ALLU Screener Crusher

OWNER’S MANUAL D-SERIES

Owner __________________________

Type __________________________

Serial number __________________________

1-M-DENG0210
Manufacturer: ALLU Finland Oy

Address: Jokimäentie 1
16320 Pennala
FINLAND

Postal address P.O. Box 22

16301 Orimattila
FINLAND

Telephone: + 358 3 882 140

Fax: + 358 3 882 1440
Web address: www.allu.net
E-mail address: info@allu.net

Product: ALLU Screener crusher

Document: D series owner’s manual

ALLU D SERIES OWNER’S MANUAL 1

CONTENTS
1. GENERAL.........................................................................................................................................................................3

2. ACCIDENT PREVENTION AND SAFETY ................................................................................................................3

2.1 SAFETY RISKS AND THEIR PREVENTION .........................................................................................................................3
2.2 ANTICIPATED, UNANTICIPATED, AND ERRONEOUS USE .................................................................................................4
2.3 SAFETY NOTICE LABELS ................................................................................................................................................4
2.4 WORKING, SAFETY, AND DANGER ZONES ......................................................................................................................4
3. OVERVIEW OF THE SCREENER CRUSHER .........................................................................................................5

4 INSTALLATION AND DEPLOYMENT.......................................................................................................................5

4.1 INSPECTION UPON RECEIPT ............................................................................................................................................5
4.2 MECHANICAL INSTALLATION OF THE SCREENER CRUSHER IN THE BASE MACHINE ......................................................5
4.3 HYDRAULIC CONNECTION OF THE SCREENER CRUSHER TO THE BASE MACHINE ..........................................................7
4.3.1 Hydraulic settings of the base machine ................................................................................................................7
4.3.2 Base machine hydraulic hoses ..............................................................................................................................8
4.3.3 Hydraulic settings for the Screener crusher .........................................................................................................9
4.4 FIRST START AND TAKING INTO USE ..............................................................................................................................9
5 DAILY USE......................................................................................................................................................................10
5.1 COMMENCING USE OF THE SCREENER CRUSHER .........................................................................................................10
5.2 OPERATING TIPS ..........................................................................................................................................................10
6 LONG TERM STORING ...............................................................................................................................................11

7 MAINTENANCE.............................................................................................................................................................11
7.1 PERIODICAL MAINTENANCE.........................................................................................................................................11
7.1.1 Lubrication of the crusher drum bearings ..........................................................................................................11
7.1.2 Changing of the lubricant in the power transmission system.............................................................................12
7.1.3 Checking of the power transmission system .......................................................................................................12
7.2 REPLACEMENT OF WEARING PARTS .............................................................................................................................12
7.2.1 Replacement of the drums ...................................................................................................................................12
7.2.2 Replacement of the counter blades of the fine-matter drums .............................................................................16
7.2.4 Replacing the counter blades of XHD and stabilising drums ............................................................................16
7.2.5 Replacing the XHD drum’s blades......................................................................................................................16
7.2.3 Replacement of the bearing protect fender .........................................................................................................17
8 OPTIONAL ACCESSORIES ........................................................................................................................................18
8.1. EXTRA SIDE.................................................................................................................................................................18
8.2 DRAIN OIL LINE ELIMINATION SYSTEM ........................................................................................................................18
9 DISMANTLING AND DISPOSAL ...............................................................................................................................19

APPENDIX 1.......................................................................................................................................................................20
BASE MACHINE’S HYDRAULIC OIL REQUIREMENTS ...........................................................................................................20
REQUIREMENTS FOR THE BASE MACHINE’S HYDRAULIC OIL FILTER.................................................................................20
APPENDIX 2.......................................................................................................................................................................21
TECHNICAL INFORMATION OF THE DN, DS AND DH SERIES ............................................................................................21
TECHNICAL INFORMATION OF THE DNS, DSB AND DHB SERIES .....................................................................................22
COMMENTS ON THE TECHNICAL TABLES OF APPENDIX 2 ..............................................................................................23

ALLU D SERIES OWNER’S MANUAL 2

1. GENERAL
Thank you for choosing an ALLU Screener crusher for your materials processing needs. To ensure
safe and smooth commissioning and use of the Screener crusher, you need to consider the following
general guidelines:
 Find out in advance about the relevant country- and work site-specific safety and fire-related
regulations affecting the use of the Screener crusher and adhere to them.
 Allow the personnel responsible for the installation, use, maintenance, and/or repair to read
this manual carefully before they perform any action.
 Keep the owner’s manual in the cabin of the base machine so that the instructions are readily
available.

2. ACCIDENT PREVENTION AND SAFETY

2.1 Safety risks and their prevention
Pay special attention to the safe use of the machine. You must comply with the following important
instructions:

 Never carry out an action the outcome of which you are not sure.
 Do not use the Screener crusher for lifting or transporting people.
 Make sure that the Screener crusher has been carefully installed in the base machine and that
it cannot cause danger to people or objects near it if it should become detached.
 Do not perform maintenance on, inspect, clean, repair, or check the Screener crusher while
the base machine’s engine is on.
 Familiarise yourself with the hydraulic system of the base machine and make sure you know
how to depressurise the hydraulic system of the Screener crusher. Before starting servicing
work or detaching hydraulic hoses, make sure that the hydraulics of the Screener
crusher are non-pressurised. In many base machines, you can do this by moving the
directional valve back and forth while the base machine engine is stopped but powered on.
 Open the hydraulic connections carefully. Use protective gloves and goggles, as the
connectors may be pressurised even when the base machine’s engine is not on.
 Do not leave the cabin of the base machine while the Screener crusher drums are rolling.
 The temperature of the hydraulic system may be high. Allow the surfaces and oil to cool
down before you begin maintenance, checks, or other work.
 Beware that rocks and other hard material can fly even 20 metres away from the Screener
crusher.
 Make sure that there is no one in the danger zone of the Screener crusher while the machine
is on.
 Make sure all covers are closed while working.

WARNING! The centre of mass of the Screener crusher is high. Perform maintenance
on and remove the Screener crusher from the base machine on an even
surface, and make sure that tilting or falling of the machine will not
cause hazards. If you use a forklift truck, ALWAYS LIFT THE
SCREENER CRUSHER FROM THE DRUM SIDE.

Drum side
ALLU D SERIES OWNER’S MANUAL 3
 WARNING! DANGER OF TIPPING!

WARNING! Under no circumstances go under the Screener crusher!

WARNING! When handling certain materials, the noise level exceeds 85 dB(A).

WARNING! Use in an explosive hazard environment is strictly forbidden!

WARNING! Rolling drums, blades, chains and chain wheels may cause serious injury
or death. Always keep sufficient distance to the rotating parts.

2.2 Anticipated, unanticipated, and erroneous use

Anticipated use
The Screener crusher is intended for the processing of various materials as described in this manual.

Unanticipated and/or erroneous use

Unanticipated and erroneous use refers to all use that is not anticipated and considered in the design
and usage specifications.

2.3 Safety notice labels

The Screener crusher has safety notice labels (Figure 1). If a label has become damaged or worn,
order a new label from the importer or manufacturer.

Figure 1. Safety notice labels used

2.4 Working, safety, and danger zones

Working area
 The Screener crusher may only be used from the cabin of the base machine.

Safety zone
 During proper use, more than 20 metres from the Screener crusher.

Danger zone during use (while the base machine is running)

 Within 20 metres from the Screener crusher.

Safety during maintenance, cleaning etc.

 Always adhere to all general and specific (Sections 1 and 2) safety regulations and
measures.

ALLU D SERIES OWNER’S MANUAL 4

3. OVERVIEW OF THE SCREENER CRUSHER
The ALLU Screener crusher is an accessory intended for hydraulic excavators, wheel loaders, and
similar work machines. The Screener crusher allows you to screen, aerate, crush, mix, and load
various types of soil. The Screener crusher can also process biowaste, bark, chopped materials, coal,
glass, wood chips, and silt.

The Screener crusher has horizontal drums that are rotated with a hydraulic motor in the same
direction. The direction and speed of rotation are controlled with the controls in the base machine.
DID drums are most suitable for screening, while XHD/stabilising drums are most suitable for
applications that also require crushing and/or mixing features.

During processing, fine material passes through the drums because of their movement and falls into
a pile under the Screener crusher. Large and uncrushed pieces remain in the bucket, from which
they can be tipped into another pile.

NOTE! You need to equip the Screener crusher and the base machine hydraulics
according to the application. It is important to select drums and blade pieces
appropriate for the application and to adjust the speed of rotation of the drums
to an optimal level. This way you can ensure that the capacity, fragment size
and operating expenses of the Screener crusher have been optimised in the best
possible way for that application.

4 INSTALLATION AND DEPLOYMENT

4.1 Inspection upon receipt
When you receive a new Screener crusher, make sure that you have received the following
documents:
 instruction manual
 spare parts list
 warranty card

NOTE! Make sure that the warranty card, properly completed, is delivered to the
factory or an authorised ALLU retailer.

4.2 Mechanical installation of the Screener crusher in the base

machine
The Screener crusher is connected to the base machine using an adapter specific to the base
machine. The adapter is bolted to the mounts welded to the frame of the Screener crusher (Figures
2 and 3).

NOTE! Before use, make sure that the tightening torques of the adapter mounting bolts
are:

DN, DNS, DS and DSB frames: M20 bolts: 540 Nm (threads oiled).
DH and DHB frames: M24 bolts: 960 Nm (threads oiled).

The order of tightening is shown in Figure 2, # a/b.

NOTE! Lubricate and shield unused mounting threads of the adapter.

Do not remove the bushing under the adapter mounting bolts without the
manufacturer’s permission.
ALLU D SERIES OWNER’S MANUAL 5
The excavator adapter can be turned 180 degrees, which means that the Screener crusher can be
used as both a face shovel and a back hoe model with the same adapter. For examples of installing
the excavator adapter, see Figure 2.

7 9
5
8 3
6 4
1
7
2 6 8 10
4
5 3 2
1

Base plate
a) Back hoe installation b) Face shovel installation

NTP type
c) Back hoe adapter installation d) Face shovel adapter installation

Montabert/Rammer
e) Back hoe adapter installation f) Face shovel adapter installation

Figure 2: Examples of installing the excavator adapter

ALLU D SERIES OWNER’S MANUAL 6

Figure 3: Example mounting of wheel loader adapter (Volvo)

a) Basic angles of the frame top b) Emptying position c) Working position

Figure 4: Operation angles

NOTE! When welding the mounts of the base plate specific to the base machine, make
sure that the Screener crusher can be tipped to the positions shown in Figure 4.

4.3 Hydraulic connection of the Screener crusher to the base

machine
4.3.1 Hydraulic settings of the base machine
The ALLU Screener crusher requires two-way hydraulics, to allow two-way drum rotation. Set the
hydraulic flows of the base machine according to the material being processed so that they are
within the range shown in APPENDIX 2. You do not need to limit the maximum pressure of the
base machine hydraulics. In addition to two-way hydraulics, a drain line is needed for conducting
the oil accumulated in the housing of the hydraulic motor back to the hydraulic tank of the base
machine. Proper connection of the drain line is shown in Figure 5.

NOTE! In most cases, the drums will rotate too fast if the Screener crusher is used at
the maximum hydraulic flow allowed by the power valve. We recommend that
you set the hydraulic flow of the base machine as low as possible without
affecting capacity.

NOTE! The back-pressure of the drain line may not exceed 30 bar. Excessive back-
pressure may break the hydraulic motor.

ALLU D SERIES OWNER’S MANUAL 7

 Correct drain line connection Incorrect drain line connection
(Straight to tank, through filter) (Through valve, ball valve or the like)

Figure 5: Drain line connection

NOTE! If a drain line cannot be used, a drain line elimination system can be obtained
for the Screener crusher as an accessory. You should, however, always favour
the use of a separate drain line, if possible.

NOTE! Make sure the base machine’s hydraulic oil and the filters meet the
requirements specified in APPENDIX 1.

4.3.2 Base machine hydraulic hoses

Before you connect the base machine hoses, you must remove the protective caps of the Screener
crusher and install suitable base nipples to the connectors (Figure 6, #1 and 2). The recommended
minimum base machine hose sizes are shown in Table 1.

Machine type Minimum hose size

Work line hoses
¾” / 300 bar
DNS 2-09, 2-12 and DN 2-09, 2-12, 2-17, 3-09 (Figure 6; #1)
Other types 1” / 300 bar
Drain oil line hoses (Figure 6; #2) 3/8”
Table 1: Sizes of the base machine hydraulic lines

NOTE! If the hose connections of the base machine use quick coupling connectors, the
connections must be done carefully to avoid pressure increase from the
connections. This is particularly important in the drain line connector.

1
2

4
MAIN G1”
3

DRAIN G 3/8”
MAIN G1”

Figure 6: Screener crusher power valve and hydraulic connections

ALLU D SERIES OWNER’S MANUAL 8
 Hydraulic connections
Work line output thread in power valve (Figure 6, #1) Female thread G 1”
Drain oil line output (Figure 6, #2) Female thread G 3/8”
Work line pressure measurement point thread in power Female thread G ¼”
valve (Figure 6, #3)
Table 2: Screener crusher hydraulic connections

4.3.3 Hydraulic settings for the Screener crusher

The Screener crusher comes with a factory-preset power valve (see Figure 6, #4) that protects the
Screener crusher from hydraulic overload. The power valve limits the hydraulic pressure in all
models to 280 bar. The hydraulic flow power valve restricts the pressure for different models to
maximum values shown in APPENDIX 2.

NOTE! The valve may be readjusted only by service personnel authorised by the
manufacturer (Allu Finland Oy).

NOTE! If the hydraulic flow of the base machine exceeds the value in Appendix 2, the
base machine hydraulic oil heats up more than normal.

4.4 First start and taking into use

When all of the required steps (see Sections 4.1–4.3) have been completed, start the Screener
crusher for the first time as follows:
 Start the engine of the base machine.
 Tip the Screener crusher into different positions, making sure that the Screener crusher or its
extra sides (optional accessory) do not hit the base machine boom.
 Tip the Screener crusher so that the drums are visible from the base machine’s cabin. Rotate
the drums for approximately two minutes at low speed in both directions to remove any air
in the hydraulic system.
 Stop the engine of the base machine.
 Check the hydraulic system for leaks.
 Visually check that the adapter mounting bolts are not loose and that all mechanical parts
appear to be in working order.

Figure 7: Normal drum rotation direction and the lined area in which materials must not be
transported.
ALLU D SERIES OWNER’S MANUAL 9
5 DAILY USE
5.1 Commencing use of the Screener crusher
At the beginning of the day, before you start working, always go around the Screener crusher and
visually check that it is in appropriate working condition. Pay particular attention to the following
points:
 Hydraulic leaks
 Frame bends and possible ruptures
 Adapter mounting to the base machine and Screener crusher
 The condition of the wearing parts (drums, blades, bearing protect fender, and
counter blades)
 The condition of warning labels
 Make sure that the Screener crusher is empty and that there is no material around or
between the drums.

5.2 Operating tips

The best way to learn to use the device is to work with it. The following material includes some tips
that make it easier to start use and prolong the life of the Screener crusher.

Issues that affect safety and durability

 Do not use the back part of the Screener crusher (Figure 7, lined area) for transporting
materials, as this will introduce matter between the bearing protect fender and the frame
plate.
 Do not use the bucket as a support in moving the base machine.
 We do not recommend that you use the sides of the Screener crusher for moving material.
 Do not change the direction of rotation of the drums too rapidly. First stop the drums. Rapid
alteration imposes a strong load on the hydraulic motor and power transmission and shortens
the life of the device.
 Do not load the Screener crusher while the drums are moving.
 Use protective caps at the hydraulic connectors whenever the Screener crusher’s hydraulic
hose is not connected.
 Always clean the Screener crusher and drums at the end of the work day.
Issues that affect capacity
 Different materials require different drum rotation speeds for optimum capacity. Use
the lowest possible drum speed that does not affect the capacity.
 Do not overfill the Screener crusher, as some materials may then bend against the sides. If
this occurs, the capacity decreases considerably. The correct load amount and method must
be tested when you start the work.
 Using the correct in-work tipping angle (see Figure 4) guarantees the greatest capacity. The
correct tipping angle makes the material rotate within the Screener crusher. Large particles
move about on top of the processed material, and fine matter can fall into the pile
unobstructed. The proper working angle depends on the material and should be tested when
you start the work.
 If the processing time of the material becomes longer or the material causes congestion,
change the direction of drum rotation momentarily or tip the bucket to allow the material to
pass through the Screener crusher again normally.
 With XHD and stab drums, worn blades reduce the capacity.
Issues that affect wear
 To minimise wear to the Screener crusher, we recommend that you use the lowest
drum rotation speed that does not affect the capacity.
 When loading, avoid big stones from getting into the bucket. Stones wear the rolling parts
and may cause damage.
ALLU D SERIES OWNER’S MANUAL 10
  When the bucket is almost empty, stop the drums. This way, you will also prevent stones
from shooting out of the bucket.
Issues that affect the quality of the end product
 The average fragment size of the processed material is determined by the drum type and the
drum rotation speed.
 If the drums, blades or counter blades are worn, the end product is more rough.

6 LONG TERM STORING

Store the Screener crusher, if possible, in a dry and warm location with a constant temperature.

Before long term storing:

 Wash and lubricate the Screener crusher carefully.
 Remove any rust, and paint affected areas.
 Protect bare metal surfaces with anti-corrosive agent.

Recommended storage environment:

Temperature -40 °C to 40 °C (NOTE: operation temperature differs from these values)
Relative humidity <60%

NOTE! When start using the Screener crusher again, follow the instructions in Section 4.

7 MAINTENANCE
7.1 Periodical maintenance
In addition to the daily visual inspection (see Subsection 5.1), the Screener crusher must be
serviced according to the schedule in Table 3.

Grease the drum bearings (see Section 7.1.1) 40h

Replace the power transmission system lubricant (see Section 7.1.2) 500 h / 1 a
Check the power transmission system (bearings, chains, chain wheels, and
500 h / 1 a
lubrication tubes) (see Section 7.1.3)

Table 3: Service schedule

NOTE! Service measures listed for multiple intervals should be carried out at the
service interval elapsing first.

The structure of the Screener crusher includes several NordLock lock plates,
in various locations. We recommend that you replace the lock plates with new
ones whenever the bolt connection is opened.

7.1.1 Lubrication of the crusher drum bearings

Lubricate the drum bearings on both sides every 40 hours
(Figure 8, item 1). Add grease to each grease nipple until you 1
see the new grease coming up on the drum side. There are as
many grease nipples on each side as there are drums.

NOTE! We recommend that you use Rocol Sapphire

1 B/N01204 – 424 or an equivalent.
Figure 8: Bearing grease nipples

ALLU D SERIES OWNER’S MANUAL 11

7.1.2 Changing of the lubricant in the power transmission system
Power transmission components (chains and chain wheels) have been lubricated with the lubricant
Teboil Universal CLS at the factory. The following alternative lubricants can be used also:
- ESSO Unirex Lotemp (PP Grease)
- SHELL Centra W
- SHELL ALVANIA EP GREASE
Change the lubricant every 500 hours or at least once a year. The required lubricant amount is:

DN and DNS series: 4 kg for both chain housings

DS, DSB, DH and DHB series: 5 kg for both chain housings

NOTE! Spread the lubricant evenly on chains and chain wheels.

7.1.3 Checking of the power transmission system

Check the power transmission system every 500 hours or at least once a year. When you change the
power transmission lubricant, check the condition of the power transmission components. Pay
particular attention to the following.

Drum bearings:
 We recommend that you replace the bearings in regular maintenance every 4000 hours –
or earlier, if the radial gap exceeds 0.5 mm (total gap of 1 mm). This way, you can
minimise bearing replacements between regular maintenance.
 Check the condition of the bearing lubrication tubes and connectors.
Chains and chain wheels
 Replace the chains and chain wheels if they are worn or stretched.
 Always replace the chains and chain wheels at the same time.
7.2 Replacement of wearing parts
7.2.1 Replacement of the drums
Detach the drums as follows:
 Make sure that the Screener crusher remains solidly in place.
 Make sure that the drum to be detached cannot fall and cause an accident. (Fix the crushing
drum to a suitable lifting device, such as a hoist.)
 Open the mounting bolts of the chain wheel housings and remove the covers
(Figure 9, #1).
 Open the mounting bolts of the bearing unit that hold the back plate in place, and remove the
back plates (#2 in Figure 9). (Figure 9, #2).

NOTE! In certain Screener crusher models, the top drum has a 15/23-tooth chain wheel
(Figure 10, #1). In this case, the bearing unit’s mounting bolts are
opened/closed through the holes in the chain wheel (Figure 10, #2). Use an 85-
mm long 14-mm wide hexagonal tool.

ALLU D SERIES OWNER’S MANUAL 12

 1

2
1

Figure 9: Cover detachment Figure 10: 15/23 chain wheel

 Open the chain locks and remove the chains.
 Detach the greasing tubes from the bearing units.
 Remove the remaining bearing unit mounting bolts.
 Pull the bearing unit out until you can pull the drum off. Use the pull-out threads in the
bearing unit.

4 5
3
2
1

Figure 11: Detaching the bearing unit

Remove the bearing unit from the drum shaft as follows:

 Remove the lock ring (Figure 11, item 1) and pull the chain wheel off with the jaw puller.
 Remove the key (Figure 11, item 2).
 Pull out the bearing unit (Figure 11, item 3), using the jaw puller.
 Remove the gasket plate (Figure 11, item 4) and end sleeve (Figure 11, item 5).

Disassemble the bearing unit as follows:

 Remove the lock nut and screw of the rotating cover (Figure 12, item 1).
 Twist open the cover (Figure 12, item 2) and remove the gasket in the cover (Figure 12,
item 3).
 Pull the bearing (Figure 12, item 4) out of the bearing housing.

ALLU D SERIES OWNER’S MANUAL 13

  Remove the gasket plate (Figure 12, item 5) from behind the bearing.

6
5
4

3
2

1
7

Figure 12: Disassembly of the bearing unit

Reassemble the bearing unit preliminarily as follows:

 Grease the bearing.
 Install the gasket plate in the bearing housing so that the straight surface of the gasket faces
the bearing.
 Put the bearing in the bearing housing.

NOTE! Do not push the gasket seal and the bearing all the way to the bottom.

 Install a new gasket in the twist cover.

 Twist the cover loosely into place.

Install the drums as follows:

 Check the condition of the bearing cover, chain wheels, chains, keys, and drum shaft before
installation, and replace, if necessary.
 Wash the shaft of the new drum to remove storage grease, and install a new end sleeve and a
new gasket plate (Figure 11, items 4 and 5) on the drum shaft.
 Install new O-rings in the bearing units (Figure 12, item 6).
 Install the bearing units on the drum shaft.

NOTE! Do not push the bearing units all the way to the bottom, or you will not
be able to install them between the side plates of the frame.

 Lock the chain wheel with the lock ring.

 Lock the chain wheel with a lock ring.
 Position the drum in its place in the groove of the side plates in the frame, and mount
with mounting bolts.

NOTE! DID-drums are different, and you need to take this into account in the
assembly order. In two drum ALLU, the top drum has less discs than the
bottom drum. In three drum ALLU, the top and the bottom drum are
identical and have less discs than the middle drum.
 Tighten the bearing unit’s mounting bolts (screw lock + 200 Nm).
 Using a spanner, close the bearing unit covers.
ALLU D SERIES OWNER’S MANUAL 14
 NOTE! Turn the wrench, alternating between sides, and ensure that the drum is
centred with respect to the frame (equal distance from the exterior
blades to the side plate of the frame) and that the drum can roll freely.
Leave a gap of approximately 1 mm on the shafts.

 Use a 4-mm drill to drill an indentation of 1–2 mm in the lock screw for locking.

NOTE! Be careful with the lock screw’s thread when performing the drilling.

 Lock the cover with a lock screw and nut.

 Install the lubrication tube connectors and hexagonal caps on the bearing units (Figure 12,
item 7).
 Install rest of the drums.
 Attach the lubrication tubes to the bearing units.
 Install the power transmission chains.

NOTE! Position the mutual phase difference between the drums so that it is
approximately 36 degrees for DIDB drums. Other drums (small DID,
XHD and stab drums) are positioned so that all drums are in the same
phase.

Tip

Valley

Tip

Figure 13: DiDB drum phase difference.

 Grease the bearings and lubricate the power transmission system according to Sections 7.1.1
and 7.1.2.
 Install the back plates and tighten the remaining bearing unit mounting screws (screw lock
+ 200 Nm). Tighten the back plate’s cutting surface with a sealant (e.g. Wurth RTV silicone,
0893 270 050-C/SF).
 Install the chain housing covers. Check the condition of the gasket, and seal the corners with
a sealant (e.g. Wurth RTV silicone, 0893 270 050-C/SF).

ALLU D SERIES OWNER’S MANUAL 15

7.2.2 Replacement of the counter blades of the fine-matter drums
Replace the counter blades as follows:
 Loosen the adjustment screws of the counter blade mounting side (Figure 14, item 1) on
both sides of the frame.
 Loosen the lock screws of the counter blade mounting side (Figure 14, item 2) on both
sides of the frame.
 Detach the worn counter blade and install a new one.

NOTE! In a two drum ALLU, the top and bottom counter blades are different.

 Tighten the adjustment screws of the counter blade mounting side (Figure 14, item 1) on
both sides of the frame.
 Tighten the lock screws of the counter blade mounting side (Figure 14, item 2) on both
sides of the frame.

2 2
1

Figure 14: Replacement of the Figure 15: Replacing the straight

DiD counter blade and comb counter blade

7.2.4 Replacing the counter blades of XHD and stabilising drums

Replace the counter blades as follows:
 Open the fixing bolts of the counter blade’s lock piece (Figure 15, item) and remove the
lock piece.
 Move the counter blades (Figure 15, item 2) toward the gap from the lock piece and remove
the counter blades.
 Install the new counter blades in place in reverse order.

7.2.5 Replacing the XHD drum’s blades

Replace the blades as follows:
 Push the spring pin (Figure 16, item 1) forward until you can remove the blade (Figure 16,
item 2). You can use a blade removal tool to crank the blade through the slot in the drum
flange (Figure 16, item 3).
 Install the new blades in place and move the spring pin in the opposite direction until it is
centred with respect to the blade holder.

ALLU D SERIES OWNER’S MANUAL 16

 1
3

Figure 16: Replace an XHD drum blade

NOTE! Replace the blades sufficiently often so that the material will not wear
the blade holders.

7.2.3 Replacement of the bearing protect fender

Replace the bearing protect fender as follows:
 Remove the bearing protect fender mounting bolts (Figure 17, item 1).
 Remove the worn bearing protect fender (Figure 17, item 2) and install a new one.
 Tighten the bearing protect fender mounting bolts.

NOTE! It is easiest to replace the bearing protect fender when you replace the
drums.

Figure 17: Bearing protect fender

ALLU D SERIES OWNER’S MANUAL 17

 8 OPTIONAL ACCESSORIES
8.1. Extra side
Extra sides allow you to increase the volume of the Screener crusher. The use of extra sides is
recommended for Screener crushers mounted on wheel loaders.

2 4

Figure 18: Extra sides

Install an extra side as follows:

 The same extra side is suitable for both DS and DH model frame.
 Connect the plates at the ends of the extra side (Figure 18, item 1) to the back plate
(Figure 18, item 2) with hexagonal lock bolts.
 Mount the extra side on the Screener crusher frame from the ends (Figure 18, item 3) and
the rear (Figure 18, item 4).

8.2 Drain oil line elimination system

The system transfers the oil accumulated in the hydraulic motor housing back to the oil return line.
Both work lines (P and T) serve as return lines, depending on the direction of rotation.

NOTE! When a drain line elimination system is installed, the back-pressure of the
return side (P and T line) must be under 30 bar (10 bar recommended).

NOTE! If an optional drain line elimination system have been installed in the Screener
crusher, a pressure relief valve has been installed inside the top frame in port 2
(Figure 6). If the pressure in the return line of the base machine rises above the
allowable 30 bar, the pressure relief valve opens and oil flows out of port 2
(Figure 6).

NOTE! The drain oil line elimination system contains a hydraulic accumulator. Before
starting servicing work, make sure that the hydraulics of the Screener crusher
are non-pressurised.

ALLU D SERIES OWNER’S MANUAL 18

9 DISMANTLING AND DISPOSAL
Even a good product will reach the end of its useful life at some point. This is the time when you
need to make sure that the product is disposed of in a manner that is safe for the environment.

You need to be careful when disassembling the Screener crusher, so that the individual parts cannot
become loose and uncontrolled, posing a risk of injury.

The Screener crusher does not contain problem waste, except for the hydraulic oil in the hydraulic
motor and tubes (approximately five litres) and the grease and lubricant mixture in the chain
housings (around 10 kg).

The disposal must be made according to the laws and regulations in force in the country of disposal.
Normally proceed as follows:
 Metals to reuse
 Plastic parts and rubber seals according to regulations
 Take care of the oil and lubrication grease according to regulations

ALLU D SERIES OWNER’S MANUAL 19

 APPENDIX 1

Base machine’s hydraulic oil requirements

The manufacturer of the hydraulic motor recommends the use of high-quality mineral-based
hydraulic oil HLP (DIN 51524) or HM (ISO 6743/4). The oil should have additives that protect
against wear, foaming, corrosion, and pressure. Do not use fire-resistant or vegetable-based
hydraulic fluids without the manufacturer’s permission.

Below are the threshold values specified by the manufacturer of the hydraulic motor.

Recommended ambient temperature necessary for

the shaft gasket to function as intended: -30 °C to +90 °C
Recommended working oil temperature: +30 °C to 60 °C
Recommended viscosity at operating temperature: 35 cSt
Allowed viscosity: 20 cSt to 75 cSt

Mineral-based hydraulic oil must be selected, so that the viscosity of the oil at normal operating
temperature is as close to the recommended value as possible. If the oil viscosity differs from the
recommended value, the motor’s service life is shorter.

OIL ISO class TEBOIL ESSO SHELL MOBIL TEXACO B.P.

TEMPER
ATURE
20–40 °C 32 Hydraulic NUTO TELLUS DTE 24 RANDO HLP32
oil 32S H32 37
40–50 °C 46 Hydraulic NUTO TELLUS DTE 25 RANDO HLP46
oil 46 H46 46 HD46
50–60 °C 68 Hydraulic NUTO TELLUS DTE 26 RANDO HLP68
oil 68 H68 68 HD68
60–70 °C 100 Hydraulic NUTO TELLUS DTE 26 RANDO HLP 100
oil 100 H100 100 HD100

The hydraulic oil must be replaced regularly, to keep its properties good. The oil temperature has a
great impact on the useful life of the oil. The general rule is that every eight degrees above 60 °C
halves the oil change interval.

Requirements for the base machine’s hydraulic oil filter

The greatest recommended stain level for the hydraulic oil is 20/16 (ISO 4406). In the experience of
the manufacturer of the hydraulic motor, this is attained with a filter of at least 25 μm. In very
stained environments, you may need to use a 10 μm filter.

ALLU D SERIES OWNER’S MANUAL 20

APPENDIX 2
Technical information of the DN, DS and DH series
Recommended minimum Hydraulic se ttings Volume Volume Screen Blades Measures Weight
Model weight (t) of the base machine Hydraulic flow Max. Input Power Hydraulic water heap area 60 mm 40 mm Ax Bx C 60 mm 40 mm
Excavators Wheel loaders range Continuous/ motors ISO SAE drums drums (h x d x w) X75
low / max peak
0,9 t/m³ 1,9 t/m³ 0,9 t/m³ 1,9 t/m³ l/min [drum rpm] kW pcs m³ m³ m² pcs pcs cm kg kg
Standard
DN 2-09 10 14 4 6 70 - 120 (150 - 250) 45 / 60 1 0,5 0,6 0,5 20 28 111 x 128 x 125 940 970
DN 2-12 12 16 6 8 70 - 120 (150 - 250) 45 / 60 1 0,6 0,7 0,6 28 40 111 x 128 x 151 1070 1100
DN 2-17 15 20 7 10 70 - 120 (150 - 250) 45 / 60 1 0,9 1,0 0,9 44 60 111 x 128 x 205 1330 1380
DN 3-09 12 16 6 8 70 - 120 (150 - 250) 45 / 60 1 0,7 0,8 0,7 30 42 136 x 140 x 125 1150 1200
DN 3-12 16 20 7 10 95 - 160 (150 - 250) 70 / 110 1 1,0 1,2 0,9 42 60 136 x 140 x 151 1330 1390
DN 3-17 20 24 9 13 95 - 160 (150 - 250) 70 / 110 1 1,3 1,5 1,4 66 90 136 x 140 x 205 1660 1730
Strong
DS 3-12 16 22 8 11 95 - 160 (150 - 250) 70 / 110 1 1,0 1,2 0,9 42 60 144 x 151 x 161 1620 1670
DS 3-17 20 25 9 14 95 - 160 (150 - 250) 70 / 110 1 1,3 1,5 1,4 66 90 144 x 151 x 215 1990 2070
DS 3-23 24 32 12 17 120 - 200 (150 - 250) 70 / 110 1 1,7 2,0 1,7 90 126 144 x 151 x 269 2360 2500
DS 4-12 20 25 10 13 95 - 160 (150 - 250) 70 / 110 1 1,2 1,4 1,2 56 80 169 x 175 x 161 1940 2000
DS 4-17 24 32 12 18 120 - 200 (150 - 250) 70 / 110 1 1,8 2,1 1,7 88 120 169 x 175 x 215 2400 2500
DS 4-23 30 Note 7 14 22 120 - 200 (150 - 250) 70 / 110 1 2,3 2,7 2,3 120 168 169 x 175 x 269 2930 3120
Extra heavy
DH 3-12 18 23 8 11 140 - 235 (150 - 250) 75 / 110 2 1,0 1,2 0,9 42 60 145 x 153 x 161 1890 1940
DH 3-17 22 27 10 15 140 - 235 (150 - 250) 75 / 110 2 1,3 1,5 1,4 66 90 145 x 153 x 215 2330 2410
DH 3-23 26 35 14 18 140 - 235 (150 - 250) 75 / 110 2 1,7 2,0 1,7 90 126 145 x 153 x 269 2870 3010
DH 4-12 22 28 10 14 140 - 235 (150 - 250) 75 / 110 2 1,2 1,4 1,2 56 80 170 x 177 x 161 2240 2300
DH 4-17 27 36 14 19 140 - 235 (150 - 250) 75 / 110 2 1,8 2,1 1,7 88 120 170 x 177 x 215 2770 2870
DH 4-23 32 45 16 24 190 - 315 (150 - 250) 125 / 225 2 2,3 2,7 2,3 120 168 170 x 177 x 269 3370 3560
DH 4-27 36 Note 7 18 27 240 - 400 (150 - 250) 125 / 225 2 2,9 3,4 2,8 144 208 170 x 177 x 315 4140 4450

Maximum weight Maximum weight

excavator wheel loader

t t
DN Series 28 14
DS Series 35 22
DH Series 45 30 Note 7: Factory approval required

ALLU D SERIES OWNER’S MANUAL 21

APPENDIX 2
Technical information of the DNS, DSB and DHB series
Recommended minimum Hydraulic se ttings Volume Volume Screen Discs Measures Weight
Model weight (t) of the base machine Hydraulic flow Max. Input Power Hydraulic water heap area 25 DiD 15 DiD AxB xC 25 DiD 15 DiD
Excavators Wheel loaders range Continuous/ motors ISO SAE drums drums (h x d x w)
low / max peak
0,9 t/m³ 1,9 t/m³ 0,9 t/m³ 1,9 t/m³ l/min [drum rpm] kW pcs m³ m³ m² pcs pcs cm kg kg
Standard
DNS 2-09 10 14 4 6 60 - 120 [100 - 200] 45 / 60 1 0,5 0,6 0,5 43 57 111 x 128 x 125 1030 1070
DNS 2-12 12 16 6 8 60 - 120 [100 - 200] 45 / 60 1 0,6 0,7 0,6 55 73 111 x 128 x 151 1180 1240
DNS 2-17 15 20 7 10 100 - 200 [100 - 200] 70 / 110 1 0,9 1,0 0,9 81 107 111 x 128 x 205 1480 1600
DNS 3-09 12 16 6 8 80 - 165 [100 - 200] 70 / 110 1 0,7 0,8 0,7 64 85 136 x 140 x 125 1250 1340
DNS 3-12 16 20 7 10 100 - 200 [100 - 200] 70 / 110 1 1,0 1,2 0,9 83 109 136 x 140 x 151 1460 1560
DNS 3-17 20 24 9 13 100 - 200 [100 - 200] 70 / 110 1 1,3 1,5 1,4 121 161 136 x 140 x 205 1830 2000
Strong
DSB 2-12 16 22 8 11 95 - 235 [65 - 150] 75 / 110 2 1,0 1,2 0,9 55 73 144 x 151 x 161 1740 1880
DSB 2-17 20 25 9 14 95 - 235 [65 - 150] 75 / 110 2 1,3 1,5 1,4 81 107 144 x 151 x 215 2180 2370
DSB 2-23 24 32 12 17 95 - 235 [65 - 150] 135 / 225 2 1,7 2,0 1,7 107 143 144 x 151 x 269 2730 2900
DSB 3-12 20 25 10 13 95 - 235 [65 - 150] 75 / 110 2 1,2 1,4 1,2 83 109 169 x 175 x 161 2210 2400
DSB 3-17 24 32 12 18 95 - 235 [65 - 150] 75 / 110 2 1,8 2,1 1,7 121 161 169 x 175 x 215 2780 3070
DSB 3-23 30 Note 7 14 22 95 - 235 [65 - 150] 135 / 225 2 2,3 2,7 2,3 161 215 169 x 175 x 269 3460 3870
Extra heavy
DHB 2-12 18 23 8 11 95 - 235 [65 - 150] 135 / 225 2 1,0 1,2 0,9 55 73 145 x 153 x 161 2020 2150
DHB 2-17 22 27 10 15 95 - 235 [65 - 150] 135 / 225 2 1,3 1,5 1,4 81 107 145 x 153 x 215 2520 2710
DHB 2-23 26 35 14 18 95 - 235 [65 - 150] 135 / 225 2 1,7 2,0 1,7 107 143 145 x 153 x 269 3150 3410
DHB 3-12 22 28 10 14 95 - 235 [65 - 150] 135 / 225 2 1,2 1,4 1,2 83 109 170 x 177 x 161 2520 2700
DHB 3-17 27 36 14 19 95 - 235 [65 - 150] 135 / 225 2 1,8 2,1 1,7 121 161 170 x 177 x 215 3150 3440
DHB 3-23 32 45 16 24 95 - 235 [65 - 150] 135 / 225 2 2,3 2,7 2,3 161 215 170 x 177 x 269 3910 4310

Maximum Maximum
weight weight wheel
excavator loader
t t
DNS Series 28 14
DSB Series 35 22
DHB Series 45 30 Note 7: Factory approval required

ALLU D SERIES OWNER’S MANUAL 22

APPENDIX 2
Comments on the technical tables of APPENDIX 2

Hydraulics:
 The optimal hydraulic flow depends on the material you are processing. To minimise wear to the Screener crusher and the fuel consumption of the base
machine, we recommend that you use the lowest hydraulic flow that does not affect the capacity.
 To minimise the fuel consumption of the base machine and to attain better processing power, we recommend that the back-pressure of the base
machine’s return line be kept as low as possible. When a drain line elimination system (optional accessory) is installed, the back-pressure must be
under 30 bar (10 bar recommended).
 The pressure limit of the power valve installed in the Screener crusher is adjusted to 280 bar, which means that you do not need to limit the pressure of
the base machine.

Use:
 The allowed working temperature is -20°C - +45°C (used hydraulic oil might limit).

Dimensions and weights:

 The minimum weight recommendations have been calculated without the extra side, the 300-kg adapter installed and with material density of 900 and
1900 kg/m3.
 Check the actual tipping load from the technical specifications of the base machine. It can affect the recommendation by up to 1–3 tons.
 The centre of mass of the ALLU Screener crushers is further than that of a normal wheel loader’s. Therefore, in wheel loader user, a tipping load of
approximately 1.5 times higher is required compared to a normal bucket of the same weight (bucket and material).
 Volume increases approximately 30% with extra sides.
 The bucket weights specified in the table and on the Screener crusher’s machine label do not include accessories or adapters.
 The weights, measurements, and values are presented as estimates. The manufacturer may change the technical specifications without notice.

ALLU D SERIES OWNER’S MANUAL 23