product conveyor must be secured to the
cleat on the feeder. The transport bracket must be fitted before the conveyor is lowered into the
transport position.
PROCEDURE
1. Insert the transport bracket (item 1) to the outside of the cleat on the feeder and secure with
nuts and bolts, Ref: Figure 5.15.
2 DUN00465
Figure 5.15 - Double Deck Vibrating Grid and Extended Conveyor Transport Position
2. Lower the 4th product conveyor angle until the conveyor rests on the transport bracket (item
3) and the bracket (item 2) on the extended section is in line with the cleat on the feeder,
Ref: Figure 5.15.
3. Use a pin to secure the bracket (item 2) on the extended section of the 4th product conveyor
to the cleat on the feeder, Ref: Figure 5.15.

684 Page 5-15
5 Transportation
(12) Lowering the Fines Conveyor
 WARNING
NOTICE
Use the control levers in a smooth and controlled manner. Do not rush or jerk the controls. This
will damage the machine.
PROCEDURE
1. Remove the securing pins, (item 1) from both sides of the fines conveyor, Ref: Figure 5.16.
DUN00049
Figure 5.16 - Raised and Folded Out Fines Conveyor
2. Move the fines conveyor lower lever down to lower the fines conveyor.
3. While lowering the conveyor, fold the tail section up slightly to prevent it hitting the ground
when fully lowered (Ref: Figure 5.17). Move the fines conveyor fold lever to do this.
4. Reinsert pins into both sides of the fines conveyor to secure the conveyor in the transport
Figure 5.17 - Fines Conveyor Transport Position

Page 5-16 684
Transportation 5
(13) Lowering the Screenbox and Main Conveyor
 WARNING
PROCEDURE
1. Remove the pins (item 1) from both sides of the screen telescopics, Ref: Figure 5.18.
DUN01252
Figure 5.18 - Raised Screenbox
2. Move the screenbox and main conveyor control lever down to lower the screen box and main
conveyor into the transport position.
1
DUN01253
Figure 5.19 - Screenbox Pins
3. Reinsert the pins (item 1) in both sides of the screen telescopics, Ref: Figure 5.19.
4. Remove the pins and bolts in both sides of the machine (item 2), Ref: Figure 5.19.
5. Operate the screen control lever to lower the discharge end of the screen box.
6. Reinsert the pin in both sides of the machine (item 2), Ref: Figure 5.19.
7. Remove telescopic pins (item 1), Ref: Figure 5.19.
8. Move screenbox lever down to lower the screen box sub-frame into the transport position.
9. Reinsert pins into the fines conveyor and subframe (item 2), Ref: Figure 5.19.
10. Reinsert the pins (item 1) into the screenbox telescopic at both sides of the machine, Ref:
Figure 5.19.
684 Page 5-17
5 Transportation
(14) Folding Fines Conveyor
 WARNING
Hazardous nip and crush points in this area.
NOTICE
Use the control levers in a smooth and controlled manner. Do not rush or jerk the controls. This
will damage the conveyor.
PROCEDURE
1. The fines conveyored should have already been lowered to transport postion and partially
folded, prior to lowering the screenbox into transportation (Ref. section 5.2 (5))
DUN01254
Figure 5.20 - Fines Conveyor in Lowered Position
2. Next, operate the fines conveyor fold lever to fold the tail section of the fines conveyor into
transport position
DUN01250
Figure 5.21 - Fines Conveyor Securing Pin
3. Insert securing pin (Item 1, Ref: figure 5.21), to secure the fines conveyor in transport position.

Page 5-18 684
Transportation 5
DUN01255
Figure 5.22 - Fines Conveyor in Transport Position

684 Page 5-19
5 Transportation
(15) Raising the Support Legs
 WARNING
Nip and crush hazard from lowering support legs. Keep clear of support legs. Wear personal
protective equipment.
NOTICE
Ensure that the weight of the machine is evenly spread over the support legs, chassis base and
undercarriage. It is important that the machine is completely level to ensure optimum performance.
PROCEDURE
1. Remove support leg pins.
2. Move the support legs control lever up to raise the support legs (item 1), Ref: Figure 5.20
and Figure 5.21.
Figure 5.23 - Support Legs Control Lever Decal
1
DUN00052
Figure 5.24 - Lowered Support Legs
3. Reinsert support leg pins., Ref: Figure 5.21

Page 5-20 684
Transportation 5
5.3 Loading the Machine to the Low Loading Trailer (Track Machine)
NOTICE
Securing the machine and any loose items to the low loader trailer is the responsibility of the
haulage contractor.
PROCEDURE
1. Make sure suitable ramps are positioned at the end of the trailer to load the machine.
2. Check that any loose items transported with the machine will not cause a hazard while
unloading.
3. Ensuring that the engine/motors are running at idle, load the machine slowly onto the trailer,
manoeuvring the machine with the tracks, using the umbilical control or the remote radio
control, if fitted.
4. Stop the engine, see engine stop, unless required further.

684 Page 5-21
5 Transportation
(1) Ready for Transport
 WARNING
Do not transport this machine without it being properly secured on to the lowloader.
Before transporting this machine you must read and understand the Safety section in this manual.
NOTICE
Before tracking the machine ensure the engine speed is idle.
The machine should now be ready for transport.

Secure machine with Chain shackles to the Lowloader.
Use securing eyes (Item 1) fitted on the machine undercarriage on either side, Ref: Figure 5.22.
1
TIRC00322
Figure 5.25 - Tracks Secured on Lowloader
(2) Prior to Haulage
PROCEDURE
1. Check for loose parts or debris on the machine.
2. Ensure all pins are secured with ‘R’ pins and Split pins.
3. Raise the support legs fully.
4. Ensure persons transporting the machine adhere to all safety signs and procedures.

Page 5-22 684
Initial Setup and Adjustments 6
Table of Content
6 Initial Setup and Adjustments .................................................................. 6-2
6.1 Initial Inspection..............................................................................................6-2
6.2 Machine Location Considerations ..................................................................6-2
6.3 Measures Before Setup..................................................................................6-3
6.4 Measures After Long Term Standstill..............................................................6-3
6.5 Putting the Machine into the Working Position ...............................................6-4
(1) Lowering the Support Legs ........................................................................6-4
(2) Unfolding Fines Conveyor .........................................................................6-5
(3) Raising the Screenbox and Main Conveyor ..............................................6-7
(4) Raisimg the Fines Conveyor .....................................................................6-9
(5) Raising the 4th Product Conveyor Angle (3 Deck Only) ..........................6-10
(6) Opening Out the Side Conveyors ............................................................6-12
(7) Moving the 4th Product Conveyor into the Working Position
(3 Deck Only) ....................................................................................................6-13
(8) Opening Out the Extended 4th Product Conveyor (Option) ....................6-15
(9) Fitting the Screen Walkway .....................................................................6-16
(10) Removing Walkway Access Steps from the Transport Position ..............6-17
(11) Moving the Transfer Conveyor in Working Position and
Fitting the Transfer Conveyor Chute (3 Deck Only) ..........................................6-18
(12) Raising Vibrating Grid to Working Position (Optional) .............................6-18
(13) Setting Remote Grid to Working Position ................................................6-19
(a) Manual Operation of Remote Grid ......................................................6-19
(b) Radio Operation of Remote Grid ........................................................6-19

684 Page 6-1
6 Initial Setup and Adjustments

NOTICE
Terex recommends that the assembly and installation work of the machine be carried out by the
Terex customer service department. The manufacturer/supplier will not be liable for damage
caused by improper assembly or installation.
The environment in which the machine will operate contains inherent health and safety risks,
which the operator must take steps to avoid.
Dangers from overhead conveyor discharges, overspill material, vehicle movements, etc., as well
as other site related hazards must be anticipated.
Avoid these by carrying out risk assessments before the machine is put into operation to ensure
appropriate exclusion zone measures are put in place and site personnel safety awareness
training has been undertaken.
6.1 Initial Inspection

When the machine 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 machine for any loose items that may have been
shipped inside the machine..
6.2 Machine Location Considerations

Prior to setting up the machine, consideration should be given to a suitable layout to prevent
oversize material or metal from entering the machine. In order to prevent damage of the screen
unit, no material above the size recommended should be fed into the machine.
Position the machine in a safe, level, operating position making sure both tracks are in full contact
with the ground to minimise movement of the machine. Regularly check the machine 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 machine ensure that enough space is available around the machine to enable
easy set up, servicing and repair work.
Machinery arranged before and after this machine will have to be placed on the site accordingly.

Page 6-2 684
6.3 Measures Before Setup

We recommend that the assembly/ installation work of the machine be carried out by the Terex
customer service department. The manufacturer/supplier will not be liable for damage caused
by improper assembly/installation.
PROCEDURE
1. Ensure all guards are fully secured in correct/closed position.
2. Remove all loose items from the belt by untying the securing ropes.
3. Put control valve levers in neutral (non-operational) position.
4. The machine must be placed on solid ground capable of carrying the machine‘s weight.
5. Before detaching the machine from the prime mover, it is important that the chosen site is
level. Level the work site foundation with the loading shovel.
6. Level the machine with a precision spirit level.
7. Do not position the machine above ground level, e.g. on blocks etc.
6.4 Measures After Long Term Standstill
NOTICE
Prior to putting the machine into operation perform daily (10 hour) maintenance schedule.
Check tracks before transporting or moving the machine.

684 Page 6-3
6.5 Putting the Machine into the Working Position

Refer to Chapter 4 for descriptions of operational decals.
NOTICE
Before folding out conveyors, ensure there is adequate space for the conveyors to fold out and
for material stockpiles. The machine must be unfolded and setup in the correct sequence to
prevent damage.
Use the control levers in a smooth and controlled manner. Do not rush or jerk the controls.
(1) Lowering the Support Legs
 WARNING
Nip and crush hazard from lowering support legs. Keep clear of support legs. Wear personal
protective equipment.
NOTICE
Ensure that the weight of the machine is evenly spread over the support legs, chassis base and
undercarriage. It is important that the machine is completely level to ensure optimum performance.
PROCEDURE
1. Remove support leg pins.
2. Move the support legs control lever down to lower support legs (item 1), Ref: Figure 6.1.
1
DUN00052
Figure 6.1 - Lowered Support Legs
3. Reinsert support leg pins.

Page 6-4 684
(2) Unfolding Fines Conveyor

When you receive your Machine it will arrive with the Fines Conveyor folded in the transport
position (Item 1, Ref: Figure 6.2).
DUN01255
Figure 6.2 - Fines Conveyor in Transport Position
 WARNING
Hazardous nip and crush points in this area.
NOTICE
Use the control levers in as smooth and controlled manner. Do not rush or jerk the controls. This
will damage the machine.
The fines conveyor must be unfolded before the screenbox can be raised into working position.
There is a decal (Ref: Figure 6.3), which is located above the Conveyor Control Panel highlighting
this. It is also referenced with a description in the decal list in Chapter 4.
Figure 6.3 - Fines Coneyor Folding Decal
1. Remove the pins (Item 1, Ref: Figure 6.4) on either side holding the conveyor in the transport
position and store them in the toolbox provided.

684 Page 6-5
DUN01250
Figure 6.4 - Fines Conveyor Securing Pin
2. Next to unfold the conveyor out slightly using the fines conveyor control lever. Do not fold the
conveyor out completely straight, this will prevent it from hitting the ground. Ensure there is
adequate space for the conveyor to fold out and for material stockpiles

Page 6-6 684
(3) Raising the Screenbox and Main Conveyor
 WARNING
PROCEDURE
1. Remove the pins (item 1) from the screenbox telescopic at both sides of the machine, Ref:
Figure 6.5.
2. Remove pins from the fines conveyor and subframe.
1
DUN01253
Figure 6.5 - Screenbox Pins
3. Move screenbox lever up to raise the screen box sub-frame until the screen is positioned
almost horizontally.
4. Reinsert pins (item 1), Ref: Figure 6.5.
5. Remove the pin (item 2) from both sides of the machine, Ref: Figure 6.5.
6. Operate the screen control lever to raise the discharge end of the screen box.
7. Replace the pins and bolts (item 1) on both sides of the machine, Ref: Figure 6.5.
8. Remove the screen telescopic pins (item 1), Ref: Figure 6.5.
9. Move the screenbox and main conveyor control lever up to raise the screen box and main
conveyor to the working position, Ref: Figure 6.6.

684 Page 6-7
DUN01252
Figure 6.6 - Raised Screenbox
10. Reinsert pins (item 1) into both sides of the screenbox telescopic to secure in position.

Page 6-8 684
(4) Raisimg the Fines Conveyor
 WARNING
PROCEDURE
1. Remove the securing pins from both sides of the fines conveyor (item 1), Ref: Figure 6.7.
DUN00049
Figure 6.7 - Raised and Folded Out Fines Conveyor
2. Move the fines conveyor raise lever up to raise the fines conveyor.
Figure 6.8 - Fines Conveyor Raise/Lower Decal
3. Reinsert pins (item 1) into both sides of the fines conveyor to secure in position.
4. Move the fines conveyor fold out lever up to fold out fines conveyor.
Figure 6.9 - Fines Conveyor Fold Decal

684 Page 6-9
(5) Raising the 4th Product Conveyor Angle (3 Deck Only)
 WARNING
PROCEDURE
1. Remove the pins (item 1) from the 4th product conveyor, Ref: Figure 6.10.
DUN00037
Figure 6.10 - 4th Product Conveyor Pins
2. If the extended 4th product conveyer is fitted, remove the pin from the bracket (item 2) on
the extended section, Ref: Figure 6.11.
2 DUN00465
Figure 6.11 - Extended 4th Product Conveyor Brackets
3. Move the 4th product conveyor lever down to raise the angle of the 4th product conveyor
above the tipping grid, Ref: Figure 6.12.

Page 6-10 684
DUN00048-1
Figure 6.12 - Raised 4th Product Conveyor
4. Remove the transport bracket (item 2), Ref: Figure 6.12.

684 Page 6-11
(6) Opening Out the Side Conveyors
 WARNING
Hazardous nip and crush points. Ensure there is adequate space for conveyors to fold out. Keep
clear of folding conveyors.
PROCEDURE
1. Remove the pins (item 1) from both sides of the side conveyors, Ref: Figure 6.13.
2. Remove feedboot extensions from their transport location (item 2), Ref: Figure 6.13
1
DUN00047
Figure 6.13 - Side Conveyor Pins (Folded)
3. Move the side conveyor levers down to fold out the side conveyors.
4. Reinsert pins (item 1) into each of the side conveyor telescopics, Ref: Figure 6.14.
2
1
DUN00046
Figure 6.14 - Side Conveyor Pins (Folded Out)
5. Fit the feedboot extensions (item 2) to prevent spillage at the feedboot, Ref: Figure 6.14.
6. Insert the extensions into the sockets provided.
7. Insert and tighten the securing bolts.

Page 6-12 684
(7) Moving the 4th Product Conveyor into the Working Position (3 Deck Only)
 WARNING
Fall Hazard. Pinning the height of discharge and chain securing will require working at a height.
Follow the working at a height regulations. Use suitable lifting equipment.
PROCEDURE
1. Remove the pins (item 1) from the 4th product conveyor slider frame telescopic, Ref: Figure
6.15.
1 DUN00045
Figure 6.15 - 4th Product Slider Frame Pins
2. Move the 4th product conveyor lever down to raise the 4th product conveyor above the feeder.
3. Move the 4th product slider frame lever up, to lower the slider frame on 4th product conveyor,
Ref: Figure 6.16.
DUN00036
Figure 6.16 - Lowered 4th Product Conveyor Slider Frame
4. Move the 4th product conveyor lever down to fold out the 4th product conveyor to approximately
45 degrees, Ref: Figure 6.17.

684 Page 6-13
DUN00039
Figure 6.17 - 4th Product Conveyor Folded Out
5. Move the 4th product conveyor lever down to raise the angle of 4th product conveyor to the
required discharge height.
6. Pin the 4th product conveyor into position.
7. Insert the pins into the telescopic stay (item 1) to secure the 4th product conveyor in the
working position, Ref: Figure 6.18.
DUN00146
Figure 6.18 - 4th Product Conveyor Telescopic Stay

Page 6-14 684
(8) Opening Out the Extended 4th Product Conveyor (Option)
PROCEDURE
1. Remove the pins holding the 4th product conveyor extended section in the transport position
2. Lower the control lever to fold the 4th product conveyor extended section out into the working
Figure 6.19 - 4th Product Conveyor Extended Section Control Lever Decal
3. Reinsert the pins (items 1) to hold the 4th product conveyor extended section in the working
DUN00172
Figure 6.20 - 4th Product Conveyor Extended Section Pins

684 Page 6-15
(9) Fitting the Screen Walkway
 DANGER
Fall Hazard. Do not climb onto working or moving machinery.
 WARNING
Ensure all nuts, bolts and wedges are inserted.
PROCEDURE
1. Remove the bolts (item 1) along the side of each walkway, Ref: Figure 6.21.
1
DUN00044
Figure 6.21 - Walkway Transport Position
2. Rotate the walkway frame out to the working position.

3. Remove the mesh floor section from the walkway handrail and rotate downwards to fit into
the working position, Ref: Figure 6.22.
DUN00142
Figure 6.22 - Walkway Handrail Secured in the Working Position
4. Re-insert all nuts and bolts along the walkways and hand rails.
5. Repeat for the opposite side of the machine.
6. Rotate the front handrail out to the working position.
7. Fold both ends of the front handrail out into the working position and fix in place with the
wedge fittings.

Page 6-16 684
8. Rotate the checker plate floor sections out to the working position.
(10) Removing Walkway Access Steps from the Transport Position
 DANGER
when working at a height
 WARNING
PROCEDURE
1. Remove pins holding the ladders in the transport position, Ref: Figure 6.23.
DUN00038
Figure 6.23 - Access Steps in Transport Position
2. Lift and rotate access steps onto support hooks.

3. Insert pins (items 1 and 2), Ref: Figure 6.24.
2
DUN00042
Figure 6.24 - Access Steps in Working Position

684 Page 6-17
(11) Moving the Transfer Conveyor in Working Position and Fitting the Transfer
Conveyor Chute (3 Deck Only)
 DANGER
when working at a height.
 WARNING
PROCEDURE
1. Operate the control lever to move the transfer conveyor so that the transfer conveyor head
section hangs over the 4th product base unit.
2. Locate the transfer conveyor chute.
3. Align the chute with transfer conveyor and insert the tabs of the chute into the slots on the
conveyor.
(12) Raising Vibrating Grid to Working Position (Optional)
 DANGER
when working at a height.
 WARNING
PROCEDURE
1. Operate the control lever at the main hydraulic control panel to raise the vibrating grid, Ref:
Figure 6.25.
Figure 6.25 - Vibrating Grid Decal
2. Fit the pins into the holes provided in the telescopic legs on either side of grid to hold position.
Use the same hole on either side to keep the grid level.

Page 6-18 684
(13) Setting Remote Grid to Working Position
(a) Manual Operation of Remote Grid
PROCEDURE
2. Operate the tipping/vibrating grid control valve to activate the solenoid valve.
3. Push and hold the toggle switch (item 1) on the radio tipping/vibrating grid receiver in the up
position to activate the ‘grid up’ solenoid, Ref: Figure 6.26.
4. Push and hold the toggle switch on the radio tipping/vibrating grid receiver in the down
position to activate the ‘grid down’ solenoid.
Figure 6.26 - Radio Tipping/Vibrating Grid Receiver
(b) Radio Operation of Remote Grid

Pre-stored programmed sequence
PROCEDURE
1. Start engine, Ref: Section 7.2(1).
4. Press the Start / Stop button (S).
» The ‘grid up’ solenoid will energise for a programmed time. Once this time has elapsed, the ‘grid
down’ solenoid will energise for a programmed time.
5. Press the Start / Stop button (S) during the sequence to pause the sequence.
6. Press the Start / Stop button (S) to continue the sequence.

684 Page 6-19
Figure 6.27 - Radio Tipping/Vibrating Grid Transmitter
Sequence override buttons
PROCEDURE
4. Press the ‘up arrow’ to energise the ‘grid up’ solenoid.
5. Press the ‘down arrow’ to energise the ‘grid down’ solenoid.

Page 6-20 684
Set a new programmed sequence
PROCEDURE
4. Press and hold the program button (P).
6. Continue to hold the Program button pressed for the duration of the programming sequence.
7. Press and hold the ‘UP’ button.
» This will energise the ‘grid up’ solenoid and cause the grid to rise. The status LED will flicker.
8. When the grid is at the required height, release the ‘UP’ button, keeping the Program button
(P) pressed.
9. Press and hold the ‘DOWN’ button.
» This will energise the ‘grid down’ solenoid and cause the grid to lower. The status LED will flicker.
10. When the grid is almost fully down, release the ‘DOWN’ button.
11. Release the program button (P).
» This sequence is now stored.
12. Press the Start / Stop button (S) to activate the programmed sequence.

684 Page 6-21

Page 6-22 684
Standard Operating Procedures 7
Table of Content
7 Standard Operating Procedures .............................................................. 7-2
7.1 Pre-Operating Checks ....................................................................................7-2
7.2 Initial Startup ..................................................................................................7-3
7.3 Start Up ..........................................................................................................7-4
(1) Starting the Engine (Tier 3)........................................................................7-5
(a) No Faults on Display Screen ................................................................7-5
(b) Active Fault on Display screen ..............................................................7-6
(2) Starting the Engine (Tier 4 and Tier 3 Constant Speed) ............................7-9
(a) No Faults on the Display Screen ..........................................................7-9
(b) Active Fault on the Display screen ......................................................7-13
(c) CAT Fault Indicator Lamps..................................................................7-18
7.4 Standard Operation ......................................................................................7-20
(1) Changing the Machine Setting ................................................................7-20
(2) Operating the Machine ............................................................................7-21
(a) 3 Deck Machine Operation .................................................................7-21
(b) 2 Deck Machine Operation .................................................................7-22
(3) Screening ................................................................................................7-23
(4) Conveyor Speed Control .........................................................................7-24
7.5 Manoeuvring.................................................................................................7-25
(a) Undercarriage .....................................................................................7-25
(1) Manual Tracking Information ...................................................................7-26
(2) Manual Tracking Umbilical .......................................................................7-26
(3) Tracking the Machine ..............................................................................7-27
(a) Manual tracking Handset ....................................................................7-29
(b) Radio Control Handset (Optional) .......................................................7-30
(c) Fast Tracking - Constant Speed Engine .............................................7-32
7.6 Shut Down ....................................................................................................7-33
(3) Tier 4 Final Machine Shutdown ...............................................................7-35
(4) Tier 3 Constant Speed Shutdown ............................................................7-36

684 Page 7-1
7 Standard Operating Procedures
7.1 Pre-Operating Checks

 DANGER
DO not stand on the maintenance platform whilst the screen and feeder are operating.
 WARNING
Wear personal protective equipment.
Fall hazard.
Switch off, tag out and lock out machine before carrying out pre-operating checks.
NOTICE
AVOID frequent starting and stopping of the machine unnecessarily as it WILL cause damage
to the machine.
PROCEDURE
1. Ensure the machine is placed on solid level ground capable of carrying the machine‘s weight.
Regularly check the stability of the machine. The chassis should not bounce during operation.
2. Ensure there is adequate space around the machine for operation, material stockpiles,
maintenance and vehicular movement.
3. Ensure all guards are fully secured in correct/closed position.
4. Check that all safety equipment, alarms and interlocks are operative.
5. Remove all loose items from the belt by untying the securing ropes.
6. Ensure all control valve levers are in the neutral (non-operational) position.
7. Check the engine oil level and the fuel level and replenish if necessary.
8. Check the hydraulic oil level and replenish if necessary.
9. Ensure the material being feed into the feeder or screen unit is below the size limitations
recommended by the manufacturer. Do not allow build up of material at feed points.
10. DO NOT allow the engine RPM to run at a speed not suited for the application. Check the
wear parts to ensure speed is suitable for the application and feed rate not excessive.
» Engine RPM cannot be changed on a Tier III Constant Speed machine.
11. Check setup of the screen unit and adjust as necessary to the required settings.
12. Observe all safety instructions and ensure the correct protective clothing and equipment are
used by operators.
13. Check the oil cooler fan and radiator for any build up of dust/dirt. Check regularly that the oil
cooler fan is running correctly and that dust/dirt has not built up in the fan and radiator unit
(overheating can occur if dust/dirt is allowed to build up). Blow out dust/dirt if necessary.

Page 7-2 684
7.2 Initial Startup
NOTICE
Checks on the machine are crucial during the first week of operation.
These checks must be carried out before operating the machine.
This section should be read and understood prior to starting the machine. If there are any doubts,
consult your local dealer or Terex Technical Support department.
PROCEDURE
1. Refer to the engine manufacturer’s manual for initial start up of the engine.
2. Run the machine empty for a short period of time and check for abnormal noises, vibration
or excessive heat from the shaft bearings.
3. Each day during the initial days of operation check the tension of the conveyor belts.
4. Frequently check the overall stability of the machine, re-position if necessary.
5. Check the machine is level, re-position if necessary.
6. Frequently check the hydraulic oil level in the tank.
7. Frequently check all oil levels.
8. Ensure that the tension of the screen mesh(es) is satisfactory.
9. Frequently check the flow of material over the screen mesh(es) to confirm satisfactory
separation is taking place.
10. Make sure that the screen mesh apertures are free of ‘pegged’ material and that they remain
in good condition.
11. Check the vibrating unit bearing temperatures using a contact thermometer on the end
covers; record the temperature for future reference and fault diagnosis. (Maximum acceptable
temperature is 80 ºC [176°F] .)
12. Ensure that all components of the machine are operating before any material is introduced
to the machine.

684 Page 7-3
7.3 Start Up
 WARNING
Read and understand the operations manual before starting the machine.
NOTICE
Do not start the engine if the indicated lights are not illuminated. If any red warning lights are
shown on the display screen do not start the engine until the fault has been fixed.
Refer to engine manufacturers manual for initial startup of the engine.
Preheating is normally necessary when ambient temperature is below zero degrees Celsius. If
preheating is necessary hold the pre-heat button for up to one minute (depending on ambient
temperature. The engine should be cranked for a maximum of 20 seconds only. If the engine
does not start wait for at least one minute before repeating the procedure. If the engine does not
start on the second attempt, refer to the engine operations manual.
If the tracking umbilical is not connected to the machine, a dummy plug must be inserted into to
the connection (item 2) so that the machine can be operated, Ref: Figure 7.1.
1 2
3 DUN00141
Figure 7.1 - Dummy Plug in Umbilical Connection

Page 7-4 684
(1) Starting the Engine (Tier 3)
(a) No Faults on Display Screen
PROCEDURE
1. Adjust throttle lever to idle.
2. Turn the ignition key to the “ON” position (item 2), Figure 7.2.
» The main menu will be displayed on the control panel display screen, Ref: Figure 7.3. The engine
run and fuel on symbols only should light up green.
3
DUN00001
Figure 7.2 - Ignition Key Positions
3. Turn the key to the crank position (Item 3), Ref: Figure 7.2.
» The engine will crank and start after the warning siren has sounded for approximately 7 seconds.
Figure 7.3 - Control Panel Main Menu

684 Page 7-5
(b) Active Fault on Display screen

Refer to Section 4.3(1) for descriptions of symbols and fault codes.
NOTICE
Do not start the engine if any red warning lights are shown on the display screen. The red light
symbol indicates that there is a fault relevant to that indicator which must be fixed before starting
the engine.
PROCEDURE
1. Adjust throttle lever to idle.
» The main menu is displayed on the control panel screen. A symbol or symbols is shown red (item 1)
and a yellow safety warning symbol is displayed in the bottom left hand corner of the screen indicating
that there is a fault, Ref: Figure 7.4.
2
3
DUN00022
Figure 7.4 - Main Menu Active Fault
3. Press the button under the warning symbol (item 2), Figure 7.4.
» A screen showing the active alarm and fault code will be displayed, Ref: Figure 7.5.
Figure 7.5 - Active Fault

4. The last 12 faults are stored in the control panel. Press the right direction button on the panel
to scroll through the active faults.

Page 7-6 684
5. Determine the cause of the fault(s) and ensure that the problem(s) has been fixed before
continuing.
6. Press the button (item 2) under the exit symbol on the control panel to return to the home
screen.
» The home screen will be displayed with the fault symbol shown orange indicating that the fault is
cleared, Ref: Figure 7.6.
Figure 7.6 - Main Menu Fault Cleared

7. If there is a communication loss fault (FC010), the communication loss fault icon will be
displayed in the centre of the home screen , Ref: Figure 7.7.
Figure 7.7 - Home Screen (Communication Fault)

8. Press the button (item 3) on the panel to view the machine inputs and outputs, Ref: Figure 7.4.
» The controller status screen showing the input and output connections will be displayed, Ref: Figure
7.8. If there is a communications fault, all of the icons will be shown in grey.

684 Page 7-7
Figure 7.8 - Controller Status Screen

9. If any of the inputs or outputs are illuminated green, there is healthy communication between
the PLC and the display screen. Ensure that all connections are correct. Refer to Tables 7.1
and 7.2 for descriptions of each of the inputs and outputs shown on the controller status screen.
Table 7.1 - Inputs (Tier 3)

Item Description
I0 COOLANT LEVEL
I1 TRACK REQUEST
I2 ENGINE TEMP
I3 ENGINE OIL PRESSURE
I4 ESTOP HEALTHY
I5 CONV1 START REQ
I6 CONV2 START REQ
I7 JACK LEG SENSORS
I8 AIR FILTER RESTRICTION
I9 START ENGINE
I10 REMOTE STOP
IN11 HYD OIL LEVEL
Table 7.2 - Outputs (Tier 3)

Item Description
O0 ENGINE CRANK
O1 FUEL SYSTEM
O2 HYD OIL FAN
O3 SIREN/BEACON
O4 TRACKS ENABLE
O5 SPARE
O6 SPARE
O7 SPARE
O8 SPARE
O9 SPARE
O10 CONV1 RUN
O11 CONV2 RUN
10. Press the button (item 2) on the control panel to return to the home screen, Ref: Figure 7.4 .
11. Turn the ignition key to the crank position (item 3), Ref: Figure 7.10.
» The engine will crank and start after the warning beeper has sounded for approximately 7 seconds.

Page 7-8 684
(2) Starting the Engine (Tier 4 and Tier 3 Constant Speed)
NOTICE
Do not start the engine if any red warning lights or fault symbols are shown on the display screen.
A fault symbol indicates that there is a fault relevant to that indicator which must be fixed before
starting the engine.
(a) No Faults on the Display Screen
PROCEDURE
1. Switch the engine speed switch (item 3) to low, Ref: Figure 7.9.
» On machines fitted with a CAT C4.4 97KW Tier III Constant Speed engine, there is no engine speed
switch, therefore this first step does not apply. .
O I
3
DUN00149
Figure 7.9 - Control Panel

2. Turn the ignition key on the control panel to the “ON” position (item 2), Figure 7.10.
3
DUN00001
Figure 7.10 - Ignition Key Positions
» The home screen will be displayed on the control panel display screen, Ref: Figure 7.11. The indicator
lamps in the centre of the screen will illuminate and extinguish after two seconds if there are no faults
present. If the indicator lamps do not extinguish, refer to section 7.4(3) for more information. The
e-stop healthy and fuel on symbols only should light up green. Do not start the engine if any other
lights are illuminated red or if there are any other faults shown on the display screen.

684 Page 7-9
Figure 7.11 - Home Screen (No Faults)

» On Tier 4 machines the wait to start lamp is illuminated briefly on the home screen, Ref: Figure 7.12.
The engine can be started after this lamp goes out.
Figure 7.12 - Home Screen (Wait to Start)

3. Turn the key to the crank position (Item 3), Ref: Figure 7.10.
4. To view engine information, press the button under the engine symbol (item 4), Ref: Figure 7.13.
2 4
3
DUN00080
Figure 7.13 - Control Panel Display

Page 7-10 684
» The engine information screen is displayed, Ref: Figure 7.14. Refer to Table 7.3 for a description of
each of the symbols.
Figure 7.14 - Engine Information Screen

684 Page 7-11
Table 7.3 - Engine Information Screen Symbols

Symbol Description
Engine speed
Battery voltage
Coolant temperature
Air intake temperature
Fuel rate
Engine oil pressures
Engine boost (or turbo) pressure
Engine load
Engine run hours
5. To return to the main menu home screen any time press the button under the exit symbol
(item 2), Ref: Figure 7.13.

Page 7-12 684
(b) Active Fault on the Display screen

A fault symbol will be illuminated red on the home screen when a fault occurs. The symbols
shown will depend on the fault, Ref: Table 7.4.
Table 7.4 - Display Screen Fault Codes

Indicator Fault Code Indicates
FC001 Emergency stop engaged
Flashing
Icon
FC002 Low hydraulic oil level
SPN111 Low coolant level
SPN110 High engine temperature
FC005 Air filter element restricted
SPN232 Fuel contamination
SPN100 Low oil pressure
FC008 Remote stop
FC009 Battery Voltage LOW
FC010 Communication loss between

master and display

684 Page 7-13
NOTICE
Do not start the engine if any red warning lights or fault symbols are shown on the display screen.
The fault symbol indicates that there is a fault relevant to that indicator which must be fixed before
starting the engine.
PROCEDURE
» On machines fitted with a CAT C4.4 97KW Tier III Constant Speed engine, there is no engine speed
switch, therefore this first step does not apply. .
» The main menu is displayed on the control panel screen. A fault symbol around the outer edge of
the home screen is highlighted red and a yellow safety warning symbol is displayed in the bottom
left hand corner of the screen indicating that there is a fault, Ref: Figure 7.15.
Figure 7.15 - Home Screen (Active Fault)

3. Press the button under the warning symbol (item 2) to view the alarm history, Figure 7.16.
Figure 7.16 - Main Menu Active Fault

» A screen showing the alarm symbol and corresponding fault code is displayed, Ref: Figure 7.17. The
engine run hours at which the fault occurred is also displayed. Active alarms will have the yellow
warning symbol displayed beside the fault symbol. If a fault symbol is shown without the yellow
warning symbol, this indicates that the alarm has occurred but it is now inactive.

Page 7-14 684
Figure 7.17 - Active Fault Screen

4. The last 12 faults are stored in the control panel. Press the right direction button (item 5) on
the panel to scroll through the active faults, Ref: Figure 7.16.
5. To return to the main menu home screen any time press the button under the exit symbol
(item 2), Ref: Figure 7.16
6. Determine the cause of the fault(s) and ensure that the problem(s) has been fixed before
continuing. Refer to Figure 7.11 for fault code descriptions. If the engine fault screen is shown
(Figure 7.18) there is a problem with the engine. Refer to the table in Appendix D for a list
of the engine fault codes. Refer to the engine manufacturer’s manual or your local dealer
for more information.
Figure 7.18 - Engine Fault Screen

» The home screen will be displayed with the fault symbol shown orange indicating that the fault is
cleared, Ref: Figure 7.19.

684 Page 7-15
Figure 7.19 - Home Screen (Fault Cleared)

8. If there is a communication loss fault (FC010), the communication loss fault icon will be
displayed in the centre of the home screen , Ref: Figure 7.20.
Figure 7.20 - Home Screen (Communication Fault)

9. Press the button (item 3) on the panel to view the machine inputs and outputs, Ref: Figure 7.16.
» The controller status screen showing the input and output connections will be displayed, Ref: Figure
7.21. If there is a communications fault, all of the icons will be shown in grey.
Figure 7.21 - Controller Status Screen

Page 7-16 684
10. If any of the inputs or outputs are illuminated green, there is healthy communication between
the PLC and the display screen. Ensure that all connections are correct. Refer to Table
7.5 and Table 7.6 for descriptions of each of the inputs and outputs shown on the controller
status screen.
Table 7.5 - Inputs

Item Description
I0 ESTOP HEALTHY
I1 TRACK REQUEST
I2 LOW SPEED
I3 INTERSPEED
I4 HIGH SPEED
I5 CONV1 START REQ
I6 CONV2 START REQ
I7 JACK LEG SENSORS
I8 AIR FILTER RESTRICTION
I9 START ENGINE
I10 REMOTE STOP
IN11 HYD OIL LEVEL
Table 7.6 - Outputs

Item Description
O0 ENGINE CRANK
O1 FUEL SYSTEM
O2 HYD OIL FAN
O3 SIREN/BEACON
O4 TRACKS ENABLE
O5 SPARE
O6 SPARE
O7 SPARE
O8 SPARE
O9 SPARE
O10 CONV1 RUN
O11 CONV2 RUN
12. Turn the ignition key to the crank position, Ref: Figure 7.10 (item 3).
» The engine will crank and start after the warning beeper has sounded for approximately 7 seconds.

684 Page 7-17
(c) CAT Fault Indicator Lamps

The fault indicator lamps in the centre of the home screen will flash when powering up the CAT
ECU on switch on but will switch off again if there are no faults.
If either or both of the indicator lamps are illuminated or flashing while the engine is running,
there is a fault with the engine system which must be dealt with immediately, Ref: Figure 7.22
and Figure 7.23. Refer to Table 7.7 to determine the fault indicated by the lamps.
NOTICE
All faults must be identified and resolved as soon as possible.
Figure 7.22 - Warning Lamp (Alert Lamp)
Figure 7.23 - Shutdown Lamp (Action Lamp)

Page 7-18 684
Table 7.7 - Indicator Lamps Logic

Warning Shutdown Lamp State Description Engine State
Lamp Lamp
On On Bulb Check When the ignition is turned Key on but engine has
on the EMS shall illuminate yet to be cranked.
each bulb for 2 seconds and
extinguish them afterwards.
Off Off No faults With both lamps off whilst Engine is running with
present engine is running then there no detected faults.
are no currently active warnings
diagnostic’s or events.
On Off Active Should the warning lamp Engine is running
diagnostic illuminate during engine running normally but has one
this indicates that an Active or more faults with the
diagnostic (Electrical fault) is engine management
present. system.
On Flash Derate Should the warning lamp Engine is running
(invoked illuminate and the shutdown but has one or more
by active lamp flash during engine running Active diagnostic
diagnostic) this indicates that an Active events that have
diagnostic (Electrical fault) initiated engine
is present. The diagnostic is derate.
sufficiently serious to invoke
engine derate.
Flash Off Warning Should the warning lamp flash Engine is running
(warning during engine running this normally but has one
only) indicates that one or more of or more monitored
the engine protection strategy engine parameters
warning values have been outside of the
exceeded but not to a level that acceptable range.
will invoke Derate or Shutdown.
Flash Flash Derate Should both the Warning lamp Engine is running but
(warning and and Shutdown lamp flash during one or more of the
derate) engine running this indicates monitored engine
that one, or more, of the engine parameters has
protection strategy values have gone beyond that of
been exceeded beyond the warning only and has
level required to invoke engine now exceeded those
Derate. set for engine derate.
On On Engine Should both the Warning lamp Engine is either
shutdown and Shutdown lamp illuminate shutdown or shutdown
during engine running this is imminent, one
indicates that either: or more monitored
1. One or more of the engine engine parameters
protection strategy shutdown have gone beyond
values has been exceeded. that of warning or
derate and have now
2. A serious Active diagnostic
exceeded those set
has been detected.
for engine shutdown.
Shortly after (time duration to be Or a serious Active
agreed) engine will shutdown. diagnostic has been
detected

684 Page 7-19
7.4 Standard Operation
(1) Changing the Machine Setting

There are 3 settings which are controlled by the control levers on the main control panel.
 WARNING
The machine should be put into neutral mode to prevent accidental movement.
NOTICE
Never stop or track the machine when there is material being processed through it.
PROCEDURE
1. Move the two control levers to the up position to put the machine into screening mode, Ref:
Figure 7.24 and Figure 7.25.
2. Move the two control levers to the centre position to put the machine into neutral mode.
3. Move the two control levers to the down position to put the machine into tracking mode.
Figure 7.24 - Machine Tracking and Operation Decal
Figure 7.25 - Machine Tracking and Operation Decal

Page 7-20 684
(2) Operating the Machine

 WARNING
Entanglement Hazard. Keep clear of moving conveyors.
NOTICE
Before loading material onto the grid, or into the hopper or by-pass chute, the entire machine
must be running. The machine must be started in the correct sequence.
Before starting the machine ensure that all conveyor belts are sufficiently tensioned. If the belts
are not travelling straight or equally on the idler and drive drums, the belts will need tracking.
(a) 3 Deck Machine Operation
PROCEDURE
1. Start the engine, Ref: Section 7.2.
2. Gradually increase speed to maximum (2200 rpm) using the throttle.
» In the case of machines fitted with a Constant Speed engine, the engine speed cannot be changed.
The engine will run at a constant RPM.
3. Start the side conveyors by operating the side conveyor control levers (item 5) in the main
hydraulic control panel, Ref: Figure 7.26.
» The conveyors will start after a warning siren has sounded for approximately 10 seconds.
4. Start the fines conveyor and screenbox by operating the fines conveyor and screenbox control
lever (item 3), Ref: Figure 7.26.
5. Start the main conveyor and transfer conveyor by operating the main conveyor and transfer
conveyor control lever (item 2), Ref: Figure 7.26.
6. Start the belt feeder and 4th product conveyor by operating the belt feeder and 4th product
7. Start the vibrating grid (if fitted) by operating the vibrating grid control lever (item 7), Ref:
Figure 7.26.
8. If a remote grid is fitted operate the remote grid control lever (item 7) to power the remote
tipping, Ref: Figure 7.26.

684 Page 7-21
6 7
4 5
3
2
1
DUN00462
Figure 7.26 - Power Unit Control Levers
(b) 2 Deck Machine Operation
PROCEDURE
2. Gradually increase speed to maximum (2200 rpm) using the throttle.
» In the case of machines fitted with a Constant Speed engine, the engine speed cannot be changed.
The engine will run at a constant RPM.
3. Start the side conveyors by operating the side conveyor control levers (item 5) in the main
hydraulic control panel, Ref: Figure 7.27.
» The conveyors will start after a warning siren has sounded for approximately 10 seconds.
4. Start the fines conveyor and screenbox by operating the fines conveyor and screenbox control
lever (item 3), Ref: Figure 7.27.
5. Start the main conveyor by operating the main conveyor control lever (item 2), Ref: Figure 7.27.
6. Start the belt feeder and 4th product conveyor by operating the belt feeder and 4th product
7. Start the vibrating grid (if fitted) by operating the vibrating grid control lever (item 7), Ref:
Figure 7.27.
8. If a remote grid is fitted operate the remote grid control lever (item 7) to power the remote
tipping, Ref: Figure 7.27.

Page 7-22 684
6 7
4 5
3
2
1
DUN00462
(3) Screening
 WARNING
Entanglement Hazard
Keep clear of moving conveyors.
NOTICE
Avoid any contact with the shovel, excavator or ramp against the side of the machine.
Initial feed must be low and gradually increased up to normal rate over first few hours of operation.
PROCEDURE
1. Introduce material to the machine at a low feed rate.
2. Gradually increase the feed rate to normal rate.
3. Check the belt pressure on each conveyor.
4. After initial period stop the machine and visually check belts, scrapers, skirting rubbers, rollers
and nip guards for abnormal wear and obstructions.
5. Conveyor belts may behave different with material on them, re-tracking may be necessary.
6. Check the quality of the screened material.

684 Page 7-23
(4) Conveyor Speed Control

NOTICE
The two side conveyors have their speeds set at the factory, but these can be changed if the
product is building up on one particular conveyor due to the split of material through the Screen.
When the speed of the 4th product conveyor is increased it will decrease the speed of the middle
grade conveyor and vice versa (3 deck only).
PROCEDURE
2. Start all conveyors in the correct order.
3. Turn the control knob of the correct variable speed flow control valve counter clockwise to
increase conveyor speed.
4. Turn the control knob of the correct variable speed flow control valve clockwise to decrease
conveyor speed.
5. Check that all conveyor belts are running in alignment.
6. Check that the screenbox is running and capable of screening.
1 2 DUN00152
Figure 7.28 - Flow Control Valves
1 Feeder flow control valve
2 Side conveyors flow control valve

Page 7-24 684
7.5 Manoeuvring
 DANGER
DO NOT stand on any of the platforms or ladders of the machine whilst it is being manoeuvred
using the remote control handset.
When manoeuvring your machine to its operating position make sure you stand well clear of the
machine but are in a position to have all-round vision to see any obstacles, dangers that may lie
ahead e.g personnel, overhead cables, ditches, unsafe roadways etc.
 WARNING
Prior to attempting any manoeuvring of the machine the tracks must be free of obstructions,
including screened material and fines. Do not push or tow the Machine. Failure to observe this
warning could result in danger to persons and damage to the machine which may invalidate
warranty.
• Before manoeuvring the machine, ensure the feed hopper and screen are empty, and that all
materials have run off the conveyors. STOP the feeder,screen unit and product conveyors.
• The safety warning horn/siren sounds continuously whilst the machine is being manoeuvred.
• Make sure that you do not manoeuvre the machine on a gradient steeper than 30 degrees
(moving fore or aft), damage may occur to the engine and/or machine.
• Avoid manoeuvring the machine over extremely uneven ground or damage may occur. Due to
the limited ground clearance, avoid running over isolated objects between the tracks.
• Initial start up in cold weather may result in a tendency to steer to the right whilst tracking fast
forward due to the hydraulic oil being cold. Run the machine for approx. 10 minutes with the
conveyor and feeder running prior to manoeuvring the machine.
(a) Undercarriage
Track machines are designed for ease of movement around the site and should not be used on
public roads. Haulage equipment, should be used for this purpose.

684 Page 7-25
(1) Manual Tracking Information
 WARNING
Only a fully qualified and competent electrician must connect the electrical supply to this machine.
The electrical supply to this machine must be carried out in strict accordance with all relevant
local and international electrical safety regulations.
The electrical supply to this machine must have adequate protection for safe disconnection in
the event of either over-current, short circuit or earth leakage faults.
The electrical supply to this machine must be fully tested and inspected by a qualified electrician
in strict accordance with all relevant local and international electrical regulations.
This machine must not, under any circumstances, be operated or tracked unless it is absolutely
safe to do so.
As the Electrical Hydraulic machine must be connected to a three phase 415VAC 50Hz electrical
supply to power the electrical motors that control the hydraulic track pumps, absolute care must
be taken when tracking this machine.
The operator must ensure that strict attention is paid to all relevant health and safety regulations
and guidelines when operating and tracking this machine.
The electrical supply to this machine must be connected via the supplied industrial ‘spring release’
plug with safety tension cord properly attached to facilitate safe disconnect should the cable come
under strain. No other connection method to this machine is acceptable.
When tracking the machine it must be ensured that the supply cable to the machine is behind the
direction of travel or away from the tracks and the path of travel at all times.
(2) Manual Tracking Umbilical
NOTICE
To operate the machine via the umbilical, firstly retrieve the remote control unit. Attach the remote
control unit cable to the socket at the rear of the machine.
One option available on the tracked machine is the radio controlled tracking, As with all other
standard track machines a umbilical is also fitted, these models are fitted with an automatic
changeover, thus no changeover switch will be fitted.
In this case the start up procedure is the same as for a machine which is not fitted with a radio
tracking option. That is to simply connect umbilical, start engine position appropriate levers and
than press the tracks on/off button on the umbilical to initiate tracking after the 7 second delay
finishes.
The umbilical is only used to operate the tracks. It performs no other operation. The remote
control consists of a direct lead and a handset.

Page 7-26 684
(3) Tracking the Machine
 DANGER
Ensure all personnel are clear of the machine prior to tracking. Switch of the machine and
implement the lockout and tagout procedure prior to carrying out any work on the tracks.
DO NOT stand on any of the platforms or ladders of the machine whilst it is being manoeuvred.
Stand well clear of the machine but be in a position to have all-round vision to see any
obstacles or dangers that may lie ahead e.g personnel, overhead cables, ditches, unsafe
roadways etc.

684 Page 7-27
NOTICE
Before tracking the machine on site ensure that all material has been processed through it and
that no material is left on any belts, in the hopper or the screenbox.
For large tracking manoeuvres or when loading the machine onto a low loader it is necessary to
fold in the side conveyors and remove the 4th product conveyor. Never track the machine over
long distances with the conveyors in the working position.
The rear support legs must be raised to the transport position before tracking.
Frequently check that all nuts and bolts are in place on the tracks and are sufficiently tightened.
Always check tracks for loose or missing components prior to manoeuvring. While manoeuvring,
if any of the track components become loose, stop the machine immediately. Ensure the problem
is fixed before manoeuvring the machine again.
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, Ref: Figure
7.29. Do not manoeuvre the machine on a gradient steeper than 30 degrees.
Figure 7.29 - Tracking Uphill and Downhill

Avoid manoeuvring the machine over extremely uneven ground. Ensure the terrain that the
machine is working on is firm enough to adequately support the machine.
Make certain the machine is tracked at least 10 m in either direction on a daily basis, to minimise
risk of track chain seizure.
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.
Never attempt to track the machine if there is any build up of material around the tracks and drive
sprockets or if the tracks are frozen to the ground. Ensure the track systems are free from debris
before moving the machine. Never push or tow the machine when it is unable to free itself.
Ensure that there is no leakage from the oil gearbox, roller and idler before and during tracking.
Move all of the control levers to the neutral positions to stop all machine parts prior to manoeuvring.
Stop the machine for 30 minutes after tracking it continuously for 30 minutes, to allow the
components to cool down. Never track the machine constantly for more than 30 minutes without
providing adequate rest.

Page 7-28 684
(a) Manual tracking Handset
 WARNING
An engine stop button is fitted on the tracking handsets however the engine will NOT stop if the
handset is detached from the machine. The engine stop button on the handsets are not emergency
stops. In case of an emergency, press an emergency stop button on the machine itself.
PROCEDURE
1. Remove the dummy plug from the socket (item 2) and place it in the socket (item 1) for storage.
2. Connect the umbilical handset in the socket (Item 2) at the rear of the machine, Ref: Figure
7.30.
1 2
3 DUN00141
Figure 7.30 - Tracking Handset Sockets
3. Switch on the engine, Ref: Section 7.2.
4. Move the control levers (items 1 and 2) down to put the machine into tracking mode, Ref:
Figure 7.31.
2
1
DUN00151
Figure 7.31 - Tracking Control Levers
5. Press the ‘tracks start’ button (item 8) on the manual tracking handset, Ref: Figure 7.32.
» The Led Indicator on the handset will illuminate red. The safety siren will sound and the safety beacon
will flash. After a period of 10 seconds the LED indicator will illuminate green.
6. Press the track direction buttons (Items 1-4) on the manual tracking handset to manoeuvre
the machine, Ref: Figure 7.32.

684 Page 7-29
7. When the machine has been tracked to the desired location. Press the ‘tracks stop’ button
(Item 7) on the manual tracking handset, Ref: Figure 7.32.
1 2
3 4
5 6
7 0 I 8
TEREX R
9
DUN00004
Figure 7.32 - Manual Tracking Handset
5 Unused
6 Unused
7 Stop Tracks
8 Start Tracks
(b) Radio Control Handset (Optional)
 WARNING
The engine stop button on the radio control handset will only operate when the handset is in the
range of the receiver. If the battery has died in the remote the engine stop button will not stop
the engine. The engine stop button on the handset is not an emergency stop. In case of an
emergency, press an emergency stop button on the machine itself.
PROCEDURE
1. Remove the dummy plug from the socket (item 2) and place it in the socket (item 1) for
storage, Ref: Figure 7.30.
2. Insert the lead from the radio control box (item 3) into the socket (item 2), Ref: Figure 7.30.
4. Move the control levers (items 1 and 2) down to put the machine into tracking mode, Ref:
Figure 7.31.
5. Press and hold both of the radio start buttons items 9 & 0) on the radio handset, Ref: Figure
7.33.
» The LED Indicators on the handset will flash.
6. Release the radio start buttons.

Page 7-30 684
» The top LED indicator will illuminate green and the other two LEDs will be off.
7. Press the ‘tracks start’ button (Item 6) on the handset, Ref: Figure 7.33.
» The safety siren will sound and the safety beacon will flash until the ‘tracks stop’ button is pressed.
8. After a period of 10 second, press the track direction buttons (Items 1-4) on the radio handset
to manoeuvre the machine, Ref: Figure 7.33.
9. When the machine has been tracked to the desired location, press the ‘tracks stop’ button
(Item 5) on the manual tracking handset, Ref: Figure 7.33.
10. Press the stop button at the base of the handset to disable the radio control unit.
1 2
3 4
5
0 I 6
7 8
9 START START 0
TEREX R
DUN00008
Figure 7.33 - Radio Control Handset
1 Left track forward
2 Right track forward
3 Left track reverse
4 Right track reverse
5 Stop tracks
6 Start tracks
7 Unused
8 Unused
9 Radio start button
0 Radio start button

684 Page 7-31
(c) Fast Tracking - Constant Speed Engine

Constant Speed machines are fitted with a two-speed tracking system. To engage fast tracking,
turn the central dial (Ref. Item 3; Figure 7.34) to the right. The engine speed will not increase
during this process.
O I
3
DUN00149
Figure 7.34 - Constant Speed Control Panel

You cannot slew the machine with fast tracking engaged – only both tracks going forward or both
tracks reversing together will work with fast tracking engaged.

Page 7-32 684
7.6 Shut Down
(1) Stopping the Machine (3 Deck Machine)

NOTICE
Before stopping any parts of the machine, ensure that all material has been processed through
the machine. For normal closing down of the machine, DO NOT use the emergency stop buttons
[or, if fitted, radio remote control stop buttons] or by switching off the engine ignition to close down
the machine. The machine must be stopped in the correct sequence.
PROCEDURE
1. Observe all safety warnings.
2. Disengage each machine component in the correct order using the correct control levers
3. Operate the vibrating grid control lever (item 7) to stop the vibrating grid (if fitted).
4. Operate the control lever (item 1) to stop the belt feeder and 4th product conveyors.
5. Operate the fines conveyor and screenbox lever (item 3) to stop the fines conveyor and
screenbox.
6. Operate the main conveyor control lever (item 2) to stop the main conveyor and transfer
conveyor.
7. Operate the side conveyor control lever (item 5) to stop the side conveyors.
6 7
4 5
3
2
1
DUN00462

8. Use the throttle to gradually decrease the engine speed to minimum.
» In the case of a machine fitted with a Tier 3 Constant Speed engine, there is no throttle switch to
reduce the engine speed, therefore, let the engine run with no load (machine empty) for 3 to 5 minutes
9. Let the engine run for 3 to 5 minutes.
10. Turn the ignition key to the off position to stop the engine and remove the key.
11. Wait for at least 20 seconds before switching off the isolator switch.
12. Engage an emergency stop on the machine.
13. If carrying out maintenance on the machine implement the lockout and tagout procedure,
Ref: Chapter 8.

684 Page 7-33
(2) Stopping the Machine (2 Deck Machine)

NOTICE
Before stopping any parts of the machine, ensure that all material has been processed through
the machine. For normal closing down of the machine, DO NOT use the emergency stop buttons
[or, if fitted, radio remote control stop buttons] or by switching off the engine ignition to close down
the machine. The machine must be stopped in the correct sequence.
PROCEDURE
2. Disengage each machine component in the correct order using the correct control levers
3. Operate the vibrating grid control lever (item 7) to stop the vibrating grid (if fitted).
4. Operate the control lever (item 1) to stop the belt feeder.
5. Operate the fines conveyor and screenbox lever (item 3) to stop the fines conveyor and
screenbox.
6. Operate the main conveyor control lever (item 2) to stop the main conveyor.
7. Operate the side conveyor control levers (item 5) to stop the side conveyors.
6 7
4 5
3
2
1
DUN00462

8. Use the throttle to gradually decrease the engine speed to minimum.
» In the case of a machine fitted with a Tier 3 Constant Speed engine, there is no throttle switch to
reduce the engine speed, therefore, let the engine run with no load (machine empty) for 3 to 5 minutes
9. Let the engine run for 3 to 5 minutes.
11. Wait for at least 20 seconds before switching off the isolator switch.
Ref: Chapter 8.

Page 7-34 684
(3) Tier 4 Final Machine Shutdown
 WARNING
Do not hit the emergency stop during this process unless completely necessary.
The battery isolator should not be used to close down the control panel during this period.
NOTICE
There is a need for the urea pump to continue to operate after the engine is shut down, for this
reason the control panel will remain on after the key is turned off. This will always happen. It is
safe to walk away and leave the machine. There is a light fitted beside the battery isolator switch.
The isolator switch should not be turned off until the wait to disconnect light is off.
DUN01340
Figure 7.37 - Battery Wait to Disconnect Light (Item 1)
The engine ECU records every time the engine is isolated before the wait to disconnect light has
gone out.
PROCEDURE
2. Stop all hydraulic components in the correct sequence.
4. Let the engine idle with no load for 3 to 5 minutes.
5. Turn the ignition key (item 2) to the off position to stop the engine and remove the key, Ref:
Figure 7.38.
Ref: Chapter 8.

684 Page 7-35
1
OK
4 3 2
DUN00079
Figure 7.38 - MCU300 Control Panel
(4) Tier 3 Constant Speed Shutdown
PROCEDURE
2. Stop all hydraulic components in the correct sequence.
3. Let the engine run with no load for 3 to 5 minutes.
5. If the radio remote control, if fitted, has been in use switch it off by depressing the stop button
Ref: Chapter 8.

Page 7-36 684
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 Machine ..........................................8-2
(2) After Carrying out any Work on the Machine .............................................8-4
8.2 Emergency Stop .............................................................................................8-4
8.3 Restarting after Emergency Stop ...................................................................8-6
8.4 Testing Emergency Stops...............................................................................8-6

684 Page 8-1
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: Section 4.2) appear on a safety sign it indicates that
the machine must be switched off and locked out before any work is carried out.
 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 Machine
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 key, Ref: Figure 8.1.
O I
3
DUN00149
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.

Page 8-2 684
1 2
DUN00014
Figure 8.2 - Isolator Switch
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
DUN00015
Figure 8.3 - Isolator Switch Off, Locked and Tagged
6. Release stored energy from the system, such as hydraulic fluid under pressure, 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.)

684 Page 8-3
(2) After Carrying out any 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, turn the main power isolator switch to the ON position.
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

In an emergency situation stop the machine by pressing an emergency stop button on the machine.
 WARNING
Do not hit an emergency stop button unless it is an emergency. Repeated use of the emergency
stop button could cause damage to the engine. The engine ECU records every time an emeregency
stop button is used to stop the machine.
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 to stop the engine and machine, Ref: Figure 8.4, 8.5 and 8.6.
» The safety alarm will sound until it is acknowledged and cancelled.
2. Turn the ignition key to the off position as soon as possible, if safe to do so.
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.

Page 8-4 684
1 2
DUN00026
Figure 8.4 - Emergency Stop Locations Left Side
5 4
DUN00027
Figure 8.5 - Emergency Stop Locations Right Side
DUN00140
Figure 8.6 - Emergency Stop Location Front

684 Page 8-5
8.3 Restarting after Emergency Stop
 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, Ref: Chapter 7.
8.4 Testing Emergency Stops
PROCEDURE
2. Push in an emergency stop button.
» The engine will stop, the safety alarm will sound and alarm messages are shown on the display screen..
3. Acknowledge the alarm.
4. Re-set the emergency stop by pulling or twisting, depending on the type fitted.
5. Turn the ignition key to the ‘Off’ position.
6. Turn ignition key to the first position again.
7. Wait for the pre-start warning to complete.
8. Turn ignition key to start the engine again.
9. Repeat the procedure for all other emergency stops.

Page 8-6 684
Maintenance 9
Table of Content
9 Maintenance ............................................................................................... 9-4
9.2 Non Scheduled Maintenance .........................................................................9-5
(1) Hydraulic System .......................................................................................9-5
(a) Hydraulic Rams .....................................................................................9-5
(b) Hydraulic Fluids ....................................................................................9-5
(2) Filtration .....................................................................................................9-6
(a) Air Breather ...........................................................................................9-6
(b) Suction Line Breather ...........................................................................9-6
(c) Return Line Filter ..................................................................................9-6
(3) Oil Tank Pipes and Fittings ........................................................................9-6
(4) Tracks ........................................................................................................9-6
9.3 Maintenance Schedules .................................................................................9-7
(1) Regular Servicing ......................................................................................9-7
(2) Daily, Weekly and Monthly Checks............................................................9-7
(a) Daily Checks .........................................................................................9-8
(b) Weekly Checks .....................................................................................9-8
(c) Monthly Checks ....................................................................................9-8
(3) Daily or 10 Hour Maintenance Schedule ...................................................9-9
(a) General Maintenance ............................................................................9-9
(b) Conveyor Maintenance .........................................................................9-9
(c) Screen Maintenance .............................................................................9-9
(d) Hydraulic System Maintenance ............................................................9-9
(e) Track Maintenance................................................................................9-9
(f) Twin Deck Vibrating Grid Maintenance (If Fitted)................................9-10
(4) Weekly or 50 Hour Maintenance Schedule .............................................9-10
(a) General Maintenance ..........................................................................9-10
(b) Screen Unit Maintenance ....................................................................9-10
(c) Conveyor Maintenance .......................................................................9-10
(5) Monthly or 250 Hour Maintenance Schedule .......................................... 9-11
(b) Track Maintenance.............................................................................. 9-11
(c) Belt Feeder Maintenance .................................................................... 9-11
(6) 2 Monthly or 500 Hour Maintenance Schedule ....................................... 9-11
(a) Track Maintenance.............................................................................. 9-11
(b) Belt Feeder Maintenance .................................................................... 9-11
9.4 Engine Maintenance Schedules ...................................................................9-12
(a) When Required ...................................................................................9-12
(b) Daily ....................................................................................................9-12
(c) Weekly ................................................................................................9-12
684 Page 9-1
9 Maintenance
(d) Every 50 Service Hours or Monthly ....................................................9-12

(e) Every 250 Service Hours ....................................................................9-13
(f) Every 500 Service Hours ....................................................................9-13
(g) Every 500 Service Hours or 1 Year .....................................................9-13
(h) Every 1000 Service Hours ..................................................................9-13
(i) Every 1500 Service Hours ..................................................................9-13
(j) Every 2000 Service Hours ..................................................................9-13
(k) Every 3000 Service Hours ..................................................................9-14
(l) Every 3000 Service Hours or 2 Years .................................................9-14
(m) Every 4000 Service Hours ..................................................................9-14
(n) Every 6000 Service Hours or 3 Years .................................................9-14
(o) Every 12000 Service Hours or 6 Years ...............................................9-14
(a) General Maintenance when Required ................................................9-15
(b) Daily or 10 Hour Engine Maintenance ................................................9-15
(c) 50 Hour or Weekly Engine Maintenance.............................................9-15
(d) 250 Hour Engine Maintenance ...........................................................9-15
(e) 500 Hour Engine Maintenance ...........................................................9-16
(f) 1000 Hour Engine Maintenance .........................................................9-16
(g) 2000 Hour or Annually Engine Maintenance.......................................9-16
(h) 3000 Hour or 2 Year Engine Maintenance ..........................................9-17
9.5 Lubrication ....................................................................................................9-18
(1) Recommended Lubricants .......................................................................9-18
(2) Recommended Lubricants and Capacities ..............................................9-19
(3) Lubrication Points ....................................................................................9-19
(4) Greasing Schedule ..................................................................................9-21
9.6 Conveyor Maintenance ................................................................................9-22
(a) Changing the Feed Conveyor Gearbox Oil .........................................9-22
(b) Check and Clean Conveyor Belts .......................................................9-23
(c) Tensioning Conveyor Belts .................................................................9-24
(d) Aligning Conveyor Belts ......................................................................9-25
(1) Adjusting the Belt Feeder Scraper ...........................................................9-25
9.7 Screen Unit Maintenance .............................................................................9-26
(a) Moving Main Conveyor and Screenbox for Maintenance ...................9-26
(b) Raising Screenbox for Maintenance (Option Only) .............................9-28
(c) Changing the Top and Bottom Deck Screen Mesh .............................9-29
(d) Changing the Middle Deck Screen Cloth (3 Deck Only) .....................9-30
9.8 Servicing the Hydraulic System....................................................................9-31
(1) General ....................................................................................................9-31
(2) Hydraulic Fluids .......................................................................................9-31
(3) Filtration ...................................................................................................9-33
(a) Air breather: ........................................................................................9-34
(b) Suction Line Filter: ..............................................................................9-34
(c) Return Line Filter: ...............................................................................9-34
(4) Oil Tank, Pipes & Fittings .........................................................................9-35
(a) Checking and Refilling Hydraulic Fluid ...............................................9-35
(b) Changing Hydraulic Fluid ....................................................................9-36
Page 9-2 684
Maintenance 9
(c) Changing Suction Filters .....................................................................9-36

(d) Changing Return Line Filter ................................................................9-37
9.9 Tier 3 Engine Maintenance ..........................................................................9-38
(1) Changing Engine Filters & Oil .................................................................9-38
(a) Checking Engine Oil ...........................................................................9-38
(b) Changing Engine Oil & Filter ...............................................................9-39
(2) Changing Fuel Filters ..............................................................................9-40
(a) Draining the Fuel Filter Water Trap .....................................................9-40
(b) Changing Watertrap Filter ...................................................................9-41
(c) Changing the Fuel Filters ....................................................................9-42
9.10 Tier 4 Engine Maintenance ..........................................................................9-43
(1) Changing Engine Oil & Filters ................................................................9-43
(a) Checking Engine Oil ...........................................................................9-43
(b) Changing Engine Oil & Filter ...............................................................9-44
(2) Changing Fuel Filters ..............................................................................9-45
(a) Draining the Fuel Filter Water Trap .....................................................9-45
(b) Changing Watertrap Filter ...................................................................9-46
(c) Changing the Fuel Filters ....................................................................9-47
9.11 Servicing The DEF (Diesel Exhaust Fluid) System ......................................9-48
(a) DEF Tank Location ..............................................................................9-48
(b) Changing the Pump Main Filter ..........................................................9-49
(c) Changing the DEF Tank Filler Screen .................................................9-50
(d) Changing the DEF Manifold Filters .....................................................9-52
(e) DEF Tank Flush...................................................................................9-54
(f) Filling the DEF Tank ............................................................................9-55
9.12 Inspecting the Clean Emissions Module Supports .......................................9-57
9.13 Changing Air Filters ......................................................................................9-59
(1) Air Filtration..............................................................................................9-59
(2) Check Both Air Cleaner Elements ...........................................................9-59
(3) Changing the Air Cleaner Elements ........................................................9-60
9.14 Coolant System ............................................................................................9-61
(a) Engine Coolant Level ..........................................................................9-61
(b) Topping up Coolant Level ...................................................................9-62
9.15 Priming the Fuel System ..............................................................................9-63
(1) Electic Fuel Pump Priming.......................................................................9-63
(2) Manual Fuel Pump Priming .....................................................................9-65
(3) Fuel System Prime (Tier 3 CAT4.4 83KW Mechanical Engines) .............9-66
9.16 Fuel Level and Topup ...................................................................................9-68
9.17 Electrical Maintenance .................................................................................9-69
(a) Battery Removal and Installation ........................................................9-69
(b) Removal and Installation of Fuses ......................................................9-71
9.18 Servicing the Tracks .....................................................................................9-72
(a) Measuring Track Tension ....................................................................9-72
(b) Adjusting Track Tension ......................................................................9-73
(c) Refilling the Track Gearbox Oil ...........................................................9-74
(d) Cleaning the Tracks ............................................................................9-75
(e) Changing Track Gearbox Oil ...............................................................9-76
684 Page 9-3
9 Maintenance
9 Maintenance
Maintenance procedures in the maintenance section of this operations manual are intended to be
carried out by trained operators. You must satisfy yourself that you have received to the correct
training before attempting any procedure in the maintenance section, if you have any doubts do
not attempt any procedure and speak to your manager. More complex machine maintenance
that is not covered in the maintenance section of the operators manual must only be carried out
by fully trained service personnel who have taken part in specific maintenance training provided
by us or our approved dealer, please contact your local dealer for further details.
 WARNING
Observe the all safety advice given, as appropriate to the task(s) in hand.
Read the appropriate manual literature relevant to the operation in hand. Carry out a Risk
Assessment for all maintenance operations; have suitable lifting gear available for the weights
involved and all necessary tools/equipment ready for the task(s) in hand before starting work.
Terex Service Department is available for advice when required.
Keep clear of moving parts when trying to identify or isolate any unusual noises whilst the machine
is running.
Fit dismantled parts in the same location from which they were removed.
Ensure that the area surrounding the maintenance site is clear of any obstructions.
If arc welding work is involved in any maintenance operation, ensure that the current does not
pass through any bearings. The machinery must be fully isolated prior to any welding work.
Implement a lockout procedure by removing the engine isolation key and keeping on person
or take steps to guarantee integrity of electrical isolation whilst working on the machinery, as
appropriate to the installation.
The machinery should be completely emptied of material i.e. stone. Implement switch off, lockout
and tagout procedure before carrying out any maintenance

When performing maintenance tasks, always observe the local site safety rules or as provided
in the safety section of this manual.
The following section contains maintenance instructions as well as maintenance schedules for
normal operating conditions.
 WARNING
Practice Safe Maintenance
Always wear the appropriate protective clothing and use the correct tools and appliances.
Understand the service procedures before doing any work. Keep the area clean and dry.
Never lubricate, clean, service or adjust the machine whilst it is moving.
Keep hands, feet and clothing clear of power driven parts and in-running nip points.
Disengage all the power and operate controls to relieve pressure. Stop the engine and implement
lockout procedure. Isolate the electrical supply. Allow the machinery to cool.
Securely support any machine elements that must be raised for service work.

Page 9-4 684
Maintenance 9
Keep all parts in good condition and properly installed. Attend to damage immediately. Replace
worn or broken parts.
Remove any build up of stones, dust, grease, oil or other debris from the machine.
9.2 Non Scheduled Maintenance
(1) Hydraulic System

The Hydraulic system which used in the 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 1500 hours and
every 500 hours afterwards and replaced if necessary.
(a) Hydraulic Rams

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 cylinders Terex recommends that any cylinder exposed
for more than one week should have the rod coated with a good quality water resistant grease.
(b) Hydraulic Fluids

Hydraulic fluids play an important part in any hydraulic system. The hydraulic fluids transmit power
and 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.
The selected fluid should also prevent rot, corrosion, depress foaming, formation of sludge, gum
and varnish and retain its own stability, thereby reducing fluid replacement.
For best operating results it is strongly recommended that the hydraulic fluid used is selected
from the recommended range.
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.

684 Page 9-5
9 Maintenance
(2) Filtration
In order to maintain the hydraulic oil at its peak performance, three different types of filter are
fitted to the hydraulic system namely:
• Air breather
• Suction line filters
• Return line filters
(a) Air Breather

This combined unit, which also acts as a filter cap, filters the displacement of air.
The filter is rated at 40 microns, and is of non-replacement type. This must not be left off the
machine at any time.
(b) Suction Line Breather

5x125 microns filter, which are matched to pump capacity, are fitted inside the hydraulic tank
where they are readily accessible.
New filter element should be fitted at regular intervals (see routine maintenance schedule for
frequency).
(c) Return Line Filter

The 2 x 25 micron filters, which are fitted on the tank, remove 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.
(3) Oil Tank Pipes and 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.
(4) Tracks
The maintenance schedule for the tracks will depend greatly on the amount of travel a machine is
expected to do in its day to day operation and for that reason is not included in the following hourly
schedules. Before any attempt is made to move this machine refer to the Tracks Maintenance
section of this manual.

Page 9-6 684
Maintenance 9
9.3 Maintenance Schedules
(1) Regular Servicing
NOTICE
Failure to carry out scheduled maintenance or exercise due care may invalidate any warranty
that might apply.
Particular attention should be paid to institute a regime of strict adherence to routine regular
maintenance schedules from the start of operations. Keep records.
It is most important to keep the oil lubrication system in good order by only using an approved
lubricant of the correct grade for the prevailing conditions, changing at the appropriate intervals
and observing the filter change schedule using only the correct pattern of replacement part.
Make sure that all the various lubrication system protection devices (as detailed on the wiring
diagram) are operative and acted upon.
The hydraulic system as a whole should not be neglected from regular inspections for damage
or leaks.
(2) Daily, Weekly and Monthly Checks
 WARNING
It is imperative that the operator carries out regular and diligent checks before operating the
machine especially with operational safety in mind including (but not limited to) those listed below.
Additionally, the operator should always consider what particular safety hazards could occur at
specific operating sites and take steps to eliminate them before commencing work.

684 Page 9-7
9 Maintenance
(a) Daily Checks
PROCEDURE
1. Check that all guarding is complete and properly secured prior to start up. Also that any
warning signs are present and readable.
2. Check that walkways and railings are safe and secure.
3. Check that all the machine emergency stop buttons are operative.
4. Carry out a general inspection of the machinery to ascertain that nothing untoward is out of
place or damaged so as to cause a safety hazard.
5. Carry out the daily Lubrication and Servicing Schedule, Ref: Section 9.5(4).
6. Look for loose fixings and rectify. Check the security of nuts and bolts on the machine. Verify
there are no leaks of lubricating/hydraulic oils.
(b) Weekly Checks
PROCEDURE
1. Perform all checks on the daily check list.
2. Carry out the weekly Lubrication and Servicing Schedules, Ref: Section 9.3.
3. Ensure all hydraulic hoses and joints are free from leaks.
4. Check drive belts for damage, wear and fraying.
5. Clean away dust, dirt and grit from maintenance platforms and any moving parts.
6. Check conveyor belts for damage and fraying.
(c) Monthly Checks
PROCEDURE
1. Perform all checks on the daily and weekly check lists.
2. Visually examine the machine for wear and damage at regular intervals. Renew as necessary.
3. Check all drive belts are at the correct tension and for signs of wear. Renew as necessary.

Page 9-8 684
Maintenance 9
(3) Daily or 10 Hour Maintenance Schedule

(a) General Maintenance
Object Task Notes Signature
Check for material build up Check/Remove
Check all safety guards are in place Check/Replace
Check walkways and railings are Check. Insert and
safe and secure tighten any loose
bolts
Check for loose parts, missing nuts Tighten/Replace
and bolts
Check hydraulic hoses, rams and Tighten/Replace
pumps for leaks
Check hydraulic oil level on site Check/Refill
gauge
Check diesel level in fuel tank Check/Refill
(b) Conveyor Maintenance

Check conveyor belts for rips and Check/Repair
tears
Check belt tension Check/Tension
Check belt alignment Check/Align
Check all rollers are free moving Check/Free
and free from obstruction
(c) Screen Maintenance

Check mesh securing bolts are Check/Tighten
tight
Check meshes for wear and Check/Change
damage
Check for material build up Check/Remove
Check screen mesh tension Check/Tune
(d) Hydraulic System Maintenance

Check hydraulic oil level Check/Refill
Check hydraulic return line filter Check/Refill
indicator
(e) Track Maintenance

Check tension of tracks Check/Tension
Check tracks for oil leakage Check/Repair

684 Page 9-9
9 Maintenance
(f) Twin Deck Vibrating Grid Maintenance (If Fitted)

Check mesh and securing bolts are Check/Tighten
tight
Check meshes for wear Check/Change
(4) Weekly or 50 Hour Maintenance Schedule

Carry out daily or 10 hour maintenance
schedule
After first 50 hours replace return Replace
filters
Grease all bearings Grease
Drain the watertrap Drain
(b) Screen Unit Maintenance

Check grease filled bearings Grease
Check Labyrinth Seals Grease
(c) Conveyor Maintenance

Check tension of belt scrapers Check/Adjust/
Replace
Check tension of belt skirting Check/Adjust/
rubbers - no spillage Replace
Check for obstruction to drums Check/Remove
obstruction

Page 9-10 684
Maintenance 9
(5) Monthly or 250 Hour Maintenance Schedule

Drain the watertrap Drain
(b) Track Maintenance

After first 250 hours, change feeder Change
gearbox oil
(c) Belt Feeder Maintenance

After first 250 hours, change feeder Change
gearbox oil
(6) 2 Monthly or 500 Hour Maintenance Schedule

Adjust V belt tension Check/Adjust
Change hydraulic return filters Remove and
replace

Check hydraulic oil Carry out analysis
on oil and change
if required**
Change suction filters Remove and
replace
**Your local oil supplier will be able to analyze your hydraulic oil.

(a) Track Maintenance
Change track gearbox oil Drain and refill
(b) Belt Feeder Maintenance

Change the belt feeder gearbox oil Drain and refill

684 Page 9-11
9 Maintenance
9.4 Engine Maintenance Schedules

For further engine maintenance information, refer to the engine manufacturer‘s operation manual
supplied.
(1) Tier 4 Engine Maintenance Schedules

(a) When Required
Object Task Remarks Sign
Battery Replace
Battery or battery cable Disconnect
Engine Clean
Engine air cleaner element (Dual Clean/replace
element)
Engine air cleaner element (single Inspect/Replace
element)
Engine air cleaner element (single Replace
element)
Fuel System Prime
Severe service application Check
(b) Daily
Coolant system coolant level Check
Engine air cleaner service indicator Inspect
Engine air precleaner Check/Clean
Engine oil level Check
Fuel system primary filter / water Drain
separator
Walk around inspection
(c) Weekly
Hoses and clamps Inspect/Replace
(d) Every 50 Service Hours or Monthly

Fuel tank water and sediment Drain
Battery electrolyte Level Check

Page 9-12 684
Maintenance 9
(e) Every 250 Service Hours

Coolant system coolant sample (Level 1) Obtain
Engine oil sample Obtain
Engine oil and filter change Change*
* Due to the severe environment that most crushers and screens operate in the engine oil and
filter change should be every 250 hours of service. However if oil sampling and analysis is carried
out it is possible to increase the engine oil and filter change to every 500 hours of service.
(f) Every 500 Service Hours

Belt Inspect
Engine oil and filter Change
Fan clearance Check
(g) Every 500 Service Hours or 1 Year

Cooling System Supplemental Coolant Test/Add
Additive (SCA)
Engine air cleaner element (Dual Clean/Replace
Element)
Engine air cleaner element (Single Inspect/Replace
Element)
Engine air cleaner element (Single Replace
Element)
Fuel system primary filter (water Replace
separator) element
Fuel system secondary filter Replace
Radiator Clean
(h) Every 1000 Service Hours

Water pump Inspect
(i) Every 1500 Service Hours

Engine crankcase breather element Replace
(j) Every 2000 Service Hours

Aftercooler Core Inspect
Engine Mounts Inspect
Starting Motor Inspect
Turbocharger Inspect
Hydraulic Oil Change

684 Page 9-13
9 Maintenance
(k) Every 3000 Service Hours

Alternator Inspect
Alternator and Fan Belts Replace
Belt Tensioner Inspect
Radiator Pressure Cap Clean/Replace
(l) Every 3000 Service Hours or 2 Years

Cooling system coolant (DEAC) Change
(m) Every 4000 Service Hours

Aftercooler core Clean/Test
(n) Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) Add
(o) Every 12000 Service Hours or 6 Years

Cooling System Coolant (ELC) Change

Page 9-14 684
Maintenance 9
(2) Tier 3 Engine Maintenance Schedules

(a) General Maintenance when Required
Battery Replace
Engine Clean
Engine air cleaner element Replace
Fuel system Prime
(b) Daily or 10 Hour Engine Maintenance

Inspect/ Adjust/
Alternator belt Replace
Cooling system coolant level Check
Driven equipment Check
Engine air cleaner service indicator Inspect
Engine air precleaner Check/ Clean
Engine oil level Check
Fuel system primary filter/water
separator Drain
Hoses and clamps Inspect/ Replace
Inspect/ Adjust/
V-belts Replace
(c) 50 Hour or Weekly Engine Maintenance

Check fuel tank for water and Drain
sediments
Battery electrolyte level Check
(d) 250 Hour Engine Maintenance

Cooling system coolant sample Obtain
(Level 1)
Engine oil sample Obtain

684 Page 9-15
9 Maintenance
(e) 500 Hour Engine Maintenance

INITIAL 500 HOURS
Engine valve lash Inspect/Adjust
EVERY 500 HOURS

Fan clearance Check
Inspect/adjust/
V-belts replace
EVERY 500 HOURS OR 2 MONTHS

Crankcase Breather (Canister) Replace
EVERY 500 HOURS OR 1 YEAR

Cooling system supplemental coolant Test/add
additive (SCA)
Engine air cleaner element (Dual Clean/replace
element)
Engine air cleaner element (Single Replace
element)
Fuel system primary filter (water Replace
separator) element
Fuel system secondary filter Replace
Radiator Clean
(f) 1000 Hour Engine Maintenance

Engine valve lash Inspect/ adjust
(g) 2000 Hour or Annually Engine Maintenance

Aftercooler core Inspect
Belt tensioner Inspect
Exhaust manifold Inspect
Starting motor Inspect
Turbocharger Inspect
Water pump Inspect
Alternator Inspect
Engine mounts Inspect
Cooling system coolant sample (level 2) Obtain
Hydraulic Oil Change

Page 9-16 684
Maintenance 9
(h) 3000 Hour or 2 Year Engine Maintenance

Alternator belt Inspect/ Adjust/
Replace
Cooling system coolant Change
Cooling system water temperature Replace
regulator

684 Page 9-17
9 Maintenance
9.5 Lubrication
It is important that a strict routine of regular servicing is undertaken from the start of operation
of the machine.
Regular checks on fluids and the lubrication of the machine, in accordance with the schedule,
is essential.
NOTICE
Do not mix greases. The blend can have a lower specification than the individual greases and
can lead to premature bearing failure. USE ONE BRAND ONLY. To prevent contamination of the
grease, wipe the grease nipples clean before applying the grease gun.
It is the operators responsibility to ensure that all bearings are greased with the correct quantity
and type of grease at the correct intervals specified.
(1) Recommended Lubricants
NOTICE
The feeder unit gearbox does NOT use the same type of gear oil as the track gearbox.
A different type of grease is used for lubricating the screen bearings than that used on the rest
of the machine. Always use the correct grease as specified.
The coolant used in all machines is a 50 - 50 mix of coolant to water. Always check if coolant
supplied is premixed or in concentrate form.
Table 9.1 - Recommended Lubricants

Type Special Screen Grease Screen Grease for Hot General Purpose
Materials Grease
BP ENERGREASE LSEP2 - ENERGREASE L21M
OTAL MULTIS EP2 - MULTIS MS2
DUCKHAMS ADAMAX LEP2 - ADAMAX LM2
CASTROL SPHEEROL EPL2 - SPHEEROL AP3
SHELL ALVANIA EP2 LIPLEX EP2 ALVANIA R3
ESSO BECON EP2 UNIREX EP2 BECON Q2
TEXACO MULTIFAK EP2 - MOLYTEX 2
CHEVRON DURALITH EP2 - -
GULF GULFCROWN EP2 SUPERCROWN EP2 -
MOBIL MOBILUX EP2 MOBILGREASE HP2 MOBILGREASE MP
CENTURY REGULUSA2EP LUPLEX M2 REGULUS A3
F.A.G. ARCANOL L135 - ARCANOL L71
ROCOL SAPPHIRE BG 151 -
OPTIMOL LONGTIME PD - -
OMEGA - 85 -
Table 9.1 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.

Page 9-18 684
Maintenance 9
(2) Recommended Lubricants and Capacities

Volume International Spec Recommended
Fuel 345L (76Gal) DIN51 601
Engine Oil (C4.4) 7.3L (1.61 Gals) API CDCF CAT DEO15w/ 40
Engine Oil (2013) 14L (3.1 Gals) API CDCF Maxol Optima15w /40
Coolant (C4.4) 11.4L (2.5 Gals) BS 6580-1992 CAT ELC
Coolant (2013) 13.6L (3 Gals) BS 6580-1992 Maxol C200
Hydraulic Oil 564L (124 Gals) ISO 46 Maxol Hydramax 46
Hydraulic Oil ** 564L (124 Gals) ISO 100 HyRenolin CL100
Feeder Gearbox Oil 1.3L (0.26 Gals) ANSI/AGMA 9005-D94 Shell Omala 150
Track Gearbox Oil 5L (1.3 Gals) DIN51 517-3 Renogear SG320
General Grease DIN51 826 Maxol EP2 (Brown)
Screen Bearing ISO 3448 Maxol Heavy Duty
Grease Synthetic 220
Vibrating Grid Grease ISO 3448 Maxol Heavy Duty
Synthetic 220
**Where ambient temperature is above 30°C.
(3) Lubrication Points

There are a number of lubrication points on the machine, Ref: Figure 9.1 and Figure 9.2.
3
4
5
6
7
8
9
10
11
12
13
12 DUN00053
Figure 9.1 - Lubrication Points Right Hand Side

684 Page 9-19
9 Maintenance
6 8 14
15
16
15 14
10
DUN00054
Figure 9.2 - Lubrication Points Left hand Side
1 Main conveyor drive drum

2 Screen box bearings
3 Fines conveyor drive drum
4 Fines conveyor drive drum
5 Fines conveyor idler drum
6 Fines conveyor idler drum
7 Side conveyor drive drum
8 Side conveyor idler drum
9 Transfer conveyor idler drum (3 Deck Only)
10 Transfer conveyor drive drum (3 Deck Only)
11 Main conveyor ider drum
12 Belt feeder drive and idler drum
13 Vibrating grid (option)
14 4th product conveyor idler drum (3 Deck Only)
15 4th product conveyor swivel support (3 Deck Only)

Page 9-20 684
Maintenance 9
(4) Greasing Schedule

Table 9.2 lists the greasing schedule for the machine. The item number in the table Refers to the
location of this components lubrication points, Ref: Figure 9.1 and Figure 9.2.
Table 9.2 - Greasing Schedule

Item Component Frequency Quantity
1 Main conveyor drive drum 50Hrs 4 grams/ 4 pumps
2 Screenbox bearings 50Hrs 16 grams/ 16 pumps
3 Fines conveyor drive drum 50Hrs 4 grams/ 4 pumps
4 Fines conveyor drive drum 50Hrs 4 grams/ 4 pumps
5 Fines conveyor idler drum 50Hrs 4 grams/ 4 pumps
6 Fines conveyor idler drum 50Hrs 4 grams/ 4 pumps
7 Side conveyor drive drum 50Hrs 4 grams/ 4 pumps
8 Side conveyor idler drum 50Hrs 4 grams/ 4 pumps
9 Transfer conveyor idler drum 50Hrs 4 grams/ 4 pumps
10 Transfer conveyor drive drum 50Hrs 4 grams/ 4 pumps
11 Main conveyor idler drum 50Hrs 4 grams/ 4 pumps
12 Belt feeder drive and idler drum 50Hrs 4 grams/ 4 pumps
13 Vibrating grid (option) 50Hrs 16 grams/ 16 pumps
14 4th product conveyor drive 50Hrs 4 grams/ 4 pumps
drum
15 4th product conveyor Idler 50Hrs 4 grams/ 4 pumps
Drum (3 Deck Only)
16 4th product conveyor Swivel 250Hrs 4 grams/ 4 pumps
Support (3 Deck Only)
*Each grease gun will put out a differing amount. Check greasing equipment before use.

684 Page 9-21
9 Maintenance
9.6 Conveyor Maintenance

(a) Changing the Feed Conveyor Gearbox Oil
NOTICE
Do not overfill the gearbox.
PROCEDURE
DUN00030
Figure 9.3 - Belt Feeder Gearbox
1. Remove the fill plug to allow air into the gearbox to allow it to drain
2. Remove the drain plug and drain the oil to an external container large enough to hold all of
the oil.
3. Replace the drain plug.
4. Refill the gearbox through the filler plug with the exact amount of oil required.
5. Replace the filler plug.
6. Close the beltfeeder gearbox cover guard.

Page 9-22 684
Maintenance 9
(b) Check and Clean Conveyor Belts
 WARNING
Do not carry out any work on the machine until it has been shut down and the lockout and tag
out procedure has been carried out. Do not reach into moving conveyors. Ensure that eyes are
protected by wearing safety glasses.
Do not unfasten or remove any guard while the machine is running or start the machine while a
guard is unfastened or removed.
If any damage to the belt is found, do not operate the machine until it is repaired or replaced
entirely by your local Terex dealer.
PROCEDURE
1. Stop the machine and implement the lockout and tagout procedure.
2. Open the guard doors where necessary.
3. Clean the conveyor belts using a high pressure hose.
4. Check the belts for cuts, tears, rips or any other physical damage.

684 Page 9-23
9 Maintenance
(c) Tensioning Conveyor Belts
 WARNING
Do not reach into moving conveyors. Wear personal protective equipment.
NOTICE
Do not over tension the conveyor belts as this will damage the drum bearings.
PROCEDURE
3. Start the conveyor to be tensioned.
4. Tighten the belts by adjusting both belt adjusters evenly, 2 turns at a time until slippage stops,
Ref: Figure 9.4 and Figure 9.5.
1 2 DUN00143
Figure 9.4 - Feeder Conveyor Tensioners
DUN00009
Figure 9.5 - Conveyor Belt Tensioners

Page 9-24 684
Maintenance 9
(d) Aligning Conveyor Belts
PROCEDURE
3. Start the conveyor to be aligned.
4. Observe the conveyor and determine which side the conveyor is ‘tracking off’.
5. If the conveyor is tracking off to the right side, operate the right side adjuster one turn at a
time until the belt tracks correctly.
6. If the conveyor is tracking off to the left side, operate the left side adjuster one turn at a time
until the belt tracks correctly.
(1) Adjusting the Belt Feeder Scraper
PROCEDURE
1. Switch off the machine and implement the lockout and tagout procedure..
2. Open the side guard door on the left hand side of the machine.
3. Remove the adjuster spanner by removing the securing nut.
4. To tension the scraper firstly loosen the bolts securing the rosta on both sides of the scraper.
Access can be gained to the scraper rosta from underneath the beltfeeder.
5. Fit the spanner over the rosta and tension the scraper. When tensioned retighten the bolt
to hold rosta in position.
6. Repeat for the rosta on the other end of the scraper.
7. Replace the Spanner and ensure all guards have been closed

684 Page 9-25
9 Maintenance
9.7 Screen Unit Maintenance

Maintenance of your sreenbox is minimal, however it is recommended to carry out the following
procedures to increase its effectiveness and prolong is lifespan.
After the initial 10 hours of operation, Carry out the following procedure.
 WARNING
Ensure all personnel are clear of the machine. Switch off the machine and implement the lockout
and tagout procedure before carrying out any maintenance on the machine
PROCEDURE
1. Visually check all the screen meshes for clogging.
2. Check and tension the clamping bolts where necessary.
3. Check for wear and replace where necessary.
4. Screen cloths should be re-tensioned after 2 hours, 8 hours,16 hours and 40 hours after
replacement.
(a) Moving Main Conveyor and Screenbox for Maintenance

The following procedure must be carried out to ensure that the main conveyor does not move
while maintenance is being carried out on the screenbox.
 WARNING
Hazardous nip points. Keep clear of moving parts. Ensure that all personnel are clear of the
machine.
Fall hazard. Ensure walkways are fully secure prior to mounting the machine.
PROCEDURE
1. Lower the screenbox to the horizontal position so that the main conveyor rests on the slider
pads of the 4th product conveyor frame.

Page 9-26 684
Maintenance 9
2. Slide the main conveyor forward, towards the screenbox, so that the holes in the main
conveyor line up with the holes in the support on the 4th product conveyor frame (item 1),
Ref: Figure 9.6.
1
2
DUN00148
Figure 9.6 - Main Conveyor Support
3. Insert pins (item 2) to hold the main conveyor in position, Ref: Figure 9.6.
4. Switch off the machine and implement the lockout and tagout procedure before carrying out
any maintenance on the machine.

684 Page 9-27
9 Maintenance
(b) Raising Screenbox for Maintenance (Option Only)

Optional double control bank for the screenbox which allows the screenbox to be raised further
to allow more room for changing the top deck mesh.
 WARNING
Hazardous nip points. Keep clear of moving parts.
Fall hazard. Ensure walkways are fully secure prior to mounting the machine.
PROCEDURE
1. Remove pin from the screenbox telescopic (item 2), Ref: Figure 9.7.
2. Move the lever (item 1) to raise the screenbox to allow more room for changing the top deck
screen mesh, Ref: Figure 9.7.
DUN00147
Figure 9.7 - Screenbox Telescopic (Optional)
3. Insert pin into the screenbox telescopic (item 2), Ref: Figure 9.7.
4. Switch off the machine and implement the lockout and tagout procedure before carrying out
any maintenance on the machine.

Page 9-28 684
Maintenance 9
(c) Changing the Top and Bottom Deck Screen Mesh
PROCEDURE
2. Raise the screenbox to its highest angle when changing the meshes to allow greater access
between the main conveyor and the screenbox.
3. Shut down the machine and implement the tagout and lockout procedure.
4. Remove the wedges (item 4) holding the mesh clamps in position, Ref: Figure 9.8.
4
3
2
1
DUN00034
Figure 9.8 - Screen Mesh Clamps
5. Remove the clamps.

6. Remove the screen mesh.
7. Clean the screenbox from material especially along the sides where the mesh is clamped.
8. Check and ensure that the cushion rubbers are in good condition and replace if required.
9. Put the new mesh on the screen and centralise it taking care not to let it slip.
10. Place one of the clamps on the screen and fix, starting with the bottom wedge and tighten
loosely.
11. Now place the clamp on other side and fix in position in similar fashion.
12. When tightening, move from one side to the other following the letters in the diagram
13. Start again at the bottom wedge and re-tighten.

684 Page 9-29
9 Maintenance
(d) Changing the Middle Deck Screen Cloth (3 Deck Only)
PROCEDURE
1. Shut down the machine and implement the tagout and lockout procedure.
2. Remove the screen box covers (item 2) by loosening the nuts (item 1), Ref: Figure 9.9.
4
3
2
1
DUN00034
Figure 9.9 - Screen Mesh Clamps
3. Remove the wedges (item 3) holding the mesh clamps in position.

4. Remove the clamps.
5. Remove the screen mesh.
6. Clean the screenbox from material especially along the sides where the mesh is clamped.
7. Check and ensure that the cushion rubbers are in good condition and replace if required.
8. Put the new mesh on the screen and centralise it taking care not to let it slip.
9. Place one of the clamps on the screen and fix, starting with the bottom wedge and tighten
loosely.
10. Now place the clamp on other side and fix in position in similar fashion.
11. Repeat steps 9 and 10 until all of the clamps are tightened.
12. Start again at the bottom wedge and re-tighten.

Page 9-30 684
Maintenance 9
9.8 Servicing the Hydraulic System
(1) General
 WARNING
Before maintenance you must read and understand the safety sections in this manual.
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.
Regular monitoring of the gauges on the filters is essential. 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 1500 hours and
every 500 hours afterwards and replaced if necessary.
(2) Hydraulic Fluids
 WARNING
Before maintenance you must read and understand the safety sections in this manual.
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
• Prevent formation of sludge, gum and varnish

684 Page 9-31
9 Maintenance
• 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 Section 9.5.1 “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.

Page 9-32 684
Maintenance 9
(3) Filtration
 DANGER
High pressure hydraulic fluid can penetrate the skin causing serious injuries.
In order to maintain the hydraulic oil at its peak performance, three different types of filter are
fitted to the hydraulic system, namely:
1 Air breather (Item 1, Ref: Figure 9.10 & Figure 9.11)
Figure 9.10 - Air Breather
Figure 9.11 - Air Breather (Tier 4)
1 Suction line filters (Item 1, Ref: Figure 9.12)

684 Page 9-33
9 Maintenance
Figure 9.12 - Suction Line Filter
1 Return line filters (Item 1, Ref: Figure 9.13)
Figure 9.13 - Return Line Filter
(a) Air breather:

This combined unit, which also acts as a filter cap, filters the displacement of air. The filter is rated
at 40 microns, and is of non-replacement type. This must not be left off the machine at any time.
(b) Suction Line Filter:

4 X 125 microns filter, which are matched to pump capacity, are fitted inside the hydraulic tank
where they are readily accessible. (There are 3 x 125 microns on Tier 4 machines). New filter
element should be fitted at regular intervals (see routine maintenance schedule for frequency).
(c) Return Line Filter:

The 2 x 25 micron filters, which are fitted on the tank, remove any tiny particles which can cause
damage to the pumps and motors etc. There is 1 x 25 micron filter on Tier 4 machines. The
filter element gauges should be checked regularly and changed in accordance with the routine
maintenance schedule.

Page 9-34 684
Maintenance 9
(4) Oil Tank, Pipes & Fittings
 DANGER
High pressure hydraulic fluid can penetrate the skin causing serious injuries.
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.
5 2
3
4
DUN00032
Figure 9.14 - Hydraulic Tank
(a) Checking and Refilling Hydraulic Fluid
PROCEDURE
1. Turn engine off and return all control levers to the neutral position.
2. Check the hydraulic fluid level on the gauge (item 3) on the side of the hydraulic tank, Ref:
Figure 9.14.
3. Clean the area around the filler cap.
4. Refill the tank through the filler cap (item 2) until the oil is between the minimum and maximum
levels on the tank level gauge (item 3).

684 Page 9-35
9 Maintenance
(b) Changing Hydraulic Fluid
PROCEDURE
1. Return all hydraulic cylinders to their closed position to return as much hydraulic oil back to
the tank as possible.
3. Use the hydraulic tank drain valve on the right hand side of the tank and drain the fluid to an
external container large enough to hold all of the fluid.
4. Remove the inspection plate (item 1) on the hydraulic tank and flush the tank out with hydraulic
fluid to remove dirt or other particles.
5. Refill the tank through the filler cap (item 2) until the oil is between the minimum and maximum
levels on the tank level gauge (item 3).
6. Run the machine and operate hydraulic equipment to circulate oil.
7. Stop the machine and top up the hydraulic system.
(c) Changing Suction Filters

It is strongly recommended to change the suction filter when the hydraulic oil is being changed.
PROCEDURE
2. Open the filler cap (item 2) to relieve any pressure inside the tank.
3. Remove the bolts holding the inspection plate (item 1) down.
4. Lift off the inspection plate.
5. Unscrew the filters from the internal suction pipes and replace with new filters.
6. Hand tighten filers.
7. Replace inspection covers and filler cap.

Page 9-36 684
Maintenance 9
(d) Changing Return Line Filter

It is strongly recommended to change the return filter elements when the hydraulic oil is being
changed.
PROCEDURE
2. Run the engine at full speed and ensure all the hydraulic equipment is operating.
3. Check the return line filter blockage indicator. The filer needs to be changed when the
blockage indicator points to red.
5. Open the filler cap slowly to release any pressure inside the tank.
6. Clean the area around the return filters to prevent dirt contaminating the hydraulic
oil when the filters are removed.
7. Loosen the bolts (item 1) on the top of the filter plate, Ref: Figure 9.15.
1
2
DUN00020
Figure 9.15 - Return Line Filter
8. Rotate the top plate (item 2) slightly to remove.

9. Remove the filter element by pulling the removal handles.
10. Dispose of the old filter safely.
11. Insert the new filter element.
12. Replace the top plate (item 2).
13. Tighten the bolts on the top of the filter plate (item 1).

684 Page 9-37
9 Maintenance
9.9 Tier 3 Engine Maintenance
(1) Changing Engine Filters & Oil

(See the engine Operators Manual for more detailed information regarding the Engine)
 CAUTION
Hot surfaces. Beware of burns from hot oil.
(a) Checking Engine Oil
PROCEDURE
1. Turn off the engine. Open the engine inspection door (Item 1, Ref: Figure 9.16).
1
DUN01191
Figure 9.16 - Engine Inspection Door
2. Remove dipstick (Item 1, Ref: Figure 9.17) from the engine and clean. Re-insert the dipstick
fully.
1
2
DUN01197
Figure 9.17 - Engine view through inspection door
3. Remove the dipstick again and observe that the oil level is between the minimum and
maximum levels. If the level is below the minimum mark oil has to be added through the
filler cap (Item 2, Ref: Figure 9.17).

Page 9-38 684
Maintenance 9
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 & Filter
PROCEDURE
1. Operate the engine to ensure the oil is warm, this enables the oil to flow more easily, also
when the oil is cool waste particles settle on the bottom of the oil pan and will not drain off.
2. Stop the engine and open the filler cap (Item 2, Ref: Figure 9.18).
3. Remove the drain plug located underneath the engine and drain the oil to an external container
large enough to hold all the oil.
1
DUN01198
Figure 9.18 - Engine Oil Filter
4. When all the oil has drained off replace the drain plug.
5. Loosen the Filter (Item 1, Ref: Figure 9.18) and dispose off properly. Replace the new filter
and hand tighten.
6. Refill the engine with oil and dip the engine.

684 Page 9-39
9 Maintenance
(2) Changing Fuel Filters

(a) Draining the Fuel Filter Water Trap
 WARNING
Lock-out machine.
Wear personal protective equipment
Diesel fuel is highly flammable.
Do not smoke or carry out maintenance on the fuel system near open flame or sources of sparks,
such as welding equipment, etc.
PROCEDURE
3. Unscrew the drain bung (Item 1, Ref; Figure 9.20) at the bottom of the water trap (item 2,
Ref; Figure 9.19) and allow the water to drain out into a suitable container.
1
2
DUN01192
Figure 9.19 - Engine Oil Filters
4. Tighten the drain plug when pure diesel starts to come out.
5. Clean up any spilt diesel.

Page 9-40 684
Maintenance 9
1
DUN01201
Figure 9.20 - Water Trap
(b) Changing Watertrap Filter

To change the watertrap filter element (Item 2, Ref: Figure 9.19) follow the procedure outlined.
PROCEDURE
1. Stop the machine and turn the fuel supply off.
2. Remove the bleed.
3. Remove the filter& watertrap bowl.
4. Remove the watertrap bowl from the filter element.
5. Oil the watertrap bowl.
6. Attach new element to watertrap bowl.
7. Oil top of filter element.
8. Attach the filter element.
9. Prime the fuel system to fill the element and watertrap, and to remove air from the system.
(Refer to section 9.15 for more information on how to do this).
10. Replace the bleed.

684 Page 9-41
9 Maintenance
(c) Changing the Fuel Filters
 WARNING
Lock-out machine.
NOTICE
Fill up the new fuel filter with diesel. This will make the restart of the machine easier.
PROCEDURE
2. Unscrew the fuel filter (Item 1, Ref; Figure 9.21)
DUN01200
Figure 9.21 - Engine Fuel Filters
3. Fill the new filters with diesel and fit into position.
4. Tighten the new fuel filter and o-ring.

Page 9-42 684
Maintenance 9
9.10 Tier 4 Engine Maintenance
(1) Changing Engine Oil & Filters

(See the engine Operators Manual for more detailed information regarding the Engine)
 CAUTION
Hot surfaces. Beware of burns from hot oil.
(a) Checking Engine Oil
PROCEDURE
1
DUN01191
Figure 9.22 - Engine Inspection Door
2. Remove dipstick (Item 1, Ref: Figure 9.23) from the engine and clean. Re-insert the dipstick
fully.
DUN01193
Figure 9.23 - Engine Oil Filler Cap & Dipstick

684 Page 9-43
9 Maintenance
3. Remove the dipstick again and observe that the oil level is between the minimum and
maximum levels. If the level is below the minimum mark oil has to be added through the
filler cap (Item 2, Ref: Figure 9.23) .
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 & Filter
PROCEDURE
1. Operate the engine to ensure the oil is warm, this enables the oil to flow more easily, also
when the oil is cool waste particles settle on the bottom of the oil pan and will not drain off.
2. Stop the engine and open the filler cap (Item 2, Ref: Figure 9.24).
3. Remove the drain plug located underneath the engine and drain the oil to an external container
large enough to hold all the oil.
1 DUN01194
Figure 9.24 - Engine Oil Filter
4. When all the oil has drained off replace the drain plug.
5. Loosen the Filter (Item 1, Ref: Figure 9.24) and dispose off properly. Replace the new filter
and hand tighten.
6. Refill the engine with oil and dip the engine.

Page 9-44 684
Maintenance 9
(2) Changing Fuel Filters

(a) Draining the Fuel Filter Water Trap
 WARNING
Lock-out machine.
Never remove filler cap or refuel, with the engine running.
Never add gasoline or any other fuel mixes to diesel because of increased fire or explosion risks.
PROCEDURE
3. Unscrew the drain bung (Item 1, Ref; Figure 9.26) at the bottom of the water trap (item 2,
Ref; Figure 9.25) and allow the water to drain out into a suitable container.
1
2
DUN01192
Figure 9.25 - Engine Oil Filters
4. Tighten the drain plug when pure diesel starts to come out.
5. Clean up any spilt diesel.

684 Page 9-45
9 Maintenance
1
DUN01201
Figure 9.26 - Water Trap
(b) Changing Watertrap Filter

To change the watertrap filter element (Item 2, Ref: Figure 9.25) follow the procedure outlined.
PROCEDURE
1. Stop the machine and turn the fuel supply off.
2. Remove the bleed.
3. Remove the filter& watertrap bowl.
4. Remove the watertrap bowl from the filter element.
5. Oil the watertrap bowl.
6. Attach new element to watertrap bowl.
7. Oil top of filter element.
8. Attach the filter element.
9. Prime the fuel system to fill the element and watertrap, and to remove air from the system.
(Refer to section 9.15 for more information on how to do this).
10. Replace the bleed.

Page 9-46 684
Maintenance 9
(c) Changing the Fuel Filters
 WARNING
Lock-out machine.
Never remove filler cap or refuel, with the engine running.
Never add gasoline or any other fuel mixes to diesel because of increased fire or explosion risks.
NOTICE
Fill up the new fuel filter with diesel. This will make the restart of the machine easier.
PROCEDURE
2. Unscrew the fuel filters (Item 1, Ref; Figure 9.27)
DUN01195
Figure 9.27 - Engine Fuel Filters
3. Fill the new filters with diesel and fit into position.
4. Tighten the new fuel filter and o-ring.

684 Page 9-47
9 Maintenance
9.11 Servicing The DEF (Diesel Exhaust Fluid) System
 WARNING
Switch off the machine and implement the lockout and tagout procedure.
Hot Surface Hazard
Beware of hot DEF and surfaces.
DEF is corrosive and therefore must be stored in tanks constructed of approved materials. (Refer
to engine manual for more details)
Care should be taken when dispensing DEF. Spills should be cleaned immediately. All surfaces
should be wiped clean and rinsed with water.
DEF that has been split will crystallize when the water within the liquid evaporates. Split DEF will
attack paint and metal. If DEF is split, wash the area with water immediately.
Caution should be used when dispensing DEF near an engine that has recently been running.
Spilling DEF onto hot components may cause the release of ammonia vapors. Do not breathe
ammonia vapors. Do not clean up any spills with bleach.
NOTICE
It is recommended that filter elements are not cleaned or reused but replaced with new items.
Do not run the engine with the filter elements removed.
Do not use agricultural grade urea solutions. Do not use any fluids that do not meet ISO 22241-1
requirements in SCR emissions reduction systems. Use of these Fluids can result in numerous
problems including damage to SCR equipment and a reduction in NOx conversion efficiency.
(a) DEF Tank Location
1
DUN01202
Figure 9.28 - Location of the DEF tank - Item 1

Page 9-48 684
Maintenance 9
(b) Changing the Pump Main Filter
 WARNING
Hot Surface Hazard
NOTICE
PROCEDURE
DUN01318
Figure 9.29 - Pump Main Filter Location - Item 1
1. Ensure that the area around the Diesel Exhaust Fluid (DEF) filter (Item 1) is clean and free
from dirt. The DEF filter threaded cap and the filter element area combined assembly. Ref
Figure 9.29.
DUN01389
Figure 9.30 - Pump Main Filter Parts

684 Page 9-49
9 Maintenance
2. Remove the protective cover (Item 1). Remove the DEF filter assembly and discard the filter
assembly. Ref Figure 9.30.
3. Install a new DEF filter assembly into DEF pumphousing (Item 2).
4. Tighten filter assembly to a torque of 14N m (124lbin). Install the protective cover.
5. Turning on the power will automatically prime the DEF system.
(c) Changing the DEF Tank Filler Screen
 WARNING
Hot Surface Hazard
NOTICE
PROCEDURE
DUN01327
Figure 9.31 - DEF Tank Remote Filter location
1. Ensure that the area around the DEF filler cap is clean and free from dirt (Item 1; Ref. Figure
9.31).

Page 9-50 684
Maintenance 9
Figure 9.32 - DEF Tank Remote Filter parts
2. Unscrew the filler cap (Item 1; Ref. Figure 9.32), and unclip the chain (Item 2).
3. Remove the 3 screws holding the filter in place (Item 3).
4. Remove the filter (Item 4) and insert the new one.
» Depending on the condition of the filter, it can be cleaned in water and dried out using compressed
air. If the filter screen cannot be cleaned or the filter screen is damaged, then the filter screen must
be replaced.
5. Insert the 3 screws to secure the filter in place.
6. Reattach the filler cap chain and screw the filler cap in place.

684 Page 9-51
9 Maintenance
(d) Changing the DEF Manifold Filters
 WARNING
Hot Surface Hazard
NOTICE
If contamination of the Diesel Exhaust Fluid (DEF) is suspected, the DEF tank (3) will need to be
drained and the DEF tank flushed.
PROCEDURE
2
DUN01330
Figure 9.33 - DEF Tank Cover
1. Remove the 2 bolts (Item 1; Ref. Figure 9.33) securing the DEF Tank cover in place and
remove the cover (Item 1; Ref. Figure 9.33).
DUN01329
Figure 9.34 - DEF Manifold Filter
2. Unclip the hoses and the sensor from the top of the DEF Manifold (Item 1; Ref. Figure 9.34).

Page 9-52 684
Maintenance 9
3. Remove the 2 screws securing the Manifold to the top of the tank and lift it out.
Figure 9.35 - DEF Manifold Filter
4. Remove the filter (Item 1; Ref. Figure 9.35) and replace with a new one.
5. Insert the Manifold back in to the tank and secure in place with the 2 screws.
6. Reattach all the hoses and the sensor.

684 Page 9-53
9 Maintenance
(e) DEF Tank Flush
 WARNING
Hot Surface Hazard
NOTICE
Ensure that the vessel that will be used is large enough to collect the fluid to be drained.
Dispose of the drained fluid in accordance with local regulations.
PROCEDURE
1
DUN01332
Figure 9.36 - DEF Drain Plug
1. Ensure that the purging of the DEF system has been completed.
2. Position a suitable vessel below the drain plug (Item 3; Ref. Figure 9.36). Remove the tank
filler cap.
3. Remove the drain plug and allow the fluid to drain.
4. Remove the Manifold (DEFHeater) (Item 1; Ref. Figure 9.36) after draining the fluid.

Page 9-54 684
Maintenance 9
5. Install the drain plug (Item 3). Tighten the drain plug to a torque of 6N·m (53lbin). Remove
the vessel used for draining.
6. Reinstall the Manifold in to the tank.
7. Refill the DEF tank, refer to section 9.10 (3)(f) for guidance on how to do this.
(f) Filling the DEF Tank
 WARNING
Hot Surface Hazard
NOTICE
Before filling the DEF tank, ensure that the DEF lines have been purged. Purging of the DEF
lines will take place, after the engine has stopped. Only after purging the DEF lines should the
DEF tank be filled. For more information on the time taken for purging the DEF lines, refer to the
Engine Operation and Maintenance Manual.
Ensure that the tank is full before starting work.
Do not over fill the tank. The DEF will require room for expansion.

684 Page 9-55
9 Maintenance
PROCEDURE
DUN01333
Figure 9.37 - DEF Tank Filler Cap
1. Ensure that the DEF cap (Item 1; Ref. Figure 9.37) and the surrounding area is clean and
free from dirt. Ensure that all equipment used in filling the tank is clean and free from dirt.
2. Remove the DEF filler cap.
3. Fill the tank with the required amount of DEF,. Ensure that dirt is not introduced into the tank
during filling.
4. Reinstall the DEF filler Cap.
5. Visually inpect the DEF tank for any signs of leakage.

Page 9-56 684
Maintenance 9
9.12 Inspecting the Clean Emissions Module Supports
 WARNING
Hot Surface Hazard
Beware of hot surfaces on and around the engine.
PROCEDURE
DUN01336
Figure 9.38 - Power Unit Inspection Door
1. Open the Power Unit inspection door (Item 1; Ref. Figure 9.38) to gain access to the Clean
Emissions Module.
DUN01334
Figure 9.39 - Clean Emissions Module Mount
2. Inspect mount (Item 1; Ref. Figure 9.39) for wear or damage.

684 Page 9-57
9 Maintenance
Figure 9.40 - Clean Emissions Module Mounts
3. Inspect mounts (Item 2 and 3; Ref. Figure 9.40).

4. If wear or damage is found the mounts must be replaced.
» Refer to Engine Manual for detailed instructions on this procedure.

Page 9-58 684
Maintenance 9
9.13 Changing Air Filters
(1) Air Filtration

The air required to run the engine is inducted into the engine after passing through a filtration
system. As air passes into the breather system it is initially met by the first filter known as the
precleaner. This removes the heaviest of the dust,some of which escapes through a vent at the
bottom or at the back of the precleaner.
The air then passes through the outer filter which removes more dust and than finally the air
passes through the inner air filter. This filtration system removes virtually all the dust being
inducted into engine.
(2) Check Both Air Cleaner Elements
NOTICE
It is recommended that air cleaner elements are not cleaned or reused but replaced with new items.
Do not run the engine with the cover (Item 3) removed.
PROCEDURE
2. Ensure machine is switched off, locked out and tagged out, Remove the ignition key and
carry it with you.
3. Release the tension clips (Item 4) at side of the outer cover (Item 5), Ref: Figure 9.41.
4. Remove the outer cover.
5. Carefully remove outer filter (Item 3) and inner filter (Item 2), Ref: Figure 9.41.
6. Discard the elements if they are distorted.
7. Hold each element up to the light to check for damage to the paper. The elements should
be discarded if pin pricks of light can be seen or if there are areas of paper that appear thin.
8. Refit new or existing elements as required.
3
5
DUN00101
Figure 9.41 - Air Cleaner Elements

684 Page 9-59
9 Maintenance
(3) Changing the Air Cleaner Elements
NOTICE
It is recommended that air cleaner elements are not cleaned or reused but replaced with new items.
Do not run the engine with the filter cover (item 3) removed, Ref: Figure 9.42.
If the outer element has not been changed for 500 operating hours, a leak in the induction system
must be suspected. Check that the air cleaning casing and hoses to the engine are not damaged.
Check that all hose connections are airtight.
PROCEDURE
2. Ensure machine is switched off, locked out and tagged out, Remove the ignition key and
carry it with you
3. Release the tension clips (item 4) at the side of the cover (item 5), Ref: Figure 9.42.
4. Remove the cover (item 5).
5. Carefully remove the outer filter (item 3), minimizing the amount of dust spilled.
6. Remove the inner element (item 2).
7. Clean the inside of the air cleaner casing using a damp, lint free cloth.
8. Fit a new inner filter element (item 2).
9. Fit a new outer filter element (item 3).
10. Replace the outer cover (item 5) and fasten the tension clips (item 4).
3
5
DUN00101
Figure 9.42 - Engine Air Filter

Page 9-60 684
Maintenance 9
9.14 Coolant System

(a) Engine Coolant Level
(For more details of engine coolant level view the engine operators manual)
 WARNING
Switch off and lockout before working at a machine.
Beware of scalds from hot water under pressure.
Figure 9.43 - JMG Panel - Low Coolant Level Indicator
Figure 9.44 - MCU300 Panel - Low Coolant Level Indicator
If the engine coolant level indicator illuminates on the control panel the radiator must be topped
up. Refer to Engine Manual for Fill and Bleed procedures.

684 Page 9-61
9 Maintenance
(b) Topping up Coolant Level

Refer to Engine Manual for Fill and Bleed procedures.
DUN01233
Figure 9.45 - Engine Inspection Doors
PROCEDURE
1. Turn off the engine.
2. Carefully open the radiator cap (Item 1, Ref: Figure 9.45) through the hole located on top
of the power unit.
3. Fill the radiator with coolant.
4. Check the indicator on the control panel to ensure the indicator is no longer illuminated.

Page 9-62 684
Maintenance 9
9.15 Priming the Fuel System
(1) Electic Fuel Pump Priming
 WARNING
NOTICE
Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool
for two minutes before cranking again.
If air enters the system, the air must be purged from the fuel system befofre the engine can be
started.
Do not loosen the high pressure fuel line in order to purge air from the fuel system. This procedure
is not required.
After the engine has stopped, you must wait for 60 seconds in order to allow to allow the fuel
pressure to be purged from the high pressure fuel lines before any service or repair is performed
on the engine or fuel lines.
PROCEDURE
1. Ensure the fuel system is in working order and that the fuel supply is switched on.
2. Turn the ignition key to the ‘ON’ position (Item 2, Ref. Figure 9.46).
3
DUN00001
Figure 9.46 - Key Positions
3. This allows the electric priming pump to operate. Operate the electric priming pump.The
ECM will stop the pump after 2 minutes.
4. Turn the ignition key to the ‘OFF’ position (Item 1’ Ref. Figure 9.46). The fuel system should
now be primed and the engine should be able to start.
5. Turn the ignition key to the crank position (Item 3, Ref. Figure 9.46)

684 Page 9-63
9 Maintenance
6. After the engine has started, operate it at low idle for a minimum of 5 minutes, immediately
after the air has been removed from the fuel system. This will help ensure that the fuel
system is free of air.
7. Ensure that the fuel system is free of leaks.

Page 9-64 684
Maintenance 9
(2) Manual Fuel Pump Priming
 WARNING
NOTICE
for two minutes before cranking again.
If air enters the system, the air must be purged from the fuel system befofre the engine can be
started.
Do not loosen the high pressure fuel line in order to purge air from the fuel system. This procedure
is not required.
After the engine has stopped, you must wait for 60 seconds in order to allow to allow the fuel
pressure to be purged from the high pressure fuel lines before any service or repair is performed
on the engine or fuel lines.
PROCEDURE
1. Ensure the fuel system is in working order and that the fuel supply is switched on.
DUN01234
Figure 9.47 - Fuel Priming Pump
2. Operate the fuel priming pump (Item 1, Ref. Figure 9.47). Count the number of operations
of the priming pump. After 100 depressions of the priming pump, stop.
3. The fuel system should now be primed and the engine should be able to start.
4. Turn the ignition key to the crank position (Item 3, Ref. Figure 9.46)
5. After the engine has started, operate it at low idle for a minimum of 5 minutes, immediately
after the air has been removed from the fuel system. This will help ensure that the fuel
system is free of air.
6. Ensure that the fuel system is free of leaks.

684 Page 9-65
9 Maintenance
(3) Fuel System Prime (Tier 3 CAT4.4 83KW Mechanical Engines)

If air enters the fuel system, the air must be purged from the fuel system before the engine can
be started. Air can enter the fuel system when the following events occur:
• The fuel tank is empty or the fuel tank has been partially drained.
• The low pressure fuel lines are disconnected.
• A leak exists in the low pressure fuel system.
• The fuel filter is replaced.
 CAUTION
NEVER leave your product unattended whilst it is in operation.
Diesel fuel is highly flammable and is an explosion/burns hazard. NEVER remove the filler cap
or refuel, with the engine running. NEVER add gasoline, petrol 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.
NOTICE
Unless the cause of the air in fuel has been rectified, it is likely that any replacement fuel injection
pump will have a problem in a short space of time. Ensure that the source of the air leak in the
fuel system has been located and rectified. Ensure that the fuel system has been primed in order
to ensure that there is no trapped air in the fuel system.
The fuel injection pump can be damaged by trapped air.
Air that is present in the fuel can collect in the fuel injection pump. If the hydraulic damping for
the fuel is not effective the movement of the automatic advance piston is uncontrolled. This can
damage the cover plate, the O-ring seal and the fasteners. Investigations have shown that this
can lead to fuel leaks. In extreme cases, the advance piston travel can shear the cover screws.
Problems can occur within a few hours of the start up of the engine, depending on the duty cycle
and the amount of air in the fuel.
for two minutes before cranking the engine again.
Use the following procedure to remove air from the fuel system.
PROCEDURE
1. Turn the keyswitch to the RUN position.
2. Leave the keyswitch in the RUN position for three minutes. If a manual purging screw is
installed, the purging screw should be slackened during priming the fuel system.
3. Crank the engine with the throttle lever in the CLOSED position until the engine starts.
4. If necessary, loosen the union nuts (1) on the fuel injection lines at the connection with the
fuel injector until fuel is evident. Stop cranking the engine. Tighten the union nuts (1) to a
torque of 30 N•m (22 lb ft).

Page 9-66 684
Maintenance 9
Figure 9.48 - Union Nuts
5. Start the engine and run the engine at idle for one minute.
6. Cycle the throttle lever from the low idle position to the high idle position three times. The
cycle time for the throttle lever is one second to six seconds for one complete cycle.
7. In order to purge air from the fuel injection pump on engines with a fixed throttle, the engine
should be run at full load for thirty seconds. The load should then be decreased until the
engine is at high idle. This should be repeated three times. This will assist in removing trapped
air from the fuel injection pump.
8. Check for leaks in the fuel system.

684 Page 9-67
9 Maintenance
9.16 Fuel Level and Topup

 DANGER
NEVER leave your product unattended whilst it is in operation.
Diesel fuel is highly flammable and is an explosion/burns hazard. NEVER remove the filler cap
or refuel, with the engine running. NEVER add gasoline, petrol 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.
NOTICE
Ultra low sulfur diesel must be used in machines with CAT Tier 4 engines.
The use of fuel additives is not recommended. Additives may not be compatible with the fuel.
Do not fill the tank to overflow or full capacity.
Allow room for expansion and wipe up spilt fuel immediately.
PROCEDURE
2. Check the fuel level gauge / indicator.
3. Clean the area around the filler cap.
4. Remove the filler cap (item 1) and top up fuel level as required with specified diesel fuel,
Ref: Figure 9.49. Refer to the engine manufacturer’s operation manual.
5. Preferably re-fuel at the end of each day where possible, to reduce overnight water
condensation within the tank.
6. Replace the filler cap and close the door if applicable.
7. If required, switch on the ignition briefly to check the fuel gauge.
1 DUN00144
Figure 9.49 - Diesel Tank

Page 9-68 684
Maintenance 9
9.17 Electrical Maintenance

(a) Battery Removal and Installation
 WARNING
DO wear protective eye wear, clothing and gloves. DO NOT expose the battery to flame, sparks,
or incendiary devices, including cigarettes.
Explosion Hazard. The battery contains sulphuric acid, electrolyte which can cause severe burns
and produce explosive gasses. Avoid contact with the skin, eyes or clothing.
Electrocution Hazard. Always disconnect the battery leads before carrying out any maintenance
to the electrical system.
The battery weighs approximately 30kg and should be lifted out with extreme care. Do not tip or
drop the battery. Many newer batteries are made with a handy strap. This should be used to lift
the battery if available.
NOTICE
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.
Extreme care should be taken when removing the battery. Do not tip or drop the battery. Many
newer batteries are made with a handy strap handles.
Dumping the battery will be a hazard to the environment. Dispose if 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. Switch of the machine.
2. After 20 seconds turn the isolator switch to the OFF position.
3. Implement the lockout and tagout procedure, Ref: Section 8.1.
4. Remove the two battery access covers (item 1), Ref: Figure 9.50.
DUN00147
Figure 9.50 - Battery Access Covers
5. Remove the bolt (item 2) from the battery strap, Ref: Figure 9.51.

684 Page 9-69
9 Maintenance
6. Rotate the battery strap (item 3) away from the battery, Ref: Figure 9.51.
Figure 9.51 - Battery Strap
7. Disconnect the negative (- black) terminal first (Item 4) and flex the cable away from the battery.
8. Disconnect the positive (+ red) terminal (Item 5) and flex the cable away from the battery.
Figure 9.52 - Battery Connections
9. Lift the battery straight up and out by holding it at opposite corners.

10. Clean the battery cables, pan and clamp.
11. If there is corrosion present (white powder), neutralize it with a mixture of baking soda and
water using an old toothbrush.
12. Carefully lower the new battery into place making sure it is sitting flat in the battery pan, and
not on the lip.
13. Reconnect the positive terminal (+ red).
14. Reconnect the negative terminal (- black).
15. Rotate the battery strap (item 3) over the battery, Ref: Figure 9.51.
16. Replace the bolt (item 2) in the battery strap to hold it in place, Ref: Figure 9.51.
17. Replace the two battery access covers and bolt into place.

Page 9-70 684
Maintenance 9
(b) Removal and Installation of Fuses
PROCEDURE
1. Switch of the machine and implement the lockout and tagout procedure..
2. Disconnect both battery terminals.
3. Unlock fuse box at the lock on front of control panel, turning one quarter revolution
clockwise
4. Identify which fuse is to be changed, using fuse relay diagram.
5. Grip fuse carefully using needle nose pliers or preferably with plastic fuse removal
tweezers.
6. Check fuse to see if it is blown, a blown fuse should have a gap in the ampoule.
7. Insert new fuse into fusebox
8. Close the fuse box
9. Start engine and test if new fuse corrects original problem.

684 Page 9-71
9 Maintenance
9.18 Servicing the Tracks

Keeping the tracks correctly adjusted will increase the service life of the track and drive components.
Frequently check for loose bolts, oil leaks, master pins are correctly located and tight, general
wear and damage, correct track tension, etc. to ensure safe working and long life
NOTICE
To maximise the life of the track, keep it movable and avoid damage, the machine should be
moved at least every week, by a distance exceeding four times the track length. It should also
be parked on level ground overnight and during periods to of non-usage. This is particularly
important when working in adverse conditions.
It is essential that the tracks are correctly tensioned at all times. Check track tension regularly.
Moving the machine with incorrectly tensioned tracks can cause severe damage to the
undercarriage components and may invalidate the warranty.
(a) Measuring Track Tension

As the tracks wear, they become slack,and should be checked daily. Always ensure that both
tracks are checked.
PROCEDURE
1. Ensure the machine is positioned on solid, level ground.
2. To establish if the tracks require adjustment move the machine, a few metres backwards
and forwards on solid, level ground, in a straight line.
3. Shutdown the machine and implement the lockout and tagout procedure.
4. One track at a time, measure the sag on the top part of the track on the longest section of
unsupported track by placing a ‘straight edge’ long enough to reach from the drive sprocket
to the nearest skid plate, Ref: Figure 9.53.
DUN00018
Figure 9.53 - Measuring Track Tension
5. Measure the maximum amount of track sag from the high point of the track to the bottom of
the ‘straight edge’.
6. This measurement must be between 5-20 mm. If it is less than 5 mm the track tension should
be released and if it is more than 20 mm the track tension should be increased.

Page 9-72 684
Maintenance 9
(b) Adjusting Track Tension

Reduce Track Tension
 WARNING
Injection hazard from high pressure fluid.
Grease coming out of the relief valve under pressure can penetrate the body causing injury or
death. Care must be taken not to loosen the relief valve too quickly. DO NOT watch the relief
valve to see if grease is escaping, but instead watch the track adjustment cylinder to verify that
the track is being loosened. Wear personal protective equipment.
NOTICE
If the track fails to slacken after the grease fitting has been loosened, do not attempt to remove
the tracks or disassemble the track tensioner, or remove the grease fitting. It is possible that
running the tracks with the grease fitting loosened may help to expel the grease. Ensure a risk
assessment is carried out before carrying out such a procedure.
PROCEDURE
1. Shut down the machine and implement the lockout and tagout procedure.
2. Locate the access aperture on the side of the track frame and remove the cover (item 1) to
reveal the relief valve inside, Ref: Figure 9.54.
DUN00010
Figure 9.54 - Tracks
3. Loosen the relief valve by turning it counter clockwise with a spanner, using gradual
increments, until the grease begins to be expelled.
» Grease will be expelled from the tension cylinder and the track tension will be reduced.
4. When the correct track tension has been measured, turn the relief valve clockwise using a
spanner to tighten it.
5. Clean away all traces of the expelled grease.
6. Replace the cover of the access aperture on the side of the track frame.
7. Repeat the measuring track tension procedure to check if the track tension is now within the
specified dimensions.

684 Page 9-73
9 Maintenance
Increase Track Tension
NOTICE
It is important that the tracks are not tensioned too tightly as this places excessive loads on the
gearbox grease cylinder and idler bearings. It will also lead to accelerated wear and premature
failure.
PROCEDURE
2. Locate the access aperture on the side of the track frame and remove the cover (item 1) to
reveal grease fitting inside, Ref: Figure 9.54.
3. Connect the grease gun to the grease fitting, (a special grease gun adaptor may be required).
4. Add grease until the track tension is within the specified dimensions.
5. Remove the grease gun from the grease fitting.
6. Clean away all traces of the expelled grease.
7. Replace the cover of the access aperture on the side of the track frame.
8. Repeat the measuring track tension procedure to check if the track tension is now within he
specified dimensions.
(c) Refilling the Track Gearbox Oil
 WARNING
Injection hazard. Burn Hazard. Oil may be hot and under high pressure. Wear personal protective
equipment.
NOTICE
Ensure the machine is positioned on a level surface.
Cleanliness is essential when checking, filling or replacing oil in the gearbox. Gearbox operating
life will be dramatically shortened if the oil becomes contaminated. Only use new clean oil in
clean containers and fillers.
The Gearbox should hold approximately 5 liters of oil, which should be filtered through a 10 micron
filter before entering the gearbox.

Page 9-74 684
Maintenance 9
PROCEDURE
1. Track the machine until the oil fill holes are in the positions as shown in Figure 9.55.
2
DUN00017
Figure 9.55 - Track Gearbox Fill Position
3. Thoroughly clean around both plugs, removing all potential contaminants.
4. Remove both plugs (items 1 and 2), Ref: Figure 9.55.
5. Fill the oil through the filler plug (item 1) until the oil begins to flow from the level plug (item
2), Ref: Figure 9.55.
6. Wait a few moments until any trapped air has escaped and then re-check the level.
7. Add more oil if necessary.
8. Replace both plugs (items 1 and 2), Ref: Figure 9.55.
(d) Cleaning the Tracks
PROCEDURE
2. On a daily basis the tracks should be hosed down to dislodge any build up of material on
the tracks.

684 Page 9-75
9 Maintenance
(e) Changing Track Gearbox Oil
 WARNING
Injection hazard. Burn Hazard. Oil may be hot and under high pressure. Wear personal protective
equipment.
NOTICE
Ensure the machine is positioned on a level surface.
Cleanliness is essential when checking, filling or replacing oil in the gearbox. Gearbox operating
life will be dramatically shortened if the oil becomes contaminated. Only use new clean oil in
clean containers and fillers.
The Gearbox should hold approximately 5 liters of oil, which should be filtered through a 10 micron
filter before entering the gearbox.
The machine needs to be tracked a very small distance to bring the plugs to the correct position.
Do not move the machine any further until the track gearbox oil has been replaced.
PROCEDURE
1. Track the machine until the oil drain holes are in the positions as shown in Figure 9.56.
2
DUN00016
Figure 9.56 - Track Gearbox Drain Position
3. Thoroughly clean around both plugs, removing all potential contaminants.
4. Remove both plugs (items 1 and 2), Ref: Figure 9.56.
5. Allow the oil to drain into a suitable container large enough to hold all of the oil.
6. Startup the machine.
7. Refill the track gearbox oil, Ref: Section 9.6 (11)(c) Refilling the Track Gearbox Oil.

Page 9-76 684
Troubleshooting 10
Table of Content
10 Troubleshooting....................................................................................... 10-2
10.1 No Response from any Hydraulic System....................................................10-2
10.2 Machine Operating Slowly with No External Oil Leaks ................................10-2
10.3 Excessive Noise from Hydraulic Pump ........................................................10-2
10.4 Vibrating Grid Not Working ...........................................................................10-3
10.5 Vibrating Grid will not Start ...........................................................................10-3
10.6 Tracks will not Operate .................................................................................10-3
10.7 Belt Feeder not Working when Conveyor is Running...................................10-3
10.8 Screeching Noise when Conveyor is Running .............................................10-3
10.9 Conveyor Belt Not Running ..........................................................................10-4
10.10 Conveyor Belt Tends to Run Back if Stopped with a Load on the Belt .........10-4
10.11 Conveyor Belt Not Tracking Correctly ..........................................................10-4
10.12 Reject Grid will not Hinge .............................................................................10-4
10.13 Speed Screen Wire Breaking Prematurely...................................................10-5
10.14 Meshes Breaking Prematurely .....................................................................10-5
10.15 Vibrating Grid and Screen Bearings Fail Prematurely..................................10-5
10.18 Engine Stops ................................................................................................10-6
10.19 Conveyor Belts Running Out of Line ............................................................10-6

684 Page 10-1
10 Troubleshooting
10 Troubleshooting
10.1 No Response from any Hydraulic System

Possible Fault Remedy
Low oil level. Top up hydraulic system with correct fluid.
Choked suction line filter. Fit new element.
Hydraulic pump shaft broken. Replace relevant hydraulic pump.
Coupling damaged or broken Replace coupling.
Pressure relief valve stuck in open position. Repair or replace valve cartridge.
Restricted or broken suction line. Check restriction on tank. Replace if broken.
Override button not functioning. Check wires, fuses
Loose suction line. Tighten suction line
Motor not turning/ram not moving. Check hydraulic pressure/Adjust
10.2 Machine Operating Slowly with No External Oil Leaks

Low oil level. Top up hydraulic system with correct fluid.
Incorrect hydraulic fluid. Drain tank and replace with correct fluid.
Choked suction line filter. Replace filter element.
Leaking relief valve. Repair or replace relief valve.
Worn control valve spool. Replace control valve.
Worn hydraulic pump. Replace relevant hydraulic pump.
Engine performance not to standard. Consult engine manual fault finding section.
Loose suction line. Tighten suction line.
Hydraulic oil leaking through motor. Check or replace motor.
Engine running slow. Set throttle cable.
Engine slowing down under normal load. Change air filter and fuel filters.
Detent loose on control valve. Tighten detent.
Spool loose. Tighten spool.
10.3 Excessive Noise from Hydraulic Pump

Choked suction line filter. Fit new element.
Damaged hydraulic pump coupling. Replace hydraulic pump coupling.
Worn hydraulic pump. Replace hydraulic pump.
Low oil level pump cavitating. Top up hydraulic tank.
Loose connections in suction line. Tighten all joints.
Flexible suction hose worn. Replace hose.

Page 10-2 684
Troubleshooting 10
10.4 Vibrating Grid Not Working

When machine is new grease may have Remove weight cover and turn weight to top
settled in the bearing. dead centre, replace cover and restart.
Grid bearing seized. Replace bearing.
Hydraulic motor coupling broken. Replace coupling.
Flow control valve incorrectly set. Reset flow control valve.
10.5 Vibrating Grid will not Start

When machine is new grease may have Remove weights cover turn weight to top
settled in bearings. dead centre, replace cover, restart grid.
Grid bearing seized. Replace bearings.
Hydraulic motor coupling broken. Replace coupling.
Hydraulic motor shaft broken. Replace hydraulic motor.
10.6 Tracks will not Operate

Remote control Fuse blown Replace fuse in the starter box
system not working Batteries flat in hand Replace batteries
held transmitter
Broken wire in Repair or replace wire
electrical circuit
Control valves levers not pushed Push both control valve levers
Jack legs are down Raise jack legs
Jack leg limit switch loose Tighten limit switch
Material logged in tracks drive system Isolate machine and clear obstruction
10.7 Belt Feeder not Working when Conveyor is Running

Taper lock bushes not tight or broken Repair or replace taper lock bushes
Key missing Replace key
Faulty control valve Replace or adjust
Flow control valve incorrectly set Reset flow control valve
Belt is loose Tighten the belt
Kickout pushes control valve into neutral Tighten the belt

684 Page 10-3
10 Troubleshooting
10.8 Screeching Noise when Conveyor is Running

Lack of bearing lubrication. Grease all bearings.
Conveyor belt wedged or rubbing against Clear obstruction, adjust and track conveyor
fixed parts. belt.
Top end drum belt scraper too tight. Ease pressure at scraper.
Roller Seized. Replace relevant roller.
Rubbers over tight. Readjust rubbers.
Faulty flow control. Replace flow control.
Idler drum jammed. Free idler drum.
10.9 Conveyor Belt Not Running

Belt drive coupling broken or loose. Replace or tighten coupling.
Bearing collapsed or seized. Replace bearing.
Debris obstructing end drum. Remove obstruction.
Skirting rubber to tight. Adjust skirting rubber.
Material build up around return rollers. Clean build-up of material.
Belt stopped with to much load. Clear material of belt and restart.
10.10 Conveyor Belt Tends to Run Back if Stopped with a Load on the Belt
Non return valve worn. Replace non return valve (contact your local
dealer).
Non return valve stuck in open position due Test oil & change filters change oil if required.
to soiled hydraulic fluid. Clean and Replace Valve.
10.11 Conveyor Belt Not Tracking Correctly

Insufficient aligning of drums and idlers. Align all drums, carrying idlers and return
idlers at right angles to the travelling direction
of the belt.
Check that all drums and idlers are level to
each other.
Misalignment of frame. Oblique travel can be reduced by turning
forward outer carrying idlers 1-3 degrees in
travelling direction of the belt.
Material built up on drums and idlers. Clean idlers and drums.
Check belt cleaners and replace if necessary.

Page 10-4 684
Troubleshooting 10
10.12 Reject Grid will not Hinge

Leaking relief valve. Repair or replace valve.
Remote control Fuse blown. Replace fuse in the starter box.
system not working. Batteries flat in hand Replace batteries.
held transmitter.
Broken wire in Repair or replace wire.
electrical circuit.
Faulty control valve. Replace or adjust valve.
10.13 Speed Screen Wire Breaking Prematurely

Wires not tightened evenly all the way Tighten wires evenly.
across.
Screen too Flat. Raise Screen angle.
Material on screen too large. Fit smaller top mesh.
Screen Blinding up. Change screen angle/ change screen
rotation. Add weight segments evenly per
side.
Too much material on the screen. Same as above with slow down material flow.
10.14 Meshes Breaking Prematurely

Meshes not tightened up evenly. Tighten meshes evenly.
Meshes are not supported by the cushion Change cushion rubber. Re-tension the
rubber. meshes.
Mesh is not made from a large enough grade Fit a heavier grade of mesh.
of wire.
Heavy material landing on one spot of the Move the impact spot or hang rubber over the
mesh. mesh
Mesh pegging. Lower screen angle/add weight segments
(same both sides). Reverse screen rotation to
through forward. Clean meshes regularly.
10.15 Vibrating Grid and Screen Bearings Fail Prematurely

Wrong grease is being used. Use proper grease.
To much grease is being used. Use 4-6 gms of grease per bearing every 50
hrs.
The screen is low on one side. Fit a heavier grade of mesh.
Not enough grease. Grease every 50 working hrs.

684 Page 10-5
10 Troubleshooting
10.16 Engine Fails to Start

Start delay is faulty. Replace start delay.
Starter relay faulty. Replace starter relay.
Diesel Hose drawing air. Repair diesel hose.
Main fuse blown. Check glow plugs or for a electrical short.
Heater plugs is faulty. Replace heater plug.
10.17 Belt Stops Under Load

Skirting rubbers to tight Adjust Skirting rubber
Plough scraper to tight Adjust plough scraper
Material build up under the belt Clean away all obstructions around the belt
(switch off and lockout before clearing).
Idler drum is jammed Clear obstruction.
Bearing has seized Replace bearing.
Drum coupling has failed Repair or replace coupling.
Pressure relief valve set to low Set pressure relief valve.
Motor check valve stuck open. Clean motor check valve.
10.18 Engine Stops

Engine overheats Check fan belt. Check water level. Clean
engine (see Engine Manual)
Stop button pressed Reset stop button
Intermittent signal from switches Check each circuit independently, an
intermittent fault will stop the engine without
showing up on the starter panel. Check
water level, for air in the water, for faulty
temperature switch/oil pressure switch/fan
belt switch/stop buttons/electrical short.
10.19 Conveyor Belts Running Out of Line

Belt running of the Idler drum Adjust idler drum
Belt running of the drive drum Adjust drive drum
Belt wanders under load If the belt wanders to the right underload,
push the right hand side of the centre rollers
forward or the left hand side back. (Switch off
machine and lockout before carrying out any
repairs)

Page 10-6 684
Glossary of Terms 11
11 Glossary of Terms
Anti Rock Stay - A strap which is used to stabilise the screen unit whilst in transport.
Antiloosen Fastener - A type of fastener used to secure some doors.
Assemblies - Individual sections of the platform made up of different components parts.
Auxiliary Control Valve - A bank of hydraulic valves which carry out various movement
functions throughout the platform.
Belt Scraper - A device fixed or flexible mounted across the width of a belt of a conveyor for
removing adherent material.
Bogie - Undercarriage on chassis to which axles are bolted.
Centre Roller - A roller, which supports the loaded belt.
Collection Conveyor - A conveyor used to transfer the fines material from underneath the
drum onto the incline conveyor.
Control Panel - A panel that is situated in the power unit which is used to start the engine and
view the various warning lights.
Controller - An electromechanical device or assembly of devices for starting, stopping,
accelerating, or decelerating a drive, or serving, to govern in some predetermined manner the
power delivered to the drive.
Conveyor - A horizontal, inclined, or vertical device for moving or transporting bulk material,
packages, or objects, in a path determined by the design of the device, and having points of
adding and discharge, fixed or selective.
Conveyor belt - A belt used to carry materials and transmit the power required to move the
load being conveyed.
Conveyor, extendable - A conveyor that may be lengthened or shortened to suit operating
needs.
Conveyor, live roller - A series of rollers over which objects are moved by the application of
power to all or some of the rollers. The power transmitting medium is usually belting or chain.
Conveyor, mobile - Conveyor supported on a mobile self propelled structure. These conveyors
normally handle bulk material.
Conveyor, portable - A transportable conveyor which is not self propelled, usually having
supports that provide mobility.
Conveyor, screw - A conveyor screw revolving in a suitably shaped stationary trough or casing
fitted hangers, trough ends, and other auxiliary accessories.
Control Valve - A hydraulic valve, which carries out a movement function on the machine.
Depressurised - To release the pressure from a vessel i.e. a tyre, hydraulic system.
Discharge Area - The area where material is dumped from the machine.
Dolly Axle - An axle that can be fitted to king pin, used for towing purpose.
Drive - An assembly of the necessary structural, mechanical, and electrical parts provide the
motive power to change direction.
Drive Drum - The drum that drives the conveyor belt sometimes called the head drum.
Non Drive Drum - The drum that is non-driven in the conveyor belt sometimes called the tail drum.
Drum Lagging - Rubber glued around the drive drum to grip the conveyor belt.
Feed Conveyor - Conveyor used to move the material from the hopper to the main conveyor.
Feedboot - An extended metal surround located at the bottom of the main, tail & side conveyors.

684 Page 11-1
Feeder Unit - Conveyor which feeds the material onto the incline conveyor at an even rate.
Filler Cap - A cap used to seal a tank and is removed in order to fill the tank.
Fines Material - Material that is screened through the lower screen deck and is discharged on
to the tail conveyor.
Four Bank - A bank of hydraulic control valves used to control functions of the machine.
Flywheel - A half moon shaped counter weight, which is mounted on the screen unit shaft for the
purpose of counter acting the weight of the eccentric of the screen shaft.
Gate - A device or structure by means of which the flow of material may be stopped or regulated;
also a section of a machine equipped with a hinge mechanism for movable service often called
a hinge section.
Grid Aperture - The spacing between the grid bars (typically 100mm) which determines the
material size that enters the feed hopper.
Grid Bar - Bars used on the grid spaced out with equal spacing. Used to roughly screen material.
Grating - A coarse screen made of parallel and crossed bars used to prevent passage of oversized
material.
Guard - A covering, barricade, grating, fence, or other form of barrier used to prevent inadvertent
physical contact with operating components such as gears, sprockets, chains, and belts.
Hopper - A box having a funnel shaped bottom, or a bottom reduced in size, narrowed, or necked
to receive material and direct it to a conveyor, feeder, or chute.
Hydraulic Components - A part used in the hydraulic system of the machine i.e. valve, motor etc.
Hydraulic Screen Tension - The assistance of hydraulic rams when tensioning the screen
meshes.
Jacking legs - Hydraulic adjustable legs which raise or lower the back of the machine for the
purpose of coupling to the tractor unit.
King Pin - Coupling used for towing by the tractor unit.
Landing Leg - A support leg which lowers from the machine and is used to stabilise it whilst in
the working position.
LHS - Left Hand Side, used with reference to the side conveyors.
Lockout - Procedure to be carried out to ensure the machine is safe for maintenance or repairs.
Machine Stop - A stop arising from a sudden and unexpected need, and not as a part of the
normal operation.
Main Conveyor - Conveyor used to move the material from the hopper to the screen unit.
Nip Point - A point at which a machine element moving in line meets a rotating element in such
a manner that it is possible to nip, pinch, squeeze, or entrap a person or objects coming into
contact with one or two of the members.
Optimum Speed - The best or most favorable speed to run a conveyor for example.
Oversize material - Material that is larger than the mesh size and runs off the top screen deck.
Power unit - An inclosed unit situated under the main conveyor which houses the component
parts which together drive the machine.

Page 11-2 684
Glossary of Terms 11
PPE - Personal Protective Equipment

Prevent - When used in a context such as prevent access or prevent physical contact, means
to impede or block; when used in a context such as prevent injury, means to reduce the chances
of, but does not imply that an injury cannot occur.
P.S.I - Pounds per square inch. Unit of Pressure. Conversion 1 Bar = 14.5 P.S.I
Rated speed - The speed, as established by the manufacture or a qualified person, at which safe
and satisfactory service can be expected.
Recommissioning - To prepare the machine for use.
Reject Grid - An arrangement of equally spaced grid bars which is used to separate the large
stones before the material enters the feed hopper.
Remote control - Any system of controls in which the actuator is situated in a remote location.
Retract - Withdraw or fold up conveyor.
Return Roller - A roller, which is used to support the unladened belt on the underside of the
conveyor.
RHS - Right Hand Side, used with reference to the side conveyors.
Safety device - A mechanism or an arrangement placed in use for the specific purposes of
preventing an unsafe condition, preventing the continuation of an unsafe condition, warning of
an unsafe condition, or limiting or eliminating the unsafe effects of a possible condition.
Scraper - A device fixed or flexibly mounted across the width of a belt of a conveyor for removing
adherent material.
Screen Drum - Drum which mesh is fitted onto rotates during operation to screen material
(Trommel).
Screen Unit - Vibratory unit used to separate by size raw materials.
Should - As used in the context of a provision of this manual, indicates a recommendation, the
advisability of which depends on the facts in a particular situation.
Shredder Safety Stay - Metal strap which restrains the shredder unit whilst in the raised position.
Shredder Unit - Swinging flail type unit which is located at the discharge end of the feed conveyor
and is used to break down material.
Side Conveyor - Conveyor used to collect the material from the screen unit and move it to the
discharge area at 90 degrees to the main machine.
Side Roller - Roller used to create arc on the belt to reduce spillage.
Sound Baffles - Plates used to blank out noise from the power unit.
Spillage - Material that spills over the edge of a conveyor etc.
Spill guard - A stationary device of sufficient strength and capacity to catch, retain, and contain
any reasonably foreseeable spillage from a conveyor passing overhead.
Spreader Plate - Swinging plate located at the discharge end of the main conveyor and is used
to spread the material evenly on the screen unit.
Sprocket - A toothed wheel arranged to fit into the links of a chain.
Strut - Rigid support used to hold an assembly in place.
Swivel Conveyor - Conveyor used to discharge fines material. Swivel through 180° to increase
stockpiling capacity.
Tail Conveyor - Conveyor used to collect the fines material from the screen unit and move it to
the discharge area.

684 Page 11-3
Take-up - The assembly of the necessary structural and mechanical parts that provides the means
to adjust the length of belts, cables, chains, etc. to compensate for stretch, shrinkage, and wear.
Telescopic Head Section - A section of a conveyor which extends out telescopically into transport
position.
Tow pin - A movable or fixed member, used to engage a push or pull.
Tracks - The beams, shapes, or formed section on which trolleys, rollers, shoes, or wheels roll
or slide while propelled.
Transport Bracket - A bracket used to hold an assembly in place whilst in transport.
Transport Position - The position of the machine when conveyors are folded.
Variable Speed Flow Control - A device which is used to hydraulically vary the speed of the
conveyor belt.
Viewing Apertures - Opening holes to view the conveyor belt.
Vulcanized Belt - A conveyor belt that has been joined seamlessly using a special treatment.
Wheel Nut Torque - A measure of pressure applied to tighten a nut.

Page 11-4 684
Appendix
Table of Content
Appendix
Appendix A EC Declaration of Conformity
Appendix B Warranty
Appendix C Schematics
Appendix D Engine Fault Codes

684 Page 12-1
Appendix

Page 12-2 684
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.

684 Page A-1
Appendix A
Example

Page A-2 684
Appendix B
Appendix B Warranty
The following pages show an example of the warranty information.
Upon delivery of the machine the warranty must be registered online via:
http://warranty.finlayhydrascreens.com
Upon delivery of the machine the engine warranty also needs registered online. For Scania
engines the warranty is registered via:
www.scania.co.uk/engines/service/start-up-report/index.aspx
For CAT engines the warranty is registered via:
http://www.cat.com/cda/layout?m=37532&x=7&id=3836261.

684 Page B-1
Appendix B
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 replacing, 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.
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, disposal or
handling of tires, batteries, petrochemical items, or any other charges whatsoever, or any liability for direct, indirect, incidental, or
consequential damages.
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 either (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 product 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.
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.

Page B-2 684
Appendix B
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 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 fi led
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” warranties.
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, TORTUOUS 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 REPLACEMENT 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 LIABILITY 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 DEATH OR PERSONAL INJURY.
Rev 2 June 2010

684 Page B-3
Appendix B
LIMITED PRODUCT WARRANTY (USA)

Terex GB Ltd. trading as Terex Mobile Processing Equipment and Terex USA, LLC (collectively, “Seller”) 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:
¾ Cone machines :- Main frame, Upper frame Countershaft and Housing, Drive pulley Drive Pinion and Gear, Eccentric, Wedge Ring (Excluding Pads)
¾ Jaw Machines: - Mainframe including Cross Beam, Eccentric Shaft, Jaw Stock, Toggle Beam, Flywheels.
¾ Impactor Machines: - Rotor, Main shaft, Crusher Body and Drive Pulley.
¾ 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 replacing, 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.
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, disposal or handling of tires, batteries, petrochemical items, or any other charges whatsoever, or any liability for
direct, indirect, incidental, or consequential damages.
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 either (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 product 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.
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
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” warranties.
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, EXPRESS OR IMPLIED (INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE) AND ALL OTHER OBLIGATIONS OR LIABILITY ON SELLER'S PART. 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 REPLACEMENT OF
ANY DEFECTIVE EQUIPMENT COVERED BY THE WARRANTY. IN NO EVENT SHALL SELLER, OR ANY SUBSIDIARY OR DIVISION THEREOF BE LIABLE FOR INCIDENTAL, INDIRECT, CONSEQUENTIAL OR
OTHER DAMAGES OR LOSSES RESULTING FROM A BREACH OF WARRANTY INCLUDING, WITHOUT LIMITATION, LABOR COSTS, LOSS OF USE OF OTHER EQUIPMENT, THIRD PARTY REPAIRS, LOST
PROFITS, LOST TIME, TOWING OR HAULING OF EQUIPMENT, RENTAL COSTS, PERSONAL INJURY, EMOTIONAL OR MENTAL DISTRESS, IMPROPER PERFORMANCE OR WORK, PENALTIES OF ANY KIND,
LOSS OF SERVICE OF PERSONNEL, OR FAILURE OF EQUIPMENT TO COMPLY WITH ANY FEDERAL, STATE OR LOCAL LAWS.
Rev 2 June 2010

Page B-4 684
Appendix C
Appendix C Schematics
(1) Tier 3 Schematics

684 Page C-1
F
E
B
D
C
A
For this document and the object represented in that we reserve all rights according to DIN 34.
Duplication announcement onto third party or utilization of his contents are without forbidden to our.
1
1
-X1
Battery Cable 70mm-B 1/2 Battery Cable 70mm-R
2/2
-X1
JUMP START
CONNECTOR
2
2
-X2
1/1
3
3
only in
the E3!
drawing
Changing
80A
-LF2
-X8 -X6
1/1 Battery Cable 16mm-R 1/1 Battery Cable 16mm-R #2
1
0
3
2
/2.A1
1
Revision
1/1 1/1
-X10
-X9 -X7
12V
1/1
ECO
1/1
-X11
50A
-LF3
-X17 -X15
30
87
1/1 AUTO 6mm-N 1/1 AUTO 6mm-N AUTO 6mm-N

1/1 1/1
1
1/1 1/1 1/1

2
ENGINE
-X16 -X12
4
-X18 -X14 -X13
Revision text
PREHEAT
4
FIRST DRAFT
-K1
Battery Cable 70mm-B
-X20
-X19 1/1 Battery Cable 70mm-R
1/1 300A
14
-1
13
-X25 -X23
1/1 1/1
Date
M
17.11.11
1/1 -X148
-X24
5
1/1
5
-X27
1/1 Battery Cable 35mm-B
1/1
1/1
CD
Name
1/1
-X30
-X28
-X26
Battery Cable 25mm-R
User
Proved
Date
AUTO 3mm-B
AUTO 3mm-G
6
6
-X149
#138 1/1
Name
#-VE_SPLICE
#-VE
/2.F5
/2.F1
7
7
Type C4.4M PU
M.-Nr.: MPE 684 T3
8
8
POWER UNIT
60552196
Description: Electrical Kit
Drawing number
9
9
No.
Sheet
Location
Assignment
1
16 Sh.
F
E
B
D
A
F
E
B
D
C
A
/1.B3
/1.F6
-S8
-K1
#2
-X22 -X21
#-VE
1
1
1/1 1/1 AUTO 1mm-RS -X152 -X153

1
4/8 4/8
85
86
293
RELAY
-S1
ENGINE PREHEAT
-X32 -3 -X31 -2
-S7
-S6
2/5 1/4 AUTO 1mm-R 2/5 1/4AUTO 1mm-R 2/8 2/8

1
1
1/5 1/5
39
2/4 2/4
30
-W4 2BU
-W4 BN
-W3 2BU
-W3 BN
-X152 -X153
-3 -X32 -2 -X31
ON 15 START
AUTO 1mm-R 3/8 3/8

2
2
38
50
-X152 -X153
ESTOP
ESTOP
-5 -4
CHASSIS
CHASSIS
1/4 1/4
46
AUTO 1mm-R
37
2/4 2/4
-5 -4
AUTO 1mm-R
1/8
-X153
AUTO 1mm-R
3
3
36
1/8
-X152
#280
only in
the E3!
drawing
Changing
ESTOP
ESTOP
1
0
3
2 -7 -6
CHASSIS
CHASSIS
Revision
1/4 AUTO 1mm-R 1/4
35
2/4 2/4
ECO
-7 -6
254
AUTO 1mm-R
4
Revision text
4
#IGN_ON
34
10A
FIRST DRAFT
-F1
AUTO 1mm-R
1

/3.A1
-K2
/2.F5
-X38 -X37
30
1/1 1/1
85
86
-K2
/2.E4
87 /2.C5
Date
17.11.11
/1.F6
-F2
30A
30
5
87
5
AUTO,AUTO 6mm-R,6mm-R AUTO 6mm-R

/3.A1
1
#280 -F7:1
33
1/1 1/1
CD
Name
-X40 -X39
49,161
-K2
/2.F5
#-VE_SPLICE
User
Proved
Date
30A
-F3
-X43
30
87
6
6
STARTER SOLENOID 1/1 AUTO 3mm-RW AUTO 3mm-RW

1
32
48
1/1 1/1
167
CONNECTION
Name
-X42 -X41
-K4
/7.F2
AUTO 3mm-B
-X162
1/2 AUTO 1mm-P
2/2
FUEL
PUMP
-X162
7
7
15A
-F4
-X161
Splice-2.5
-X164
30
87
1/2 AUTO 1mm-P AUTO 3mm-P AUTO 3mm-P
1
31
2/2 1/11/1
FUEL
Type
-X161 -X45 -X44
SOLENOID
-K5
/7.F3
-X163
C4.4M PU
1/1 AUTO 1mm-P
M.-Nr.: MPE 684 T3

KBS
ENGINE
8
8
POWER UNIT
15A
-F5
HYD OIL -X48
Splice-2.5
-X49
30
87
COOLER 1/2 AUTO 3mm-P AUTO 3mm-P
1
60552196
28
30
AUTO,AUTO 3mm-B,1mm-B 2/2 FAN No.1 1/1 1/1
-X48 -X47 -X46
-K6
/7.F4

-X55:2
Drawing number
#-VE
#-VE_SPLICE
HYD OIL -X160
9
9
COOLER 1/2
2/2 FAN No.2
No.
-X160
Sheet
/4.A1
/3.E1
Location
Assignment
2
16 Sh.
F
E
B
D
A
1 2 3 4 5 6 7 8 9
#280 -X40:1 #280

/2.D5 /4.A1
#IGN_ON -X167:A #IGN_ON
/2.C4 /4.A1
AUTO 1mm-R
A A
1
-F7
15A
2
62
B B
1
-S4
AUTO 3mm-P
2
/8.B1
TRACKS
SUPPLY
C C
AUTO 1mm-GW
53
-X55
1/2
-H1
D 2 D
2/2
-X55
E E
#-VE_SPLICE 167 #-VE_SPLICE
/2.F9 /7.E5
POWER UNIT
LIGHT
F F
3 Date Name Type C4.4M PU Description: Electrical Kit Assignment

Changing
2 M.-Nr.: MPE 684 T3 POWER UNIT Location
drawing
1 User
only in Drawing number Sheet 3
0 FIRST DRAFT 17.11.11 CD
the E3! Proved 60552196 No. 16 Sh.
Revision ECO Revision text Date Name
1 2 3 4 5 6 7 8 9
F
E
B
D
C
A
/3.A9
/3.A9
/2.F9
#280
#-VE
1
1
AUTO 1mm-S
CAN_L
#IGN_ON -S4:1, /3.A1
AUTO 1mm-Y
CAN_H
3
AUTO 1mm-B
GND
2
AUTO 1mm-R
2
2
8...32 V DC
1
N.C
-P1
CR0451
3
3
only in
the E3!
drawing
Changing
-A1
1
0
3
2
Revision
CR0403
ifm
ECO
A CR0403
1 VBBs
N 1/1
IN0 -X56 AUTO 1mm-R
/5.E2 2 COOLANT LEVEL VBBs 1
IN1 1/1 -X57 AUTO 1mm-B
/8.A1 3 TRACK REQUEST GND 2
4
Revision text
4
FIRST DRAFT
4 GND CAN2_H 3
5 GND CAN2_L 4
/5.E5 6 IN2
ENGINE TEMP SW
IN3
/5.E6 7 ENGINE OIL PRESSURE
8 VBBs
B
1 VBBs
/5.E8 2 IN4
ESTOP HEALTHY
Date
/5.E9 3 IN5
CONV1 ST REQ
17.11.11
4 GND
5
5
5 GND
IN6
CD
/6.E2 6 CONV 2 START DELAY
Name
/6.E3 7 IN7
JACK LEG SENSORS
8 VBBs
P/N1 1/1 -X60 AUTO 1mm-R
VBBs 1
1/1 -X61 AUTO 3mm-R
C VBB1 2
1/1 -X62 AUTO 3mm-R
1 VBBs VBB2 3
1/1
User
IN8 -X63 AUTO 1mm-B
GND 4
Proved
/6.E5 2 AIR FILTER RESTRICT
IN9 1/1 -X64 AUTO,AUTO 1mm-Y,1mm-Y
/6.E6 3 ENG START REQ CAN1_H 5
Date
1/1 -X65 AUTO,AUTO 1mm-S,1mm-S
4 GND CAN1_L 6
5 GND
6
6
IN10
/8.A8 6 MACHINE STOP
IN11
/6.E9 7
Name
HOL
8 VBBs
D
49
46
55
58
167
OUT0
/7.A1 1 ENG CRANK
2 GND
OUT1 -8
/7.A2 3 FUEL SYSTEM 1/5 AUTO 1mm-R
4 GND
OUT2
2/5 AUTO,AUTO 3mm-R,1mm-R
/7.A3 5 HYD OIL FANS 3/5 AUTO 1mm-B
6 GND
4/5 AUTO,AUTO 1mm-Y,1mm-Y
7
OUT3
7
/7.A5 7 SIREN/BEACON
SOCKET
5/5 AUTO,AUTO 1mm-S,1mm-S

8 GND
EXPANSION NODE
#280
#-VE
-X167:A #IGN_ON
Type
E OUT4
/8.A2 1 TRACKS ENABLE
2 GND
/5.A1
/5.A1
/5.D7
OUT5
/9.A1 3 SPARE
4 GND
/9.A2 5 OUT6
C4.4M PU
SPARE
M.-Nr.: MPE 684 T3

6 GND
OUT7
/9.A3 7 SPARE
8
8
8 GND
-R1
F OUT8
1W
5/5
4/5
-X66
-X66
120 Ω
/9.A5 1 SPARE
POWER UNIT
2 GND
OUT9
/9.A6 3 SPARE
4 GND
60552196
/9.A7 5 OUT10
CONV 1 RUN SOCKET
6 GND
Drawing number
OUT11
/9.A8 7 CONV 2 RUN
8 GND
PROGRAMMING
9
9
No.
Sheet
Location
Assignment
4
16 Sh.
F
E
B
D
A
1 2 3 4 5 6 7 8 9
#IGN_ON -S4:1, /3.A1 #IGN_ON

/4.A7 /6.A1
#-VE #-VE
/4.A7 /6.A1
AUTO 3mm-B
A A
B -B1 -X72 B
IFS208 1 1/5 #IGN_ON
/6.B1
2 -X72
3 3/5 AUTO 1mm-B #-VE
/6.B1
-X72
4 4/5
CONVEYOR 1 START
DELAY SENSOR
COOLANT LEVEL
C
-X74
23/31 AUTO 1mm-BW
-X165
2/2
-X166
C
1/2
SWITCH
C/3 C
23/31
P
-X73
B/3 B
A/3 A
-X167 -B6
1/2
2/2
331-7352
-X165
-X166
#280 -8:2 46
/4.A7
D D
AUTO 1mm-BR
AUTO 1mm-WO
AUTO 1mm-GP
AUTO 1mm-G
AUTO 1mm-R
-X67
-X68
-X69
-X70
-X75
1/1
1/1
1/1
1/1
1/1
2 6 7 2 3
IN0 IN2 IN3 IN4 IN5
E /4.E4 /4.E4 /4.E4 /4.E5 /4.E5
E
COOLANT LEVEL ENGINE TEMP SW ENGINE OIL PRESSURE ESTOP HEALTHY CONV1 ST REQ
-A1 -A1 -A1 -A1 -A1
Input Input Input Input Input
F F

Changing
drawing
1 User
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
#IGN_ON #IGN_ON
/5.A9 /8.B7
A A
#-VE #-VE
/5.A9 /7.F1
AUTO 1mm-GR
13/31 13/31
-X73 -X74
AUTO 1mm-B
14/31 14/31
-X73 -X74 JACK LEG
SENSOR
#IGN_ON No.1
/5.B9
AUTO 1mm-R
B B
#-VE
-D1
1W
10k Ω
/5.B9
-X169 ALTERNATOR
1
2
Splice-2.5 1/1 D+
AUTO 1mm-RS
-X151
-R3
-X76
1/2
-X150
1/4
HYD OIL LEVEL
-X77
2/4
-B5 -X155 SENSOR
1/5 3/4
#IGN_ON 1/2
IFS208 1 188
C 4/4 3/4 3 C
AFR SWITCH
2 (BY OTHERS) 2/4 2
-X155
3/5 1/4 1
3
-X82 -B2
-X155
AUTO 1mm-GW
4/5
320428
#28
4
CONVEYOR 2
AUTO 1mm-NW
292
24/31
-X74
2/2
-X77
START DELAY
#280
2/2
24/31
-X73
-X76
22/31
-X74
D JACK LEG 192 D
25/31
-X74
SENSOR
22/31
No.2
-X73
25/31
-X73
AUTO 1mm-BR
AUTO 1mm-BO
AUTO 1mm-NW
-X156
-X154
-X78
-X79
-X81
1/1
1/1
1/1
1/1
1/1
E E
6 7 2 3 7
IN6 IN7 IN8 IN9 IN11
CONV 2 START DELAY /4.E5 JACK LEG SENSORS /4.E5 AIR FILTER RESTRICT /4.E6 ENG START REQ /4.E6 HOL /4.E6
-A1 -A1 -A1 -A1 -A1
F F

Changing
drawing
1 User
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
A A
Output Output Output Output
-A1 -A1 -A1 -A1
ENG CRANK FUEL SYSTEM HYD OIL FANS SIREN/BEACON
/4.E6 /4.E7 /4.E7 /4.E7
OUT0 OUT1 OUT2 OUT3
1 3 5 7
1/1
1/1
1/1
1/1
-X92
-X83
-X86
-X89
B B
76,77
73
74
75
-X93
-X95
1/2
1/2
C C
-X84
-X87
-X90
1/1
1/1
1/1
1/2
-X96
86 86 86
-K4 -K5 -K6
/7.F2 /7.F3 /7.F4
-W2 BN
85 85 85
MACHINE
BEACON
1/1
1/1
1/1
1
-X91
-X85
-X88
-H3
2
D D
-W2 BU
2/2
-X96
2/2
2/2
-X93
-X95
#-VE_SPLICE
E /3.E9 E
AUTO 1mm-B
AUTO 1mm-B
AUTO,AUTO 1mm-B,1mm-B
#-VE
/6.A9
-K4 -K5 -K6
/7.C1 /7.C3 /7.C4
30 87 /2.C6 30 87 /2.C7 30 87 /2.C9
F F

Changing
drawing
1 User
1 2 3 4 5 6 7 8 9
F
E
B
D
C
A
/3.C2
#-VE
1
1
/4.E4
-A1
#+VE_TRACKS
TRACKS ON SW
-X74 -X98 -X73 -X97
2/31 AUTO 1mm-B 10/16 AUTO 0.75mm-RU 10/31 AUTO 0.75mm-RU 1/1
IN1
10/31
Input
2/31 2/16
-X73 -X98 -X74
TRACK REQUEST
2
2
62
-X98 -X73
4/16 AUTO 1mm-P 4/31
4/31
/4.E7
-A1
-X74
LTF
-K7
/8.F3
14
24
12
-X74
22
-X98 -X73 -X99

5/31 AUTO 0.75mm-UO 3/16 AUTO 0.75mm-RW 3/31 AUTO 0.75mm-RW 1/1
OUT4
-K7
/8.F3
1
5/31 5/16 3/31

A2
A1
Output
21
-X73 -X98 -X74

TRACKS ENABLE
3
3
0.75mm-UO AUTO
11 /10.C3
only in
the E3!
drawing
Changing
1 AUTO 3mm-R
0
3
2
Revision
#+VE_TRACKS
ECO
LTR
-K8
/8.F4
12
14
24 -X74
22
8/31 AUTO 0.75mm-UY
/10.A1
-K8
/8.F4 8/31 8/16
A2
A1
21
4
-X73 -X98
Revision text
4
FIRST DRAFT
0.75mm-UY AUTO
11 /10.C4
RTF
-K9
/8.F5
Date
14
24
12
-X74
22
17.11.11
6/31 AUTO 0.75mm-NS
-K9
/8.F5
5
6/31 6/16
5
A2
A1
21
-X73 -X98
CD
0.75mm-NS AUTO
Name
11 /10.C5
TRACKING UMBILICAL
User
Proved
Date
RTR
-K10
/8.F6
14
24
12
-X74
22
6
6
9/31 AUTO 0.75mm-NY
/8.F6
-K10
9/31 9/16
A2
A1
Name
21
-X73 -X98
0.75mm-NY AUTO
11 /10.C7
/6.A9
#IGN_ON
FAST AUTO 1mm-R
/8.F7
-K11
7
12
14
-X74
24
7
22
1/31 AUTO 0.75mm-GY
/8.F7
-K11
1/31 1/16
A2
A1
21
-X73 -X98
Type
0.75mm-GY AUTO
-X74 RADIO TRACK -X98 -X73
11 /10.C8
15/31 AUTO 0.75mm-BP STOP LINK 16/16 AUTO 0.75mm-GY 16/31
15/31 15/16 16/31
-X73 -X98 -X74
/4.E6
-A1
C4.4M PU
AUTO 1mm-B
M.-Nr.: MPE 684 T3

MACHINE REMOTE
8
STOP
8
-X74 -X98 -X73 -X100

7/31 AUTO 0.75mm-BY 12/16 AUTO 0.75mm-WR 12/31 AUTO 0.75mm-WR 1/1
IN10
6
Input
7/31 7/16 12/31

MACHINE STOP
-X73 -X98 -X74
POWER UNIT
60552196
#-VE
Drawing number
/9.F1
9
9
No.
Sheet
Location
Assignment
8
16 Sh.
F
E
B
D
A
1 2 3 4 5 6 7 8 9
Output Output Output Output Output Output Output

A -A1 -A1 -A1 -A1 -A1 -A1 -A1 A
SPARE SPARE SPARE SPARE SPARE CONV 1 RUN CONV 2 RUN
/4.E8 /4.E8 /4.E8 /4.E8 /4.E8 /4.E9 /4.E9
OUT5 OUT6 OUT7 OUT8 OUT9 OUT10 OUT11
3 5 7 1 3 5 7
1/1
1/1
-X101
-X158
B B
82
266
AUTO 1mm-R
AUTO 1mm-R
-X73
30/31
-X73
29/31
C C
30/31
29/31
-X74
-X74
AUTO 1mm-GN
AUTO 1mm-GR
-X102
-X157
1/4
1/4
D D
2/4
2/4
-X102
-X157
31/31
-X74
E E
31/31
-X73
#-VE #-VE
/8.F9 /10.F1
F F

Changing
drawing
1 User
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
#+VE_TRACKS 62 -X73:26
#+VE_TRACKS
/8.B3 /11.A1
A A
AUTO 1mm-P
AUTO 1mm-P
AUTO 1mm-P
AUTO 1mm-P
AUTO 1mm-P
B B
12 14 12 14 12 14 12 14 12 14
-K7 -K8 -K9 -K10 -K11

/8.F3 /8.F4 /8.F5 /8.F6 /8.F7
C 11 11 11 11 11 C
-X73
-X73
-X73
-X73
20/31 AUTO 1mm-GO
17/31 AUTO 1mm-RY

18/31 AUTO 1mm-BO
19/31 AUTO 1mm-GK
17/31
18/31
19/31
20/31
-X74
-X74
-X74
-X74
D D
AUTO 1mm-RY
AUTO 1mm-BO
AUTO 1mm-GK
AUTO 1mm-GO
-X103
-X105
-X106
-X107
1/4
1/4
1/4
1/4
LEFT TRACK LEFT TRACK RIGHT TRACK RIGHT TRACK
FORWARD SOL. REVERSE SOL. FORWARD SOL. REVERSE SOL.
2/4
2/4
2/4
2/4
E E
-X103
-X105
-X106
-X107
-X104 #-VE
21/31 21/31 Splice-2.5
-X73 -X74
#-VE #-VE
/9.F9 /11.E1
F F

Changing
drawing
1 User
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
#+VE_TRACKS
/10.A1
/10.A9
A A
-X73
26/31
26/31
-X74
B B
-X108
1/4
C C
RADIO CONTROLLED TIPPING GRID
RECIEVER (TELERADIO)
2/4
-X108
D D
27/31
-X74
27/31
-X73
E E
#-VE
/10.F9
F F

Changing
drawing
1 User
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
2100MM
A A
-X2#2
-X1#2 -X1#1 Part No. 60552225/6 1 70.00 mm² Red -X1:1
1/2 ENGINE JUMP START CONNECTION 1/1
1 70.00 mm² Red -X2:1 -X2#1
2/2 TO BATTERY
2 70.00 mm² Black -X9:1 -X9#2
1 70.00 mm² Black -X1:2
1/1
-X9#1
1/1
-X10#1
1/1
-X11#1
2400MM
B B
480MM
-X19#2 -X19#1 -X18#2
1/1 Part No. 60552223
1 70.00 mm² Black -X18:1 1 70.00 mm² Black -X19:1
-VE BATTERY TO MAIN ISOLATOR 1/1
-X18#1
C C
1400MM
-X20#2 -X20#1 -X23#2
1/1 Part No. 60552221
1 70.00 mm² Red -X23:1 1 70.00 mm² Red -X20:1
+VE BATTERY TO STARTER +VE STUD 1/1
-X23#1
D D
1400MM
-X24#2 -X24#1 -X25#2
1/1 Part No. 60552224
MAIN ISOLATOR TO STARTER -VE STUD 1/1
-X25#1
E E
300MM
-X26#2 -X26#1 -X27#2
1/1 Part No. 60552222
1/1
STARTER -VE STUD TO CHASSIS GROUND -X27#1
600MM
F -X148#2 -X148#1 -X149#2 F
1/1 Part No. 60552227
1 25.00 mm² Red -X149:1 1 25.00 mm² Red -X148:1
1/1
STARTER +VE STUD TO ALTERNATOR CHARGE TERMINAL -X149#1

Changing
drawing
1 User
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9 10 11 12
-X108#2 1 2
1 1.00 mm² Green-Red -X74:26
2 1.00 mm²,1.00 mm² Black,Black /11.E1, -X74:27 -X108#1
*4/4
3
4 FRONT
VIEW -X150#1
REMOTE TIPPING GR ID *4/4 JAC KIN G L EG
RECIEVER C ONNEC TION SENSORS
3 4
-X150#2
1 1.00 mm² Green-Red -X74:13
2 1.00 mm² Green-White -X150:3
A 3 1.00 mm² Green-White -X150:2 A
-X74#2
1 0.75 mm² Green-Yellow -X98:1
2 1.00 mm² Black -X98:2
3 0.75 mm² Red-White -X98:3
4 1.00 mm² Purple -X98:4
5 0.75 mm² Blue-Orange -X98:5
6 0.75 mm² Brown-Grey -X98:6
7 0.75 mm² Black-Yellow -X98:7
8 0.75 mm² Blue-Yellow -X98:8
100MM
9 0.75 mm² Brown-Yellow -X98:9
150MM
10 0.75 mm² Red-Blue -X98:10
11
12 0.75 mm² White-Red -X98:12
1.00 mm²,1.00 mm²,1.0013mm²,1.00 mm²,1.00 mm² Green-Red,Red,Red,Green-Red,Green-Red
-X82:1, -X155:1, -X72:1, -X150:1
3
1.0014mm²,1.00 mm²,1.00 mm² Black,Black,Black -X82:2, -X155:3, /6.B1
-U62
-U6
15 0.75 mm² Black-Purple -X98:15
17 1.00 mm² Red-Yellow -X103:1
18 1.00 mm² Black-Orange -X105:1
19 1.00 mm² Green-Pink -X106:1
-U61
20 1.00 mm² Green-Orange -X107:1
21 1.00 mm² Black -X104:1
B 23 1.00 mm² Black-White -X72:4
B
25 1.00 mm² Brown-White -X82:3
26 1.00 mm² Green-Red -X108:1 -X103#2
27 1.00 mm² Black -X108:2
Part No. 60552351 1 1.00 mm² Red-Yellow -X74:17
28 LTF SOLENOID 1.00 mm²,1.00 mm²,1.002mm²,1.00 mm²,1.00 mm² Black,Bl ack,Black,Black,Black-X104:1, -X105:2
29 1.00 mm² Green-Red -X157:1 3
50MM
30 1.00 mm² Green-Brown -X102:1 PE
*4/4
31 1.00 mm²,1.00 mm² Black,Black -X102:2, -X157:2 -X103#1
1600MM 200mm
650mm 330 MM 650 MM 50mm
-X105#2
LTR SOLENOID 1.00 mm²,1.002mm²,1.00 mm²,1.00 mm² Black,Bl ack,Black,Black -X106:2, -X103:2, -X104:1
-U1 -U66 -U3 -U7 3

-U59 -U60 PE
*4/4
-X105#1
-X106#2
RTF SOLENOID 2 1.00 mm²,1.00 mm² Black,Black -X105:2, -X107:2
-U4 3
-X74#1 PE
*3 1 /3 1 *4/4
-X106#1
C C
-X107#2
RTR SOLENOID 2 1.00 mm²,1.00 mm² Black,Black -X106:2, /10.E8
3
PE
*4/4
-X107#1
300mm
300mm
400mm
JACK LEG??
D D
-U2
-U67
TRAC KING -X98#1
UMBIL ICAL CONNECTION *16/16
-X98#2
2 1.00 mm² Black -X74:2
4 1.00 mm² Purple -X74:4
300mm
300mm
1000mm
100mm
100mm
E E
10 0.75 mm² Red-Blue -X74:10
11
12 0.75 mm² White-Red -X74:12
13
14
CON VEYOR No .1 16 0.75 mm² Green-Yellow -X74:16
DEL AY SENSOR
CON VEYOR NO.2

DELAY SEN SOR
*5/5
-B1#1
-X72#1
-X72#2 *5/5
1 1.00 mm² Red -X74:13 -X155#1
2 -X155#2
3 1.00 mm² Black /5.B9 FEED CONV No.1 1 1.00 mm² Red -X74:13 FEED CONV No.2
1.00 mm² Black-White -X74:23
SOL ENOID SOL ENOID
4 2
5 3 1.00 mm² Black -X74:14
*4/4
*4/4
5
-X157#1
-X102#1
-X102#2 -X157#2
1 1.00 mm² Green-Brown -X74:30 1 1.00 mm² Green-Red -X74:29
F 2 1.00 mm² Black -X74:31 2 1.00 mm² Black -X74:31 F
3 3
PE PE
G G
HYD. OIL LEVEL

SEN SOR
*4/4
-X82#1
-X82#2
1 1.00 mm² Green-Red -X74:13
2 1.00 mm² Black -X74:14
4
H H
3 Date Name Type Description: Electrical Kit Assignment

Changing
2 Location
drawing M.-N r.: MPEPOWER
684 T3 U NIT
1 User
0 FIRST DRAFT 17.11.11 CD C4.4 M PU
the E3! Proved No. Sh.
Revision ECO Revision text Date Name 16
1 2 3 4 5 6 1 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
100mm 50 MM 200 MM 50 MM 1000MM 300mm
-U8 -U11 -U54 -U64 -U15 -U22 -U33 -U35 -U37
A A
-U10
-U9
300mm
600mm
100mm
1000MM
B B
-U12
-U38
400mm
-U16
-U34
-X55#2 W2S -X93#1
1.00 mm² Green-White -S4:2 100MM *2/2
1
2 1.00 mm² Black -X49:1 BEACON
FUEL STAR TER CONNECTION
100MM PUMP SOL ENOID
900MM
POWER U NIT
LIGHT -U83 -X93#2 60505024
W2S -X162#1
-U71 -X43#1
*2/2 1/1 1 1.00 mm² Red -X92:1
*2/2
2 1.00 mm²,1.00 mm² Black,Black -X160:2, -X95:2
-U82
-X55#1
-U70
-X43#2
DT06-2S
-X162#2
1 1.00 mm² Purple -X164:1
2 1.00 mm² Black -X49:1
C C
-U40
-X48#1
*2/2
HYD OIL COOLER 400mm
700MM
FAN No.1
150MM
-X48#2
1 3.00 mm²,3.00 mm² Purple,Purple -X47:1, -X160:1 -U36
3.00 mm²,3.002mm²,3.00 mm²,3.00 mm² Black,Bl ack,Black,Black -X49:1, /2.F9
-U41
-X160#1
*2/2
-U55
HYD OIL COOLER
-U72
FAN No.2
-X160#2
-U84
1 3.00 mm² Purple -X48:1
D 600 MM OIL PRESSURE 2 3.00 mm²,1.00 mm² Black,Black -X49:1, -X93:2 D
SWITCH
W2S -X166#1
-U74
*2/2
W2S -X95#1
*2/2
-U73
AIR FILTER
*2/2
RESTRICTION SIREN
150mm
DT06-2S CONNECTION
-X76#1
-U65
-U85
-X76#2 -X166#2 2 1
1 1.00 mm² Red -X169:1 1 1.00 mm² Black /5.A1 -X95#2 60505024 -LF2#1 -LF2#1
2 1.00 mm² Black-Red -X78:1 2 1.00 mm² Green -X69:1 1 1.00 mm² Red -X92:1 1 2
2 1.00 mm² Black -X93:2
W8S
2 1
-LF3 -LF3#1
1 2
-U42
REMOTE KEYSWITCH
*8/8
-X152#1
Cable harness for manufacturing; 8-polar; Connection-Target

DT06-8S
BOX
-X152#2
150MM
1 1.00 mm² Red -F1:2

2 1.00 mm²,1.00 mm² Red,Red -2:1, /2.C4
3 1.00 mm² Red -X79:1
4 1.00 mm² Red-Grey -X21:1
E E
50MM
5
6
7
50MM
8
-U43
*8/8
6
ALTER NATOR
DT04-8P
-X151#1
-U8
D+ TERMINAL 1/1
-X153#1
-U75
-X153#2
1 1.00 mm² Red -S1:30 0-001-06
2 1.00 mm²,1.00 mm² Red,Red -S1:15 -X151#2
-U87
3 1.00 mm² Red -S1:50 1 1.00 mm² Red-Grey -D1:2
W8P
4 1.00 mm² Red -S8:2
5
6
Cable harness for manufacturing; 8-polar; Target DevDes

7
8
400mm
100mm
-U76
-U88
F F
100MM
-U44
9
-U3
-U69
100MM
100MM
50MM
-U68
400MM
1/1
1/1
1/1
-X28#1
-X29#1
-X30#1
1/1
1/1
-X8#1
-X17#1
-U78
-X165#1 W2S
FUEL
-U
*2/2
77
9
SOL ENOID ENGINE

G G
-U8
TEMP SWITCH
*2/2
/1.F6
-X49:1
-X161#1
REMOTE
KEYSWITCH -X161#2 -X165#2 DT06-2S
-U90
-X7:1
-X16:1
ENCLOSURE 1.00 mm² Purple -X164:1 1.00 mm² Green-Pink -X68:1

1 1
2 1.00 mm² Black -X49:1 2 1.00 mm² Black /5.A1
-U79
3.00 mm² Green
3.00 mm² Black
6.00 mm² Brown
16.00 mm² Red
COOL ANT LEVEL

-X28#2
-X29#2
-X30#2
1
1
1
SWITCH
-X8#2
-X17#2
1
1
*3/3
-X167#1
100MM
-X167#2
1.00 mm²,1.00Amm²,1.00 mm²,1.00 mm² Red,Red,Red,Red -S4:1, /3.A1, /5.A9, /5.A1
B 1.00 mm² Black /5.A1
C 1.00 mm² White-Orange -X67:1
H H
KBS 0-001-22
-U
80
TERMINAL PREH EAT
-X163#2 TERMINAL
1 1.00 mm² Purple -X164:1 1/1
-U81
-X12#1
-X163#1 -X12#2
1/1 3 Date Name Type C4.4Description:
M PU Electrical Kit Assignment
6.00 mm² Brown -X13:1 Changing
1 2 Location
drawing M.-N r.: MPEPOWER
684 T3 U NIT
1 User
the E3! Proved No. Sh.
Revision ECO Revision text Date Name 16
1 2 3 4 5 6 1 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9
A A
500MM
Part No. 60552028 2

1
-X96#1
-X96#2
1 1.00 mm² Brown -H3:1 -W2
2 1.00 mm² Blue -H3:2 -W2
-H3#1
B B
-S7#1
-U48
5500MM
C E11506 C
Part No. 60552247

ESTOP POWER UNIT *5/5
OFF SIDE -X32#1
-X32#2
1 1.00 mm² Brown -S7:1 -W4
2 1.00 mm² Blue -S7:2 -W4
3
4
5
D D
-S6#1
-U51
2000MM
E11506
E E
Part No. 60552265
NEAR SIDE -X31#1
-X31#2
1 1.00 mm² Brown -S6:1 -W3
2 1.00 mm² Blue -S6:2 -W3
3
4
F 5
F

Changing
drawing
1 User
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
A A
B B
DURIT E
12 volt 120 amp
-K1
-A1
30 85 86 87
DURIT E
12 volt 120 amp
-K2
LED
30
86 85
3 4 3 4 3 4 3 4 3 4
85
30 85 86 87
12V
AY
30
REL
-K4
0- 72 7- 16
40A
-X144
86
DURITE
5 6 5 6 5 6 5 6 5 6
87 87a
87
7 8 7 8 7 8 7 8 7 8 -X127 -X133-X132 -X131-X130 -X137-X134
30
86 85
85
12V
AY
1
1 1
1 1
1 1 1 1 1
1 N2
A1 14 12
22 2 1 24
A1 14 12
22 2 1 24
A1 14 12
22 2 1 24
A1 14 12
22 2 1 24
A1 14 12
22 2 1 24
1 1 1
REL
-K6
0- 72 7- 16
30
40A
1
86
DURITE
VBBs
-X145
-F1 -F2 -F3 -F4 -F5 -F7 -F8
G ND 2
-K7 -K8 -K9 -K10 -K11 2 2 2 2 2 2 2 3
87
CAN
2_H
87 87a
11
A2
11
A2
11
A2
11
A2
11
A2
4
CAN
2_L
30
-X142 -X141 -X140 -X139 -X138 -P1
86 85
85
12V
A B C D E F P/N1
AY
1
REL
1
-K5
0- 72 7- 16
A 1
VBBs 1 VBBs 1 C VBBs
30
40A
1 B
1 2 1 2 1 2 1 2 1 2 1
VBBs
DURITE
-X146
86
2 2 2
2 D G ND
2 E G ND 2 F G ND
2
VBB1
3 3 3 3
3
3
VB
B2 3
87
4 4 4 D G ND
A G ND B G ND C G ND 4 E G ND 4 F G ND
87 87a
4
G ND 4
O I
5 5
1 2
5 5
A G ND B G ND 5 C G ND
5
CAN
1_H 5
6 6 6
5
6 D G ND 6 E G ND 6
F G ND
CAN
1_L 6
7 7 7 7
7
4 3
AY
7
12V
-P1
REL
-K3
25A
0- 72 7- 13
A 8 D G ND
VBBs 8 B VBBs 8 C VBBs 8 E G ND F G ND
8 8
1
DURITE
-X147
87 86 85 30
85 86 30 87a 87
-S4
-S4
NO
C 2
C
OK
-2 -7
1 2 1 2
4 3 4 3
X73
-8
-3 -6
3
4 2 1 2 1 2
5 1 4 3 4 3
D -4 -5 D
1 2 1 2
FRONT U9
4 3 4 3
-S1
E E
F F

Changing
drawing
1 User
0
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9 10 11 12
-X108#2 1 2
1 1.00 mm² Green-Red -X74:26
2 1.00 mm²,1.00 mm² Black,Black /11.E1, -X74:27 -X108#1
*4/4
3
4 FRONT
VIEW -X150#1
REMOTE TIPPING GRID *4/4 JACKING LEG
RECIEVER CONNECTION SENSORS
3 4
-X150#2
1 1.00 mm² Green-Red -X74:13

-X74#2
2 1.00 mm² Black -X98:2
4 1.00 mm² Purple -X98:4
100MM
150MM
10 0.75 mm² Red-Blue -X98:10
11
12 0.75 mm² White-Red -X98:12
1.00 mm²,1.00 mm²,1.0013mm²,1.00 mm²,1.00 mm² Green-Red,Red,Red,Green-Red,Green-Red
-X82:1, -X155:1, -X72:1, -X150:1
63
1.0014mm²,1.00 mm²,1.00 mm² Black,Black,Black -X82:2, -X155:3, /6.B1
-U62
-U
-U61
21 1.00 mm² Black -X104:1
B
26 1.00 mm² Green-Red -X108:1 -X103#2
27 1.00 mm² Black -X108:2
Part No. 60552351 1 1.00 mm² Red-Yellow -X74:17
28 LTF SOLENOID 1.00 mm²,1.00 mm²,1.002mm²,1.00 mm²,1.00 mm² Black,Black,Black,Black,Black-X104:1, -X105:2
29 1.00 mm² Green-Red -X157:1 3
50MM
*4/4
31 1.00 mm²,1.00 mm² Black,Black -X102:2, -X157:2 -X103#1
1600MM 200mm
650mm 330MM 650MM 50mm
-X105#2
LTR SOLENOID 1.00 mm²,1.002mm²,1.00 mm²,1.00 mm² Black,Black,Black,Black -X106:2, -X103:2, -X104:1
-U1 -U66 -U3 -U7 3

-U59 -U60 PE
*4/4
-X105#1
-X106#2
RTF SOLENOID 2 1.00 mm²,1.00 mm² Black,Black -X105:2, -X107:2
-U4 3
-X74#1 PE
*31/31 *4/4
-X106#1
C C
-X107#2
RTR SOLENOID 2 1.00 mm²,1.00 mm² Black,Black -X106:2, /10.E8
3
PE
*4/4
-X107#1
300mm
300mm
400mm
JACK LEG??
D D
-U2
-U67
TRACKING -X98#1
UMBILICAL CONNECTION *16/16
-X98#2
2 1.00 mm² Black -X74:2
4 1.00 mm² Purple -X74:4
300mm
300mm
1000mm
100mm
100mm
E E
10 0.75 mm² Red-Blue -X74:10
11
12 0.75 mm² White-Red -X74:12
13
14
CONVEYOR No.1 16 0.75 mm² Green-Yellow -X74:16
DELAY SENSOR
CONVEYOR NO.2
DELAY SENSOR
*5/5
-B1#1
-X72#1
-X72#2
*5/5
1 1.00 mm² Red -X74:13 -X155#1
2 -X155#2
4 1.00 mm² Black-White -X74:23 SOLENOID 2 SOLENOID
5 3 1.00 mm² Black -X74:14
*4/4
*4/4
5
-X157#1
-X102#1
-X102#2 -X157#2
1 1.00 mm² Green-Brown -X74:30 1 1.00 mm² Green-Red -X74:29
3 3
PE PE
G G
HYD. OIL LEVEL

SENSOR
*4/4
-X82#1
-X82#2
1 1.00 mm² Green-Red -X74:13
2 1.00 mm² Black -X74:14
4
H H

Changing
2 POWER Location
drawing M.-Nr.: MPE 684 T3 UNIT
1 User
0 FIRST DRAFT 17.11.11 CD C4.4M PU
the E3! Proved No. 16 Sh.
1 2 3 4 5 6 1 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
100mm 50MM 200MM 50MM 1000MM 300mm
-U8 -U11 -U54 -U64 -U15 -U22 -U33 -U35 -U37
A A
-U10
-U9
300mm
600mm
100mm
1000MM
B B
-U12
-U38
400mm
-U16
-U34
-X55#2 W2S -X93#1
1 1.00 mm² Green-White -S4:2 100MM *2/2
2 1.00 mm² Black -X49:1 BEACON

FUEL STARTER CONNECTION
100MM PUMP SOLENOID
900MM
POWER UNIT
LIGHT -U83 -X93#2 60505024
W2S -X162#1
-U71 -X43#1
*2/2 1/1 1 1.00 mm² Red -X92:1
*2/2
2 1.00 mm²,1.00 mm² Black,Black -X160:2, -X95:2
-U82
-X55#1
-U70
-X43#2
DT06-2S
-X162#2
1 1.00 mm² Purple -X164:1
2 1.00 mm² Black -X49:1
C C
-U40
-X48#1
*2/2
HYD OIL COOLER 400mm
700MM
FAN No.1
150MM
-X48#2
1 3.00 mm²,3.00 mm² Purple,Purple -X47:1, -X160:1 -U36
3.00 mm²,3.002mm²,3.00 mm²,3.00 mm² Black,Black,Black,Black -X49:1, /2.F9
-U41
-X160#1
*2/2
-U55
HYD OIL COOLER
-U72
FAN No.2
-X160#2
-U84
1 3.00 mm² Purple -X48:1

D 600MM OIL PRESSURE 2 3.00 mm²,1.00 mm² Black,Black -X49:1, -X93:2 D
SWITCH
W2S -X166#1
-U74
*2/2
W2S -X95#1
*2/2
-U73
AIR FILTER
*2/2
RESTRICTION SIREN
150mm
DT06-2S
CONNECTION
-X76#1
-U85
-U65
-X76#2 -X166#2 2 1
1 1.00 mm² Red -X169:1 1 1.00 mm² Black /5.A1 -X95#2 60505024 -LF2#1 -LF2#1
2 1.00 mm² Black-Red -X78:1 2 1.00 mm² Green -X69:1 1 1.00 mm² Red -X92:1 1 2
2 1.00 mm² Black -X93:2
W8S
2 1
-LF3 -LF3#1
1 2
-U42
REMOTE KEYSWITCH
*8/8
-X152#1
Cable harness for manufacturing; 8-polar; Connection-Target

DT06-8S
BOX
-X152#2
150MM
1 1.00 mm² Red -F1:2

2 1.00 mm²,1.00 mm² Red,Red -2:1, /2.C4
3 1.00 mm² Red -X79:1
4 1.00 mm² Red-Grey -X21:1
E E
50MM
5
6
7
50MM
8
-U43
*8/8
ALTERNATOR
DT04-8P
86
-X151#1
-U
D+ TERMINAL 1/1
-X153#1
-U75
-X153#2
1 1.00 mm² Red -S1:30 0-001-06
2 1.00 mm²,1.00 mm² Red,Red -S1:15 -X151#2
-U87
3 1.00 mm² Red -S1:50 1 1.00 mm² Red-Grey -D1:2
W8P
4 1.00 mm² Red -S8:2
5
6

7
8
400mm
100mm
-U76
-U88
F F
100MM
-U44
39
-U
-U69
100MM
100MM
50MM
-U68
400MM
1/1
1/1
1/1
-X28#1
-X29#1
-X30#1
1/1
1/1
-X8#1
-X17#1
-U78
-X165#1 W2S
FUEL
-U
*2/2
77
SOLENOID ENGINE
89
G G
-U
TEMP SWITCH
*2/2
/1.F6
-X49:1
REMOTE -X161#1
KEYSWITCH -X161#2 -X165#2 DT06-2S
-U90
-X7:1
-X16:1
ENCLOSURE 1.00 mm² Purple -X164:1 1.00 mm² Green-Pink -X68:1

1 1
2 1.00 mm² Black -X49:1 2 1.00 mm² Black /5.A1
-U79
3.00 mm² Green
3.00 mm² Black
6.00 mm² Brown
16.00 mm² Red
COOLANT LEVEL
-X28#2
-X29#2
-X30#2
1
1
1
SWITCH
-X8#2
-X17#2
1
1
*3/3
-X167#1
100MM
-X167#2
1.00 mm²,1.00Amm²,1.00 mm²,1.00 mm² Red,Red,Red,Red -S4:1, /3.A1, /5.A9, /5.A1
B 1.00 mm² Black /5.A1
C 1.00 mm² White-Orange -X67:1
H H
KBS 0-001-22
-U
80
TERMINAL PREHEAT
-X163#2 TERMINAL
1 1.00 mm² Purple -X164:1 1/1
-U81
-X12#1
-X163#1 -X12#2
1/1 3 Date Name Type Description:
C4.4M PU Electrical Kit Assignment
1 6.00 mm² Brown -X13:1 Changing
2 POWER Location
drawing M.-Nr.: MPE 684 T3 UNIT
1 User
1 2 3 4 5 6 1 7 8 9 10 11 12
Appendix C

Page C-2 684
Appendix C
(2) Tier 4 Schematics

684 Page C-3
F
E
A
D
C
1
1
-X1
Battery Cable 70mm-B 1/2 Battery Cable 70mm-R
2/2
-X1
JUMP START
CONNECTOR
2
2
-X2
1/1
30A
-LF1
-X5 -X3
1/1 AUTO 6mm-R 1/1 AUTO 6mm-R -X115:1 #126
1/1
/11.A5
1
-X4
3
3
only in
the E3!
drawing
Changing
80A
-LF2
-X8 -X6
1/1 Battery Cable 16mm-R 1/1 Battery Cable 16mm-R #2
0
3
1
2
/2.A1
2
1
Revision
1/1 1/1
-X10
-X9 -X7
12V
1/1
ECO
1/1
-X11
50A
-LF3
-X17 -X15
30
87
1/1 AUTO 6mm-N 1/1 AUTO 6mm-N AUTO 6mm-N

1/1 1/1 1/1 1/1 1/1
1
2
ENGINE
-X16 -X12
4
-X18 -X14 -X13
Revision text
4
PREHEAT
FIRSTDRAFT
-K1

-X20
1/1 Battery Cable 70mm-R
-X19
1/1
300A
FUSE ADDED OIL COOLER

14
-K1
-1 -X22 -X21
AUTO 1.00mm-WU 1/1 1/1 AUTO 1mm-N
13
85
86
-X25 -X23
1/1 1/1
Date
M
30.1.12
01.12.11
1/1 -X148
-X24
5
1/1
5
-X27
1/1 Battery Cable 35mm-B
1/1
1/1
1/1
CD
CD
Name
#PREHEAT_RELAY
#ECU_ACTUATOR_RTN
1/1
-X30
-X29
-X28
-X26
/11.B8
/11.B8
User
Proved
Date
AUTO 3mm-B
AUTO 3mm-B
AUTO 3mm-B
6
6
-X149
#138 1/1
Name
#-VE_SPLICE
#-VE
#-VE_ECU
/2.F6
/2.F1
/11.A4
7
7
Type MPE 6 Ser

M.-Nr.: 6 Ser T4 PU
8
8
POWER UNIT
60552352
Drawing number
9
9
No.
Sheet
Location
Assignment
1
16 Sh.
F
E
A
D
C
1 2 3 4 5 6 7 8 9
#2 16mm-R Battery Cable

/1.B3
1.0mm-RW AUTO
A A
1
-F1 1 1
10A -F2 -F3 1
2 30A 30A -F4
2 2 5A
30 2
-S1
ON 15 START 50
1mm-R,1mm-R AUTO,AUTO
33 32,281
AUTO 1.00m-RB
B B
AUTO 3mm-RW 31
2/8
-X153
3/8
-X153
254
-X153 -X152 1.0mm-RW AUTO
1/8 1/8
3/8
2/8
-X152
-X152
247 AUTO 1.00m-RB #START_REQ
1mm-R AUTO /6.D6
AUTO 6mm-R
AUTO 3mm-R
AUTO 1mm-Y
-X162 1mm-R AUTO #IGN_ON
-X39
-X41
-X46
49
1/1
1/1
1/1
/3.A1
Splice-1.5
30 30 30
/2.F5 /7.F2 /7.F4
-2
-4
-6
1-BN/4
1-BN/4
1-BN/4
-K2 -K4 -K6
C 87 87 87 C
-X44
1/1
1/1
1/1
1/5
-X31
-X40
-X42
-X47
-W3 BN CHASSIS AUTO 3mm-P 30

1
CHASSIS /7.F3
ESTOP ESTOP -K5
-S6
263 87
-W3 2BU
1/11/1
-X45
-X31
2/5
49,161 48 1 1
-F5 -F6 29
15A 15A
-2
-4
-6
2 2
D D
AUTO 1mm-W
2-WH/4
2-WH/4
2-WH/4
AUTO 3mm-WR
AUTO,AUTO 6mm-R,6mm-R
-X165 -X166 -X167 -X168 -X164 28 261
Splice-1.5 Splice-1.5 Splice-1.5 Splice-1.5 Splice-1.5 AUTO 2mm-P AUTO 2mm-P
#MP_FEED-F7:1
#IGN_ON_TO_ECU
-X43
1/1
-3
-5
-7
-X37
1-BN/4
1-BN/4
1-BN/4
1/1
1/
-X48
-X160
1/2
86
/3.A1
1/5
-K2
/2.F5
-X32
-W4 BN CHASSIS CHASSIS 85
1
ESTOP ESTOP
1/1
HYD OIL
HYD OIL
-S7
COOLER
COOLER
FAN No.1
FAN No.2
TO ECU
CONNECTION
-X38
E E
-W4 2BU
2/2
2/2
IGNITION ON /11.B8
-X48
STARTER SOLENOID
-X160
-X32
2/5
-3
-5
-7
#-VE_SPLICE -X49 -X55:2
#-VE_SPLICE
/1.F6 /3.E1
2-WH/4
2-WH/4
2-WH/4
Splice-2.5 3mm-B,1mm-B AUTO,AUTO
#-VE 167 #-VE

/1.F6 /4.A1
3mm-B AUTO
F F
-K2
/2.E4
30 87 /2.C5
3 Date Name Type MPE 6 Ser Description: Electrical Kit Assignment

Changing
2 POWER UNIT Location
drawing M.-Nr.: 6 Ser T4 PU
1 FUSE ADDED OIL COOLER 30.1.12 CD User
0 FIRSTDRAFT 01.12.11 CD
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
#MP_FEED-X40:1 #MP_FEED
/2.D5 /4.A1
AUTO 6mm-R
#IGN_ON #IGN_ON
/2.C4 /4.A1
AUTO 1mm-R
A A
1 1
-F7 -F8
15A 10A
2 2
51
62
B B
AUTO 2mm-P
1
-S4
AUTO 3mm-P
2
-X50
1/1
-X53
1/1
/8.B1 30
TRACKS /3.D4
SUPPLY -K3 86
87 -K3
/3.D4
1/1
85
-X51
C 50 C
AUTO 1mm-GW
1/1
-X54
52 53
1.00mm-NR AUTO #ELP

/11.B8
AUTO 2mm-P
-X55
1/2
-K3
/3.C4 1
30
-X52
1/2
87 /3.C3
ECU CONTROLLED -H1
FUEL LIFT PUMP
D 2 D
2/2
SUPPLY
-X55
FUEL PUMP
2/2
-X52
E E
#-VE_SPLICE 167 #-VE_SPLICE
/2.F8 /7.E5
POWER UNIT
LIGHT
F F

Changing
1 2 3 4 5 6 7 8 9
F
E
A
D
C
/3.A9
/3.A9
/2.F9
#-VE
1
1
#IGN_ON
#MP_FEED
AUTO 1mm-W
CAN_L
4
AUTO 1mm-N
CAN_H
3
AUTO 1mm-B
GND
2
AUTO 1mm-R
2
2
8...32 V DC
1
N.C
-P1
CR0451
3
3
only in
the E3!
drawing
Changing
-A1
0
3
1
2
Revision
CR0403
ifm
ECO
A CR0403
1 VBBs
N 1/1
IN0 -X56 AUTO 1mm-R
/5.E2 2 ESTOP HEALTHY VBBs 1
IN1
1/1 -X57 AUTO 1mm-B
/8.A1 3 TRACK REQUEST GND 2
4
Revision text
4
1/1
FIRSTDRAFT
-X58 AUTO,AUTO 1mm-GY,1mm-GY
4 GND CAN2_H 3
1/1 -X59 AUTO 1mm-U
5 GND CAN2_L 4
/5.E5 6 IN2
LOW SPEED

IN3
/5.E6 7 INTER SPEED
8 VBBs
-R3
B
1 VBBs
1W
IN4
120 Ω
/5.E8 2 HIGH SPEED
Date
/5.E9 3 IN5
30.1.12
CONV1 ST REQ
#CAN2_L
01.12.11
#CAN2_H
4 GND
5
5
5 GND
IN6
CD
CD
/6.E2 6 CONV 2 START DELAY
Name
IN7
/11.A8
/11.A8
/6.E3 7 JACK LEG SENSORS

8 VBBs
P/N1 1/1 -X60 AUTO 1mm-R
VBBs 1
1/1 -X61 AUTO 3mm-R
C VBB1 2
1/1 -X62 AUTO 3mm-R
1 VBBs VBB2 3
1/1
User
IN8 -X63 AUTO 1mm-B
Proved
/6.E5 2 AIR FILTER RESTRICT GND 4
IN9 1/1 -X64 AUTO,AUTO 1mm-N,1mm-N
/6.E6 3 ENG START REQ CAN1_H 5
Date
1/1 -X65 AUTO,AUTO 1mm-W,1mm-W
4 GND CAN1_L 6
5 GND
6
6
IN10
/8.A8 6 MACHINE STOP
IN11
/6.E9 7
Name
HOL
8 VBBs
D
49
46
55
58
167
OUT0
/7.A1 1 ENG CRANK
2 GND
OUT1 -8
/7.A2 3 FUEL SYSTEM 1/5 AUTO 1mm-B
4 GND
OUT2
2/5 AUTO,AUTO 1mm-U,1mm-U
/7.A3 5 HYD OIL FANS 3/5 AUTO 1mm-GY
6 GND
OUT3 4/5 AUTO,AUTO 1mm-N,1mm-N
7
7
/7.A5 7 SIREN/BEACON
SOCKET
5/5 AUTO,AUTO 1mm-W,1mm-W
8 GND
EXPANSION NODE
#-VE
#MP_FEED
#IGN_ON
Type
E OUT4
/8.A2 1 TRACKS ENABLE
2 GND
/5.A1
/5.A1
/5.D1
OUT5
/9.A1 3 SPARE
4 GND
/9.A2 5 OUT6
SPARE
MPE 6 Ser
M.-Nr.: 6 Ser T4 PU
6 GND
1mm-N AUTO
1mm-W AUTO
OUT7
/9.A3 7 SPARE
8
8
8 GND
-R1
F OUT8
1W
4/5
-X66
5/5
-X66
120 Ω
/9.A5 1 SPARE
POWER UNIT
2 GND
OUT9
/9.A6 3 SPARE
4 GND
60552352
/9.A7 5 OUT10
CONV 1 RUN
SOCKET
6 GND
Drawing number
OUT11
/9.A8 7 CONV 2 RUN
8 GND
PROGRAMMING
9
9
No.
Sheet
Location
Assignment
4
16 Sh.
F
E
A
D
C
1 2 3 4 5 6 7 8 9
#IGN_ON #IGN_ON
/4.A7 /6.A1
#-VE #-VE
/4.A7 /6.A1
AUTO 3mm-B
A A
-X152
4/8 4/8
B -B1 -X72 B
AUTO,AUTO 1mm-RS,1mm-RS-X153
IFS208 1 1/5 AUTO 1mm-R #IGN_ON
/6.B1
2 -X72
1 1 1 3 3/5 AUTO 1mm-B #-VE
/6.B1
-S5 -X72
4 4/5
2 2 2 CONVEYOR 1 START
DELAY SENSOR
AUTO 1.00mm-RG
AUTO 1.00mm-RO
AUTO 1mm-RY
5/8
-X153
6/8
-X153
7/8
-X153
C
-X74
23/31 AUTO 1mm-BW
5/8
7/8
6/8
23/31
-X152
-X152
-X152
-X73
66
67
70
1mm-RY AUTO 246
#MP_FEED 49
/4.A7
D D
AUTO 1.00mm-RG
AUTO 1.00mm-RO
AUTO 1mm-BW
AUTO 1mm-R
-X67
-X68
-X69
-X70
-X75
1/1
1/1
1/1
1/1
1/1
2 6 7 2 3
IN0 IN2 IN3 IN4 IN5
E /4.E4 /4.E4 /4.E4 /4.E5 /4.E5
E
ESTOP HEALTHY LOW SPEED INTER SPEED HIGH SPEED CONV1 ST REQ
-A1 -A1 -A1 -A1 -A1
F F

Changing
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
#IGN_ON #IGN_ON
/5.A9 /8.B7
A A
#-VE #-VE
/5.A9 /7.F1
1mm-R AUTO AUTO 1mm-R
13/31 13/31
-X73 -X74
AUTO 1mm-B
14/31 14/31
-X73 -X74
JACK LEG
SENSOR
#IGN_ON No.1
/5.B9
AUTO 1mm-R
AUTO 1mm-R
B B
#-VE
/5.B9
CORE No.1
-X76
1/2
AUTO 1mm-R
-X150
1/4
HYD OIL LEVEL
-X77
CORE No.2 2/4
-B5 -X155 SENSOR
1/5 3/4 1mm-GW AUTO
#IGN_ON 1/2
IFS208 1 188
C CORE No.2 4/4 3/4 3 C
AFR SWITCH
2 (BY OTHERS) 2/4 2
-X155
3/5 1/4 1
3
-X82 -B2
-X155 320428
4/5 280
#28
4
AUTO 1mm-GW
/2.C3
CONVEYOR 2
AUTO 1mm-NW
CORE No.1
24/31
-X74
2/2
-X77
START DELAY
AUTO 1.00mm-BG
2/2
24/31
#START_REQ
-X73
-X76
-X74
22/31
D JACK LEG 192 247 D
-X74
25/31
SENSOR
22/31
No.2
-X73
280
25/31
AUTO 1.00m-RB
-X73
AUTO 1mm-BR
AUTO 1.00mm-BG
188
AUTO 1mm-NW
-X156
-X154
-X78
-X79
-X81
1/1
1/1
1/1
1/1
1/1
E E
6 7 2 3 7
IN6 IN7 IN8 IN9 IN11
CONV 2 START DELAY /4.E5 JACK LEG SENSORS /4.E5 AIR FILTER RESTRICT /4.E6 ENG START REQ /4.E6 HOL /4.E6
-A1 -A1 -A1 -A1 -A1
F F

Changing
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
A A
Output Output Output Output
-A1 -A1 -A1 -A1
ENG CRANK FUEL SYSTEM HYD OIL FANS SIREN/BEACON
/4.E6 /4.E7 /4.E7 /4.E7
OUT0 OUT1 OUT2 OUT3
1 3 5 7
1/1
1/1
1/1
1/1
-X83
-X86
-X89
-X92
B B
76,77
1.00mm-RN AUTO
AUTO 1mm-U
AUTO 1mm-U
AUTO 1mm-U
73
74
75
-X93
-X95
1/2
1/2
C C
-X84
-X87
-X90
1/1
1/1
1/1
1/2
-X96
86 86 86
-K4 -K5 -K6
/7.F2 /7.F3 /7.F4
-W2 BN
CORE No.1
85 85 85
MACHINE
BEACON
1/1
1/1
1/1
1
-X91
-X85
-X88
-H3
CORE N0.2
2
D D
-W2 BU
2/2
-X96
2/2
2/2
-X93
-X95
#-VE_SPLICE
E /3.E9 E
1mm-B AUTO
AUTO 1mm-B
#-VE
/6.A9
-K4 -K5 -K6
/7.C1 /7.C3 /7.C4
30 87 /2.C6 30 87 /2.C9 30 87 /2.C7
F F

Changing
1 2 3 4 5 6 7 8 9
F
E
A
D
C
/3.C2
#-VE
1
1
/4.E4
-A1
#+VE_TRACKS
TRACKS ON SW
-X74 -X98 -X73 -X97
2/31 AUTO 1mm-B 10/16 AUTO 1.00mm-RU 10/31 AUTO 0.75mm-RU 1/1
IN1
10/31
Input
2/31 2/16
-X73 -X98 -X74
TRACK REQUEST
2
2
62
-X98 -X73
1.00mm-BU,1.00mm-BU,1.00mm-BU AUTO,AUTO,AUTO
4/16 AUTO 1mm-P 4/31

4/31
/4.E7
-A1
-X74
LTF
-K7
/8.F3
14
24
12
22
-X74 -X98 -X73 -X99

5/31 AUTO 1mm-UO 3/16 AUTO 1.0mm-RW 3/31 AUTO 0.75mm-RW 1/1
OUT4
-K7
/8.F3
3/31
1
5/31 5/16
A2
A1
Output
21
-X73 -X98 -X74

TRACKS ENABLE
3
0.75mm-UO AUTO
3
11 /10.C3
only in
the E3!
drawing
Changing
AUTO 3mm-R
0
3
1
2
Revision
#+VE_TRACKS
ECO
LTR
-K8
/8.F4
24
14
12
22
-X74
8/31 AUTO 1mm-UY
/10.A1
-K8
/8.F4
8/31 8/16
A2
A1
21
4
-X73 -X98
Revision text
4
FIRSTDRAFT
0.75mm-UY AUTO
11 /10.C4

RTF
-K9
/8.F5
Date
14
24
12
22
-X74
30.1.12
01.12.11
6/31 AUTO 1.00mm-NS
-K9
/8.F5
5
6/31 6/16
5
A2
A1
21
-X73 -X98
CD
CD
0.75mm-NS AUTO
Name
11/10.C5
TRACKING UMBILICAL
User
Proved
Date
RTR
-K10
/8.F6
14
24
12
22
-X74
6
9/31
6
AUTO 1.00mm-NY
/8.F6
-K10
9/31 9/16
A2
A1
Name
21
-X73 -X98
0.75mm-NY AUTO
11/10.C7
/6.A9
#IGN_ON
FAST AUTO,AUTO 1mm-R,1mm-R
/8.F7
-K11
7
14
24
12
22
-X74
7
1/31 AUTO 1mm-GY
/8.F7
-K11
1/31 1/16
A2
A1
21
-X73 -X98
Type
1mm-GY AUTO
-X74 RADIO -X98 -X73
11/10.C8
15/31 AUTO 1.00mm-BP TRACK 16/16 AUTO 1mm-GP 16/31
15/31 15/16 STOP LINK 16/31
-X73 -X98 -X74
/4.E6
-A1
MPE 6 Ser
AUTO 1mm-B
M.-Nr.: 6 Ser T4 PU
MACHINE REMOTE
8
STOP
8
1.00mm-BU AUTO
-X74 -X98 -X73 -X100
7/31 AUTO 1.00mm-BY 12/16 AUTO 1.00mm-WR 12/31 AUTO 0.75mm-WR 1/1
IN10
12/31
6
Input
7/31 7/16
MACHINE STOP
-X73 -X98 -X74
POWER UNIT
60552352
#-VE
-X114:1 #IGN_ON
Drawing number
/9.F1
9
/11.D3
9
No.
Sheet
Location
Assignment
8
16 Sh.
F
E
A
D
C
1 2 3 4 5 6 7 8 9
Output Output Output Output Output Output Output

A -A1 -A1 -A1 -A1 -A1 -A1 -A1 A
SPARE SPARE SPARE SPARE SPARE CONV 1 RUN CONV 2 RUN
/4.E8 /4.E8 /4.E8 /4.E8 /4.E8 /4.E9 /4.E9
OUT5 OUT6 OUT7 OUT8 OUT9 OUT10 OUT11
3 5 7 1 3 5 7
1/1
1/1
-X101
-X158
B B
82
266
AUTO 1mm-GN
AUTO 1mm-GB
-X73
30/31
-X73
29/31
C C
30/31
29/31
-X74
-X74
AUTO 1mm-GN
AUTO 1mm-GB
-X102
-X157
1/4
1/4
D D
2/4
2/4
-X102
-X157
31/31
-X74
E E
31/31
-X73
#-VE #-VE
/8.F9 /10.F1
F 1.00mm-BU AUTO F

Changing
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
#+VE_TRACKS 62 -X73:26
#+VE_TRACKS
/8.B3 /11.A1
A A
AUTO 1mm-P
AUTO 1mm-P
AUTO 1mm-P
AUTO 1mm-P
AUTO 1mm-P
B B
12 14 12 14 12 14 12 14 12 14
-K7 -K8 -K9 -K10 -K11

/8.F3 /8.F4 /8.F5 /8.F6 /8.F7
C 11 11 11 11 11 C
-X73
-X73
-X73
-X73
20/31 AUTO 1mm-GO
17/31 AUTO 1mm-RY

18/31 AUTO 1.00mm-OB
19/31 AUTO 1mm-GK
17/31
19/31
20/31
-X74
-X74
-X74
-X74
D D
AUTO 1mm-RY
AUTO 1.00mm-OB 18/31
AUTO 1mm-GK
AUTO 1mm-GO
-X103
-X105
-X106
-X107
1/4
1/4
1/4
1/4
LEFT TRACK LEFT TRACK RIGHT TRACK RIGHT TRACK
FORWARD SOL. REVERSE SOL. FORWARD SOL. REVERSE SOL.
E
2/4
2/4
2/4
2/4
-X103
-X105
-X106
-X107
-X104 #-VE
21/31 21/31 Splice-2.5
-X73 -X74
AUTO 1.00mm-BU
#-VE #-VE
/9.F9 /11.E1
1.00mm-BU AUTO
F F

Changing
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
ENGINE
ECU
#+VE_TRACKS
/10.A1
/10.A9
-X117
50/70 1mm-GY AUTO
/1.F6
/1.B3
A #CAN2_H /4.B5 A
48/70
-X117
#126
-X117
34/70 1mm-U AUTO
#-VE_ECU
#CAN2_L /4.B5
52/70
-X117
-X73
26/31
-X117
21/70 1.00mm-NR AUTO
#ELP /3.C5
53/70
AUTO 1mm-R
-X117
26/31
-X117
-X74
70/70 1mm-W AUTO
#IGN_ON_TO_ECU /2.D8
-X115 55/70
AUTO 1mm-R
Splice-2.5 -X117
B -X117 B
-X116 20/70 1mm-N AUTO
#PREHEAT_RELAY /1.A5
Splice-2.5 57/70
AUTO 1mm-GR
-X117
-X117
59/70 1.00mm-WU AUTO
#ECU_ACTUATOR_RTN
/1.C5
61/70
-X117
-X117 5/70 1mm-RS AUTO -X119
-X108
1/4
Splice-2.5 B/3
-X122
-X117
AUTO 1mm-B
63/70 4/70 -X170 1.00mm-OB AUTO
-X117 Splice-2.5 A/3
SENSOR
C -X122 C
-X117
RADIO CONTROLLED TIPPING GRID -X112 49/70 1mm-WO AUTO
COOLANT LEVEL
RECIEVER (TELERADIO) Splice-2.5 65/70 C/3

-X117 -X122
-X117
35/70 1mm-GU AUTO
1/3
-X123
67/70 -X120 #94
AUTO 1mm-B
2/4
-X117 Splice-2.5 2/3
FUEL
-X123
CONTAM.
-X108
1.00mm-OB AUTO
AUTO 1mm-B
-X113 3/3
D -X123
D
Splice-2.5 69/70
AUTO 1mm-B
-X117
-X117
17/70 1mm-G AUTO
27/31
-X74
#IGN_ON /8.B7 1mm-R AUTO 37/70 1/2
/8.B9 -X117 -X124
-X117
3/70 1mm-O AUTO
AIR INLET
-X121
27/31
-X73
TEMP SENSOR
38/70 Splice-2.5 2/2

1mm-WY AUTO -X117 -X124
-X117
2/70 -X118 1mm-GK AUTO
1mm-NO AUTO Splice-2.5 1/4
AUTO 1.00mm-BU
120 Ω -X125
-R4 1W -X117 E
E 26/70
#-VE 2/4
/10.F9
DPF AIR
1.00mm-BU AUTO -X125

-X117
TEMP SENSOR
14/70 1mm-P AUTO

3/4
-X125
-X111
-X111
2/2
-X114
-X114
2/6
-X114
4/6
-X114
5/6
1/2
1/6
1mm-GK AUTO
1/6
1/2
2/2
DPF SOOT SENSOR -X126

CAN C 1mm-K AUTO
-X159
-X159
F TERMINATION 3/6 F
DPF ID
MODULE
CONNECTOR -X126
1mm-RS AUTO
1W
120 Ω
6/6
-X126
-R2
Changing
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
2400MM
A A
-U75 Part No. 60552225/6 -X2#2
-X1#2 -X1#1 1 70.00 mm² Red -X1:1
1/2 1/1
1 70.00 mm² Red -X2:1 -X2#1
2/2
2 70.00 mm² Black -X9:1 -U76 -X9#2
1 70.00 mm² Black -X1:2
1/1
-X9#1
ENGINE JUMP START CONNECTION
TO BATTERY
1/1
-X10#1
1/1
-X11#1
2100MM
B B
480MM
-X19#2 -X19#1 -U70 Part No. 60552223 -X18#2

1/1
1/1
-X18#1
-VE BATTERY TO MAIN ISOLATOR
C C
1400MM
-X20#2 -X20#1 -U71 Part No. 60552221 -X23#2

1/1
1 70.00 mm² Red -X23:1 1 70.00 mm² Red -X20:1
1/1
-X23#1
+VE BATTERY TO STARTER +VE STUD
D D
1400MM
-X24#2 -X24#1 -U72 Part No. 60552224 -X25#2

1/1
1/1
-X25#1
MAIN ISOLATOR TO STARTER -VE STUD
E E
300MM
-X26#2 -X26#1 -U73 Part No. 60552222 -X27#2

1/1
1/1
-X27#1
STARTER -VE STUD TO CHASSIS GROUND
600MM
F -X148#2 -X148#1 -U74 Part No. 60552227 -X149#2 F

1/1
1 25.00 mm² Red -X149:1 1 25.00 mm² Red -X148:1
1/1
-X149#1
STARTER +VE STUD TO ALTERNATOR CHARGE TERMINAL

Changing
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9 10 11 12
-X108#2 1 2
1 1.00 mm² Green-Red -X74:26
2 1.00 mm²,1.00 mm² Black, Black /11.E1, -X74:27 -X108#1
*4/4
3
4 FRONT
VIEW -X150#1
REMOTE TIPPING GRID *4/4 JACKING LEG
RECIEVER CONNECTION SENSORS
3 4
-X150#2
1 1.00 mm² Red -X74:13
-X74#2
2 1.00 mm² Black -X98:2
4 1.00 mm² Purple -X98:4
100MM
150MM
10 1.00 mm² Red-Blue -X98:10
11
12 1.00 mm² White-Red -X98:12
mm²,1.00 mm²,1.00 mm²
1.00 mm²,1.0013 Red,Red,Red,Red -X82:1, -X155:1, -X72:1, -X150:1
63
mm²,1.00 mm²,1.00 mm²
1.0014 Black,Black,Black -X82:2, -X155:3, /6.B1
-U62
-U
18 1.00 mm² Orange-Black -X105:1
-U61
21 1.00 mm² Black -X104:1
22 1.00 mm² Black-Green -X155:4
B
26 1.00 mm² Green-Red -X108:1 -X103#2
27 1.00 mm² Black -X108:2 Part No. 60552351 1 1.00 mm² Red-Yellow -X74:17
28 LTF SOLENOID 1.00 mm²,1.00 mm²,1.002mm²,1.00 mm²,1.00 mm² Black,Black,Black,Black,Black-X104:1, -X105:2
29 1.00 mm² Green-Black -X157:1 3
50MM
*4/4
31 1.00 mm²,1.00 mm² Black, Black -X102:2, -X157:2 -X103#1
2600MM 200mm
650mm 330MM 650MM 50mm
-X105#2
LTR SOLENOID 1.00 mm²,1.002mm²,1.00 mm²,1.00 mm² Black,Black, Black,Black -X106:2, -X103:2, -X104:1
-U1 -U66 -U3 -U7 3
-U59 -U60 PE
*4/4
-X105#1
-X106#2
RTF SOLENOID 2 1.00 mm²,1.00 mm² Black, Black -X105:2, -X107:2
-U4 3
-X74#1 PE
*31/31 *4/4
-X106#1
C C
-X107#2
RTR SOLENOID 2 1.00 mm²,1.00 mm² Black, Black -X106:2, /10.E8
3
PE
*4/4
-X107#1
300mm
300mm
400mm
JACK LEG??
D D
-U2
-U67
TRACKING -X98#1
UMBILICAL CONNECTION *16/16
-X98#2
2 1.00 mm² Black -X74:2
4 1.00 mm² Purple -X74:4
300mm
300mm
1000mm
100mm
100mm
E E
10 1.00 mm² Red-Blue -X74:10
11
12 1.00 mm² White-Red -X74:12
13
14
CONVEYOR No.1 16 1.00 mm² Green-Pink -X74:16
DELAY SENSOR
CONVEYOR NO.2
DELAY SENSOR
*5/5
-B1#1
-X72#1
-X72#2
*5/5
1 1.00 mm² Red -X74:13 -X155#1
2 -X155#2
4 1.00 mm² Black-White -X74:23 SOLENOID 2 SOLENOID
5 3 1.00 mm² Black -X74:14
*4/4
*4/4
4 1.00 mm² Black-Green -X74:22
5
-X157#1
-X102#1
-X102#2 -X157#2
1 1.00 mm² Green-Brown -X74:30 1 1.00 mm² Green-Black -X74:29
3 3
PE PE
G G
HYD. OIL LEVEL

SENSOR
*4/4
-B2#1
-X82#1
-X82#2
1 1.00 mm² Red -X74:13
2 1.00 mm² Black -X74:14
4
H H

Changing
2 POWER Location
drawing M.-Nr.: 6 Ser T4 PU UNIT
0 FIRSTDRAFT 01.12.11 CD MPE 6 Ser
1 2 3 4 5 6 1 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
100mm 50MM 200MM 50MM 1000MM 300mm
-U8 -U11 -U54 -U64 -U15 -U22 -U33 -U35 -U37
A A
-U10
-U9
300mm
600mm
100MM
100mm
-X117#2
450MM
1
2 1.00 mm²,1.00 mm² Green-Pink, Green-Pink -X125:1, -X118:1
B 3 1.00 mm² Orange -X121:1
B
5 1.00 mm² Red-Grey -X119:1
6
7
8
9
-U12
-U55
-U38
400mm
10
11
-U16
-U34
-X55#2 12 W2S -X93#1
1 1.00 mm² Green-White -S4:2 13 *2/2
2 1.00 mm² Black -X49:1 14 1.00 mm² Pink -X126:3 BEACON
15 CONNECTION
16
POWER UNIT 17 1.00 mm² Green -X124:1
LIGHT -X93#2 60505024
18
-U56
19 1 1.00 mm² Red-Brown -X92:1
*2/2
20 1.00 mm² Brown -X21:1 2 1.00 mm²,1.00 mm² Black, Black -X160:2, -X95:2
200mm 100mm 100mm 21 1.00 mm² Brown-Red -X54:1 STARTER
-X55#1
22 SOLENOID
1
23
1/1
-U24 -U27
-U23 -U26 -U31 24
-X43#1
25
-X117#1 26 1.00 mm² Purple -X125:3
*70/70
-U17
27 -X43#2
28 1 3.00 mm² White-Red -X42:1
C C
29
30
-U40
31
-H1#1
ENGINE ECU 32
CONNECTOR 33
34 1.00 mm² Blue -X59:1
800MM
35 1.00 mm² Green-Blue -X123:1
36
37 1.00 mm²,1.00 mm² White-Yellow, Whit e-Yellow -X111:1, -X114:5
38 1.00 mm²,1.00 mm² Brown-Orange,Brown-Orange-X111:2, -X114:4
39 -X48#1
*2/2
800MM
40 HYD OIL COOLER 400mm
FAN No.1
41
42
43 -X48#2
44 1 2.00 mm² Purple -F5:2 -U36
57
45 3.00 mm²,3.002mm²,3.00 mm²,3.00 mm² Black,Black, Black,Black -X49:1, /2.F8
-U
46
-U41
47
400mm
48 1.00 mm² Red -X117:52 -X160#1
*2/2
-U18
700mm
49 1.00 mm² Whit e-Orange -X122:C
50 1.00 mm² Green-Yellow -X58:1 HYD OIL COOLER
-U58
FAN No.2
51
AIR INLET 52 1.00 mm²,1.00 mm² Red,Red -X117:48, -X115:1 -X160#2
*2/2
TEMP SENSOR 53 1.00 mm² Red -X117:55 1 2.00 mm² Purple -F6:2
54 2 3.00 mm²,1.00 mm² Black, Black -X49:1, -X93:2
-X124#1
D D
-X124#2 55 1.00 mm²,1.00 mm² Red,Red -X117:53, -X117:57
1 1.00 mm² Green -X117:17 56 2 1
2 1.00 mm² Orange -X121:1 57 1.00 mm²,1.00 mm² Red,Red -X117:55, -X116:1 -LF1 -LF1#1
58 W2S -X95#1 1 2
59 1.00 mm² Whit e-Blue -X22:1 *2/2
AIR FILTER 60
*2/2
RESTRICTION 61 1.00 mm² Black -X117:63 SIREN
CONNECTION
150mm
62
-X76#1
-U25
-U28
-U65
-X76#2 63 1.00 mm²,1.00 mm² Black, Black -X117:61, -X117:65 2 1
1 1.00 mm² Red /6.A1 64 -X95#2 60505024 -LF2#1 -LF2#1
2 1.00 mm² Black-Red -X78:1 65 1.00 mm²,1.00 mm² Black, Black -X117:63, -X112:1 1 1.00 mm² Red-Brown -X92:1 1 2
66 2 1.00 mm² Black -X93:2
W8S
-X123#1 W2S -X52#1 67 1.00 mm² Black -X117:69
*3/3 *2/2 68 2 1
1.0069mm²,1.00 mm²,1.00 mm² Black,Black,Black -X117:67, -X112:1, -X113:1 -LF3 -LF3#1
FUEL 70 1.00 mm² White -X45:1 1 2
CONTAMINATION
-U42
REMOTE KEYSWITCH SENSOR
*8/8
-X152#1
Fuel Pump Supply
DT06-8S
Cable harness f or manufacturing; 8-polar; Connection-Target
-U29
BOX -X123#2 -X52#2 60505024
1700MM
1 1.00 mm² Green-Blue -X117:35 1 2.00 mm² Purple -X51:1
-X152#2 2 1.00 mm² Red-Grey -X119:1 2 1.00 mm² Black /3.E1
1 1.00 mm² Red-White -F1:2 3 1.00 mm² Orange-Black -X170:1
2 1.00 mm² Red -X162:1
3 1.00 mm² Red-Black -X79:1
4 1.00 mm²,1.00 mm² Red,Red /5.A1, /5.A9
E E
5 1.00 mm² Red-Green -X68:1
6 1.00 mm² Red-Orange -X69:1
8
-U43
100mm
*8/8
DT04-8P
-X153#1
-X153#2
500mm
1 1.00 mm² Red-White -S1:30
2 1.00 mm²,1.00 mm² Red,Red -S1:15
3 1.00 mm² Red-Black -S1:50 DPF AIR
TEMP. SENSOR
W8P
4 1.00 mm²,1.00 mm² Red-Grey,Red-Grey -S5:1
5 1.00 mm² Red-Green -S5:2 -X125#2
-U
6 1.00 mm² Red-Orange -S5:2 -X125#1 1 1.00 mm²,1.00 mm² Green-Pink, Green-Pink -X117:2, -X118:1

32
7 1.00 mm² Red-Yellow -S5:2 *4/4 2 1.00 mm² Orange -X121:1

8 3 1.00 mm² Purple -X117:26
400mm
100mm
4
-U30
DPF ID
-U19
F -X126#2 MODULE F
-X126#1 1 1.00 mm² Green-Pink -X118:1
*6/6 2
100MM
3 1.00 mm² Pink -X117:14
-U44
4
ENGINE 5
PREHEAT 6 1.00 mm² Red-Grey -X120:1
1/1
TERMINAL
39
-X12#1
-U
-X12#2
-U20
-U69
1 6.00 mm² Brown -X13:1
-U68
1/1
1/1
1/1
-X28#1
-X29#1
-X30#1
1/1
1/1
1/1
-X8#1
-X5#1
-X17#1
150mm
G G
/1.F6
-X112:1
-X49:1
REMOTE
300MM
KEYSWITCH
-X4:1
-X7:1
-X16:1
ENCLOSURE
3.00 mm² Black
3.00 mm² Black
3.00 mm² Black
14
-U
6.00 mm² Red
6.00 mm² Brown
16.00 mm² Red
-X28#2
1
-X29#2
1
-X30#2
1
-X122#1
*3/3 COOLANT LEVEL
-X5#2
1
-X8#2
1
-X17#2
1
-U21
SENSOR
-X122#2
A 1.00 mm² Orange-Black -X170:1 -X114#1
B 1.00 mm²,1.00 mm² Red-Grey,Red-Grey -X119:1 *6/6
C 1.00 mm² Whit e-Orange -X117:49
-X111#1
*2/2
DPF SOOT
H SENSOR CAN C H
-X114#2 TERMINATION RESISTOR
1 1.00 mm² Red /8.B7 -X111#2
2 1.00 mm² Black-Blue -X73:27 1 1.00 mm² White-Yellow -X117:37
3 2 1.00 mm² Brown-Orange -X117:38
4 1.00 mm² Brown-Orange -X117:38
5 1.00 mm² White-Yellow -X117:37
6
W2P
-X159#1
*2/2
-X159#2
1 -R2.X2:1
3 Date Name Type MPEDescription:
6 Ser Electrical Kit Assignment
-R2.X1:1 Changing
2 2 POWER Location
drawing M.-Nr.: 6 Ser T4 PU UNIT
DT04-2P 0 FIRSTDRAFT 01.12.11 CD
1 2 3 4 5 6 1 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9
A A
500MM
Part No. 60552028 2

1
-X96#1
-X96#2
1 1.00 mm² Brown -H3:1 -W2
2 1.00 mm² Blue -H3:2 -W2
-H3#1
B B
-S7#1
-U48
5500MM
C E11506 C
Part No. 60552247

OFF SIDE -X32#1
-X32#2
1 1.00 mm² Brown -S7:1 -W4
2 1.00 mm² Blue -S7:2 -W4
3
4
5
D D
-S6#1
-U51
2000MM
E11506
E E
Part No. 60552265
NEAR SIDE -X31#1
-X31#2
1 1.00 mm² Brown -S6:1 -W3
2 1.00 mm² Blue -S6:2 -W3
3
4
F 5
F

Changing
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
A A
B B
DURITE
12 vo lt 12 0 amp
-K1
30 85 86 87
DURITE
-A1
12 vo lt 12 0 amp
-K2
30 85 86 87
LED
30
86 85
3 4 3 4 3 4 3 4 3 4
85
12 V
30
RELAY
-K4
0-727-16
40A
-X144
6 6 6 6 6
86
DURITE
5 5 5 5 5
87 87a
87
7 8 7 8 7 8 7 8 7 8 -X127 -X133 -X132 -X131 -X130 -X137 -X134
30
12
12
12
12
12
86 85
14
21 24
14
21 24
14
21 24
14
21 24
14
21 24
85
12 V
1
1 1
1 1
1 1
1 1 1 1
1 N2
1 1
22
22
22
22
22
A1
A1
A1
A1
A1
RELAY
-K6
0-727-16
30
40A
1
86
DURITE
VBBs
-X145
-F1 -F2 -F3 2 -F4 -F5 -F7 -F8
GND 2
-K7 -K8 -K9 -K10 -K11 2 2 2 2 2 2 CAN2_H 3
87
87 87a
11
11
11
11
11
A2
A2
A2
A2
A2
CAN2_L 4
30
-X142 -X141 -X140 -X139 -X138 -P1
86 85
85
12 V
A B C D E F P/N1
1 1
RELAY
-K5
1
0-727-16
A VBBs 1 VBBs 1 C VBBs
30
40A
1 B
1 2 1 2 1 2 1 2 1 2 1
VBBs
86
DURITE
2 2
-X146
2 2 D GND 2 E GND 2 F GND
2
VBB1
3 3 3 3 3
3
VBB2 3
O I 1
87
A GND 4 B GND 4 C GND 4 D GND 4 E GND 4 F GND
87 87a
4
GND 4
5 5 1 2
A GND 5 5 5
5 B GND C GND
CAN1_H 5
6 6 6 5
6 D GND
6 E GND 6 F GND
CAN1_L 6 -P1 -S4
7 7 7 7 7 4 3
7 NO
RELAY
-K3
25A 12 V
0-727-13
A VBBs 8 D GND
8 8 B VBBs 8 C VBBs 8 E GND 8 F GND
DURITE
-X147
-S4 2
87 86 85 30
C
85 86 30 87a 87
C
OK
-2 -7
1-BN 2-WH 1-BN 2-WH
4-BK 3-BLU 4-BK 3-BLU
X73
-8
-3 -6
3
4 2 1-BN 2-WH 1-BN 2-WH
5 1 4-BK 3-BLU 4-BK 3-BLU
D -4 -5 D
1-BN 2-WH 1-BN 2-WH
FRONT U9
4-BK 3-BLU 4-BK 3-BLU
LOW INT HIGH
-S1
-S5
E E
F F

Changing
1 2 3 4 5 6 7 8 9
Appendix C

Page C-4 684
Appendix D
Appendix D Engine Fault Codes

If there is an engine fault the engine fault screen will be shown on the display (Figure D.1) when
the alarm button (item 2, Figure D.2) is pressed.
Figure D.1 - Engine Fault Screen
2 4
3
DUN00084
Figure D.2 - Control Panel Display
The engine fault screen displays the following information:

• The SPN number identifies the specific component which has a fault.
• The number of hours specifies the engine run hours when the fault occurred.
• The FMI number indicates the type of failure that is associated with the component.
• The OC number specifies how many times that particular fault has occurred.
Table D.1 gives a list of the fault codes and descriptions of the faults corresponding to the
combination of codes from the engine fault screen. Table D.1 can be used to determine what
the active fault is.

684 Page D-1
Appendix D
Example:
Table D.1 gives a list of the engine fault codes along with a description of the fault.
The J1939 code is made up of two numbers separated by a dash. The first number is the SPN
number. The second number is the FMI number.
The engine fault screen in Figure D.1 is shown on the display screen. The SPN number is 111
and the FMI number is 1. The corresponding numbers in Table D.1 indicate that the engine
coolant level is low.
Extract from table:
J1939
Code Description Refer to Procedure
111-1 Engine Coolant Level : Low - most severe (3) Coolant Level is Low
The engine fault screen also shows that this fault has occurred twice and the last time it occurred
was when the engine run hours was 6 hours. The yellow warning symbol at the right hand side
of the screen indicates that the fault is currently active.

Page D-2 684
Appendix D
Table D.1 - Engine Fault Codes and Descriptions
J1939
27-3 Engine Exhaust Gas Recirculation Valve Position Valve Position Sensor - Test
Sensor : Voltage Above Normal
27-4 Engine Exhaust Gas Recirculation Valve Position Valve Position Sensor - Test
Sensor : Voltage Below Normal
29-2 Accelerator Pedal Position 2 : Erratic, Throttle Switch Circuit - Test
Intermittent, or Incorrect (Engines equipped with
a throttle switch)
29-2 Accelerator Pedal Position 2 : Erratic, Intermittent Analog Throttle Position
or Incorrect (Engines equipped with an analog Sensor Circuit - Test
throttle)
29-3 Accelerator Pedal Position 2 : Voltage Above Analog Throttle Position
Normal (Engines equipped with an analog Sensor Circuit - Test
throttle)
29-3 Accelerator Pedal Position 2 : Voltage Above Digital Throttle Position Sensor
Normal (Engines equipped with a digital throttle) Circuit - Test
29-4 Accelerator Pedal Position 2 : Voltage Below Analog Throttle Position
throttle)
29-4 Accelerator Pedal Position 2 : Voltage Below Digital Throttle Position Sensor
29-8 Accelerator Pedal Position 2 : Abnormal Digital Throttle Position Sensor
Frequency, Pulse Width or Period Circuit - Test
51-3 Engine Throttle Position : Voltage Above Normal Valve Position Sensor - Test
51-4 Engine Throttle Position : Voltage Below Normal Valve Position Sensor - Test
91-2 Accelerator Pedal Position 1 : Erratic, Throttle Switch Circuit - Test
Intermittent, or Incorrect (Engines equipped with
a throttle switch)
91-2 Accelerator Pedal Position 1 : Erratic, Intermittent Analog Throttle Position
or Incorrect (Engines equipped with an analog Sensor Circuit - Test
throttle)
91-3 Accelerator Pedal Position 1 : Voltage Above Analog Throttle Position
throttle)
91-3 Accelerator Pedal Position 1 : Voltage Above Digital Throttle Position Sensor
91-4 Accelerator Pedal Position 1 : Voltage Below Analog Throttle Position
throttle)
91-4 Accelerator Pedal Position 1 : Voltage Below Digital Throttle Position Sensor
91-8 Accelerator Pedal Position 1 : Abnormal Digital Throttle Position Sensor
Frequency, Pulse Width or Period Circuit - Test
97-3 Water In Fuel Indicator : Voltage Above Normal Water in Fuel Sensor - Test
97-15 Water In Fuel Indicator : High - least severe (1) Fuel Contains Water

684 Page D-3
Appendix D
J1939
97-16 Water In Fuel Indicator : High - moderate severity Fuel Contains Water
(2)
100-1 Engine Oil Pressure : Low - most severe (3) Oil Pressure Is Low
100-3 Engine Oil Pressure : Voltage Above Normal Engine Pressure Sensor Open
or Short Circuit - Test
100-4 Engine Oil Pressure : Voltage Below Normal Engine Pressure Sensor Open
100-17 Engine Oil Pressure : Low - least severe (1) Oil Pressure Is Low
100-21 Engine Oil Pressure : Data Drifted Low 5 Volt Sensor Supply Circuit -
Test
102-16 Engine Intake Manifold #1 Pressure : High - Intake Manifold Air Pressure Is
moderate severity (2) High
102-18 Engine Intake Manifold #1 Pressure : Low - Intake Manifold Air Pressure Is
moderate severity (2) Low
105-3 Engine Intake Manifold #1 Temperature : Voltage Engine Temperature Sensor
Above Normal Open or Short Circuit - Test
(Passive Sensors)
105-4 Engine Intake Manifold #1 Temperature : Voltage Engine Temperature Sensor
Below Normal Open or Short Circuit - Test
(Passive Sensors)
105-15 Engine Intake Manifold #1 Temperature : High - Intake Manifold Air
least severe (1) Temperature Is High
105-16 Engine Intake Manifold #1 Temperature : High - Intake Manifold Air
moderate severity (2) Temperature Is High
107-15 Engine Air Filter 1 Differential Pressure : High - Inlet Air Is Restricted
least severe (1)
108-3 Barometric Pressure : Voltage Above Normal Engine Pressure Sensor Open
108-4 Barometric Pressure : Voltage Below Normal Engine Pressure Sensor Open
108-13 Barometric Pressure : Calibration Required Sensor Calibration Required -
Test
108-21 Barometric Pressure : Data Drifted Low 5 Volt Sensor Supply Circuit -
Test
110-0 Engine Coolant Temperature : High - most Coolant Temperature Is High
severe (3)
110-3 Engine Coolant Temperature : Voltage Above Engine Temperature Sensor
Normal Open or Short Circuit - Test
(Passive Sensors)
110-4 Engine Coolant Temperature : Voltage Below Engine Temperature Sensor
(Passive Sensors)
110-15 Engine Coolant Temperature : High - least Coolant Temperature Is High
severe (1)

Page D-4 684
Appendix D
J1939
110-16 Engine Coolant Temperature : High - moderate Coolant Temperature Is High
severity (2)
111-1 Engine Coolant Level : Low - most severe (3) Coolant Level is Low
157-3 Engine Injector Metering Rail #1 Pressure : Engine Pressure Sensor Open
Voltage Above Normal or Short Circuit - Test
157-4 Engine Injector Metering Rail #1 Pressure : Engine Pressure Sensor Open
Voltage Below Normal or Short Circuit - Test
157-16 Engine Injector Metering Rail #1 Pressure : High Fuel Rail Pressure Problem
- moderate severity (2)
157-18 Engine Injector Metering Rail #1 Pressure : Low - Fuel Rail Pressure Problem
moderate severity (2)
158-2 Keyswitch Battery Potential : Erratic, Intermittent Ignition Keyswitch Circuit and
or Incorrect Battery Supply Circuit - Test
168-2 Battery Potential / Power Input 1 : Erratic, Ignition Keyswitch Circuit and
Intermittent or Incorrect Battery Supply Circuit - Test
168-3 Battery Potential / Power Input 1 : Voltage Above Ignition Keyswitch Circuit and
Normal Battery Supply Circuit - Test
168-4 Battery Potential / Power Input 1 : Voltage Below Ignition Keyswitch Circuit and
Normal Battery Supply Circuit - Test
172-3 Engine Air Inlet Temperature : Voltage Above Engine Temperature Sensor
(Passive Sensors)
172-4 Engine Air Inlet Temperature : Voltage Below Engine Temperature Sensor
(Passive Sensors)
174-3 Engine Fuel Temperature 1 : Voltage Above Engine Temperature Sensor
(Passive Sensors)
174-4 Engine Fuel Temperature 1 : Voltage Below Engine Temperature Sensor
(Passive Sensors)
174-15 Engine Fuel Temperature 1 : High - least severe Fuel Temperature Is High
(1)
174-16 Engine Fuel Temperature 1 : High - moderate Fuel Temperature Is High
severity (2)
190-8 Engine Speed : Abnormal Frequency, Pulse Engine Speed/Timing Sensor
Width or Period Circuit - Test
190-15 Engine Speed : High - least severe (1) Engine Overspeeds
411-3 Engine Exhaust Gas Recirculation Differential Engine Pressure Sensor Open
Pressure Sensor : Voltage Above Normal or Short Circuit - Test
411-4 Engine Exhaust Gas Recirculation Differential Engine Pressure Sensor Open
Pressure Sensor : Voltage Below Normal or Short Circuit - Test
411-13 Engine Exhaust Gas Recirculation Differential Sensor Calibration Required -
Pressure Sensor : Calibration Required Test

684 Page D-5
Appendix D
J1939
412-3 Engine Exhaust Gas Recirculation Temperature: Engine Temperature Sensor
Voltage Above Normal Open or Short Circuit - Test
(Passive Sensors)
412-4 Engine Exhaust Gas Recirculation Temperature: Engine Temperature Sensor
Voltage Below Normal Open or Short Circuit - Test
(Passive Sensors)
412-15 Engine Exhaust Gas Recirculation Temperature : NRS Exhaust Gas
High - least severe (1) Temperature Is High
412-16 Engine Exhaust Gas Recirculation Temperature : NRS Exhaust Gas
High - moderate severity (2) Temperature Is High
558-2 Accelerator Pedal 1 Low Idle Switch : Erratic, Idle Validation Switch Circuit -
Intermittent or Incorrect Test
626-5 Engine Start Enable Device 1 : Current Below Ether Starting Aid - Test
Normal
626-6 Engine Start Enable Device 1 : Current Above Ether Starting Aid - Test
Normal
630-2 Calibration Memory : Erratic, Intermittent or Flash Programming
Incorrect
631-2 Calibration Module : Erratic, Intermittent or ECM Memory - Test
Incorrect
637-11 Engine Timing Sensor : Other Failure Mode Engine Speed/Timing Sensor
Circuit - Test
651-2 Engine Injector Cylinder #01 : Data Incorrect Injector Data Incorrect- Test
651-5 Engine Injector Cylinder #01 : Current Below Injector Solenoid Circuit - Test
Normal
651-6 Engine Injector Cylinder #01 : Current Above Injector Solenoid Circuit - Test
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal

Page D-6 684
Appendix D
J1939
Normal
Normal
Normal
676-6 Engine Glow Plug Relay : Current Above Normal Starting Aid (Glow Plug) Relay
Circuit - Test
678-3 ECU 8 Volts DC Supply : Voltage Above Normal Digital Throttle Position Sensor
Circuit - Test
678-4 ECU 8 Volts DC Supply : Voltage Below Normal Digital Throttle Position Sensor
Circuit - Test
723-8 Engine Speed Sensor #2 : Abnormal Frequency, Engine Speed/Timing Sensor
Pulse Width or Period Circuit - Test
1075-5 Engine Electric Lift Pump for Engine Fuel Supply Fuel Pump Relay Circuit - Test
: Current Below Normal
1075-6 Engine Electric Lift Pump for Engine Fuel Supply Fuel Pump Relay Circuit - Test
: Current Above Normal
1076-5 Engine Fuel Injection Pump Fuel Control Valve : Solenoid Valve - Test
Current Below Normal
1076-6 Engine Fuel Injection Pump Fuel Control Valve : Solenoid Valve - Test
Current Above Normal
1188-5 Engine Turbocharger 1 Wastegate Drive : Solenoid Valve - Test
1188-6 Engine Turbocharger 1 Wastegate Drive : Solenoid Valve - Test
1196-9 Anti-theft Component Status States : Abnormal Data Link Circuit - Test
Update Rate
1239-0 Engine Fuel Leakage 1: High - most severe (3) Fuel Rail Pressure Problem
2659-7 Engine Exhaust Gas Recirculation (EGR) Mass NRS Mass Flow Rate Problem
Flow Rate : Not Responding
2791-5 Engine Exhaust Gas Recirculation (EGR) Valve Motorized Valve - Test
Control : Current Below Normal
Control : Current Above Normal
Control : Not Responding Properly
2882-2 Engine Alternate Rating Select : Erratic, Mode Selection Circuit - Test
Intermittent, or Incorrect
2970-2 Accelerator Pedal 2 Low Idle Switch : Erratic, Idle Validation Switch Circuit -
Intermittent, or Incorrect Test
3241-3 Exhaust Gas Temperature 1 : Voltage Above Engine Temperature Sensor
(Active Sensors)

684 Page D-7
Appendix D
J1939
3241-4 Exhaust Gas Temperature 1 : Voltage Below Engine Temperature Sensor
(Active Sensors)
3242-3 Particulate Trap Intake Gas Temperature : Engine Temperature Sensor
Voltage Above Normal Open or Short Circuit - Test
(Active Sensors)
3242-4 Particulate Trap Intake Gas Temperature : Engine Temperature Sensor
Voltage Below Normal Open or Short Circuit - Test
(Active Sensors)
3242-15 Particulate Trap Intake Gas Temperature : High - Diesel Particulate Filter
least severe (1) Temperature Is High
3242-16 Particulate Trap Intake Gas Temperature : High - Diesel Particulate Filter
moderate severity (2) Temperature Is High
3242-18 Particulate Trap Intake Gas Temperature : Low - Diesel Particulate Filter
moderate severity (2) Temperature Is Low
3251-3 Particulate Trap Differential Pressure : Voltage Engine Pressure Sensor Open
Above Normal or Short Circuit - Test
3251-4 Particulate Trap Differential Pressure : Voltage Engine Pressure Sensor Open
Below Normal or Short Circuit - Test
3251-13 Particulate Trap Differential Pressure : Sensor Calibration Required -
Calibration Required Test
3358-3 Engine Exhaust Gas Recirculation Inlet Engine Pressure Sensor Open
Pressure: Voltage Above Normal or Short Circuit - Test
3358-4 Engine Exhaust Gas Recirculation Inlet Engine Pressure Sensor Open
Pressure: Voltage Below Normal or Short Circuit - Test
3358-13 Engine Exhaust Gas Recirculation Inlet Pressure Sensor Calibration Required -
: Calibration Required Test
3358-21 Engine Exhaust Gas Recirculation Inlet Pressure 5 Volt Sensor Supply Circuit -
: Data Drifted Low Test
3464-5 Engine Throttle Actuator 1 Control Command : Motorized Valve - Test
Not Responding Properly
3473-31 Aftertreatment #1 Failed to Ignite Diesel Particulate Filter
Collects Excessive Soot or
ARD Failed to Ignite
3474-14 Aftertreatment #1 Loss of Combustion : Special ARD Loss of Combustion
Instruction
3474-31 Aftertreatment #1 Loss of Combustion Diesel Particulate Filter
Collects Excessive Soot or
ARD Loss of Combustion
3479-5 Aftertreatment #1 Fuel Pressure Control : Solenoid Valve - Test

Page D-8 684
Appendix D
J1939
3479-6 Aftertreatment #1 Fuel Pressure Control : Solenoid Valve - Test
3480-3 Aftertreatment #1 Fuel Pressure #1 : Voltage Engine Pressure Sensor Open
Above Normal or Short Circuit - Test
3480-4 Aftertreatment #1 Fuel Pressure #1 : Voltage Engine Pressure Sensor Open
Below Normal or Short Circuit - Test
3480-15 Aftertreatment #1 Fuel Pressure #1 : High - least ARD Pilot Fuel Pressure Is
severe (1) High
3480-16 Aftertreatment #1 Fuel Pressure #1 : High - ARD Pilot Fuel Pressure Is
moderate severity (2) High
3480-17 Aftertreatment #1 Fuel Pressure #1 : Low - least ARD Pilot Fuel Pressure Is
severe (1) Low
3480-18 Aftertreatment #1 Fuel Pressure #1 : Low - ARD Pilot Fuel Pressure Is
moderate severity (2) Low
3483-11 Aftertreatment #1 Regeneration Status : Other Diesel Particulate Filter
Failure Mode Requires Initial Regeneration
3484-5 Aftertreatment #1 Ignition : Current Below ARD Ignition - Test
Normal
3484-6 Aftertreatment #1 Ignition : Current Above ARD Ignition - Test
Normal
3487-5 Aftertreatment #1 Air Pressure Control : Current Motorized Valve - Test
Below Normal
3487-6 Aftertreatment #1 Air Pressure Control : Current Motorized Valve - Test
Above Normal
3487-7 Aftertreatment #1 Air Pressure Control : Not Motorized Valve - Test
Responding Properly
3488-3 Aftertreatment #1 Air Pressure Actuator Position : Valve Position Sensor - Test
Voltage Above Normal
3488-4 Aftertreatment #1 Air Pressure Actuator Position : Valve Position Sensor - Test
Voltage Below Normal
3509-3 Sensor Supply Voltage 1 : Voltage Above Normal 5 Volt Sensor Supply Circuit -
Test
3509-4 Sensor Supply Voltage 1 : Voltage Below Normal 5 Volt Sensor Supply Circuit -
Test
3510-3 Sensor Supply Voltage 2 : Voltage Above Normal 5 Volt Sensor Supply Circuit -
Test
3510-4 Sensor Supply Voltage 2 : Voltage Below Normal 5 Volt Sensor Supply Circuit -
Test
3556-7 Aftertreatment Fuel Injector #1 : Not Responding ARD Nozzle - Test
Properly
3563-3 Engine Intake Manifold #1 Absolute Pressure : Engine Pressure Sensor Open
Voltage Above Normal or Short
3563-4 Engine Intake Manifold #1 Absolute Pressure : Engine Pressure Sensor Open
Voltage Below Normal or Short

684 Page D-9
Appendix D
J1939
3563-13 Engine Intake Manifold #1 Absolute Pressure : Sensor Calibration Required -
3563-21 Engine Intake Manifold #1 Absolute Pressure : 5 Volt Sensor Supply Circuit -
Data Drifted Low Test
3609-3 Diesel Particulate Filter Intake Pressure 1 : Engine Pressure Sensor Open
Voltage Above Normal or Short
3609-4 Diesel Particulate Filter Intake Pressure 1 : Engine Pressure Sensor Open
3609-13 Diesel Particulate Filter Intake Pressure 1 : Sensor Calibration Required -
3609-15 Diesel Particulate Filter Intake Pressure 1 : High Diesel Particulate Filter Has
Least Severe High Inlet Pressure
3609-17 Diesel Particulate Filter Intake Pressure 1 : Low Diesel Particulate Filter Has
Moderate Severity Low Inlet Pressure
3609-21 Diesel Particulate Filter Intake Pressure 1 : Data 5 Volt Sensor Supply Circuit -
Drifted Low Test
3703-31 Particulate Trap Active Regeneration Inhibited Diesel Particulate Filter
Due to Inhibit Switch Collects Excessive Soot or
ARD Is Disabled
Due to Low Exhaust Gas Temperature Collects Excessive Soot or
ARD Temperature Is Low
Due to Temporary System Lockout Collects Excessive Soot
Due to Permanent System Lockout Collects Excessive Soot
3719-0 Particulate Trap #1 Soot Load Percent : High - Diesel Particulate Filter
most severe (3) Collects Excessive Soot
3719-16 Particulate Trap #1 Soot Load Percent : High - Diesel Particulate Filter
moderate severity (2) Collects Excessive Soot
3720-15 Particulate Trap #1 Ash Load Percent : High - Diesel Particulate Filter Has
least severe (1) High Ash Load
3720-16 Particulate Trap #1 Ash Load Percent : High - Diesel Particulate Filter Has
moderate severity (2) High Ash Load
3750-31 Diesel Particulate Filter 1 Conditions Not Met for Diesel Particulate Filter
Active Regeneration Collects Excessive Soot or
ARD Is Disabled
3837-3 Aftertreatment 1 Secondary Air Pressure : Engine Pressure Sensor Open
Voltage Above Normal or Short Circuit - Test
3837-4 Aftertreatment 1 Secondary Air Pressure : Engine Pressure Sensor Open
3837-13 Aftertreatment 1 Secondary Air Pressure : Sensor Calibration Required -
3837-17 Aftertreatment 1 Secondary Air Pressure : Low - ARD Combustion Supply Air
least severe Pressure Is Low

Page D-10 684
Appendix D
J1939
3837-21 Aftertreatment 1 Secondary Air Pressure : Data 5 Volt Sensor Supply Circuit -
Drifted Low Test
4265-5 Aftertreatment #1 Transformer Secondary Output ARD Ignition - Test
4265-6 Aftertreatment #1 Transformer Secondary Output ARD Ignition - Test
4301-5 Aftertreatment #1 Fuel Injector #1 Heater Control ARD Nozzle Heater - Test
4301-6 Aftertreatment #1 Fuel Injector #1 Heater Control ARD Nozzle Heater - Test
4783-2 DPF #1 Mean Soot Signal : Erratic, Intermittent, Soot Sensor - Test
or Incorrect
4783-3 DPF #1 Mean Soot Signal : Voltage Above Soot Sensor - Test
Normal
4783-4 DPF #1 Mean Soot Signal : Voltage Below Soot Sensor - Test
Normal
4783-9 DPF #1 Mean Soot Signal : Abnormal Update Soot Sensor - Test
Rate
4783-12 DPF #1 Mean Soot Signal : Failure Soot Sensor - Test
4783-13 DPF #1 Mean Soot Signal : Out of Calibration Soot Sensor - Test
4783-21 DPF #1 Mean Soot Signal : Data Drifted Low Soot Sensor - Test
5423-5 Aftertreatment Regeneration Device Fuel Pump ARD Fuel Supply - Test
Relay : Current Below Normal
5423-6 Aftertreatment Regeneration Device Fuel Pump ARD Fuel Supply - Test
Relay : Current Above Normal
5571-0 High Pressure Common Rail Fuel Pressure Fuel Rail Pressure Problem
Relief Valve : High - most severe (3)
5576-2 Aftertreatment #1 Identification Number Module : Diesel Particulate Filter
Erratic, Intermittent, or Incorrect Identification Signal - Test
Abnormal Frequency, Pulse Width, or Period Identification Signal - Test
Special Instruction Identification Signal - Test

684 Page D-11
Appendix D

Page D-12 684
www.terex.com
Terex, Drumquin Road, Omagh, Co. Tyrone, BT78 5PN, Northern Ireland,
Tel: +44 (0) 2882 418700, Fax: +44 (0) 2882 418700, E-mail: sales@terex.com
Printed in the UK

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Issue Date: 25-April-2015

Operations Manual Revision 3.0 25-April-2015

Intentionally Left Blank

25-April-2015 Revision 3.0 Operations Manual

Operations Manual Revision 3.0 25-April-2015

(2) Screen .......................................................................................................3-2

25-April-2015 Revision 3.0 Operations Manual

Operations Manual Revision 3.0 25-April-2015

(1) Manual Tracking Information ...................................................................7-26

Operations Manual Revision 3.0 25-April-2015

(d)Check and Replace Air Cleaner Elements ..........................................9-24

25-April-2015 Revision 3.0 Operations Manual

10.13 Speed Screen Wire Breaking Prematurely...................................................10-5

Operations Manual Revision 3.0 25-April-2015

Intentionally Left Blank

25-April-2015 Revision 3.0 Operations Manual

Operations Manual Revision 3.0 25-April-2015

1.1 Notes to the Operations Manual

25-April-2015 Revision3.0 Operations Manual

(2) Optional Equipment

1.2 Safety Information

(1) Safety Alert Symbol

(2) ANSI Hazard Classification System

Operations Manual Revision 3.0 25-April-2015

(3) California Proposition 65 Warnings

1.3 Intended Use

1.4 Prohibited Use

1.5 Declaration of Conformity

25-April-2015 Revision3.0 Operations Manual

To order additional copies contact your local Terex Dealer.

1.8 Bulletin Distribution and Compliance

Operations Manual Revision 3.0 25-April-2015

Intentionally Left Blank

25-April-2015 Revision3.0 Operations Manual

Operations Manual Revision 3.0 25-April-2015

2.1 General Safety

(1) Safety Alert Symbol

25-April-2015 Revision 3.0 Operations Manual

(2) ANSI Hazard Classification System

Operations Manual Revision 3.0 25-April-2015

(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.

25-April-2015 Revision 3.0 Operations Manual

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

Operations Manual Revision 3.0 25-April-2015

Wear hearing personal protective equipment.

Keep open flame away.

Flying Material Hazard