S range operations manual rev 11 (en) by Mark

Model: S80/S130/S190 Operations Manual SUBJECT TO CHANGE WITHOUT PRIOR NOTICE Original Instructions ÂŠ McCloskey International Ltd 2014

Issue Date: Language: Revision No:

05/03/2014

English (en) 11

Record of Revisions

Record of Revisions Revision Number 10 11

Reason for Change New style and updated manual released.

Date 01/10/2013

Tier 4i Control Panel Added

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Table of Content 1

Introduction ................................................................................................ 1-2 1.1 Operations Manual Guide ..............................................................................1-2 (1) Optional Equipment ...................................................................................1-2 1.2 Safety Information ..........................................................................................1-3 (1) Safety Warning Symbol .............................................................................1-3 (2) ANSI Hazard Classification System ..........................................................1-3 (3) California Proposition 65 Warnings ...........................................................1-3 1.3 Machine Designated Use ...............................................................................1-3 1.4 Declaration of Conformity ...............................................................................1-4 1.5 Warranty .........................................................................................................1-4 1.6 Copyright ........................................................................................................1-4

Safety .......................................................................................................... 2-2 2.2 Safety Symbol Classification ..........................................................................2-2 (1) Safety Warning Symbol .............................................................................2-2 (2) ANSI Hazard Classification System ..........................................................2-2 (3) Description of Safety Symbols ...................................................................2-3 2.3 Safety Signs on the Machine..........................................................................2-8 2.4 Personal Safety ............................................................................................2-12 (1) Personal Protective Equipment ...............................................................2-12 2.5 Work Area Safety .........................................................................................2-12 (1) General Work Area Guidelines ................................................................2-12 (2) Safety Warnings and Labels ....................................................................2-13 (a) Modifications .......................................................................................2-13 (3) Transportation Safety ..............................................................................2-13 (4) Operation Safety ......................................................................................2-15 (5) Hydraulic and Pneumatic Safety .............................................................2-16 (6) Electrical Safety .......................................................................................2-16 (7) Maintenance Safety .................................................................................2-17 (8) Gas, Dust, Steam, Smoke .......................................................................2-20 (9) Hazardous Substances ...........................................................................2-20 (10) Noise Levels ............................................................................................2-20 2.6 Emergency Stop Locations ..........................................................................2-20

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Table of Content 3.5 S80 General Information ................................................................................3-4 (1) Fines Conveyor..........................................................................................3-4 (2) Side Conveyor ...........................................................................................3-4 (3) Transport Dimensions................................................................................3-4 (4) Working Dimensions ..................................................................................3-4 3.6 General Layout ...............................................................................................3-5 3.7 Machine Measurements ................................................................................3-6 3.8 S190 2 Deck Elevation (Track) .......................................................................3-6 3.9 S190 3 Deck Elevation (Track) .......................................................................3-7 3.10 S190 2 Deck Elevation (Wheel) .....................................................................3-8 3.11 S190 3 Deck Elevation (Wheel) .....................................................................3-9 3.12 S190 2 Deck Plan View ................................................................................3-10 3.13 S190 3 Deck Plan View ................................................................................ 3-11 3.14 S130 2 Deck Elevation (Track) .....................................................................3-12 3.15 S130 3 Deck Elevation (Track) .....................................................................3-13 3.16 S130 2 Deck Elevation (Wheel) ...................................................................3-14 3.17 S130 3 Deck Elevation (Wheel) ...................................................................3-15 3.18 S130 2 Deck Plan View ................................................................................3-16 3.19 S130 3 Deck Plan View ................................................................................3-17 3.20 S80 2 Deck Elevation (Track) .......................................................................3-18 3.21 S80 2 Deck Elevation (Wheel) .....................................................................3-19 3.22 S80 2 Deck Plan View ..................................................................................3-20 3.23 Noise levels ..................................................................................................3-21

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Table of Content (3) Raising Tail Conveyor ..............................................................................4-37 (4) Tipping Grid Setup ...................................................................................4-38 (5) Tipping Grid Cycle Time Setup ................................................................4-38 (6) Controlling the Tipping Grid Manually ......................................................4-39 (7) Operating the Tipping Grid Using the Radio Controller ...........................4-39 (8) Vibrating Grid Setup ................................................................................4-40 (9) Hopper Landing Legs Setup ....................................................................4-42 (10) Auxiliary Conveyor Setup ........................................................................4-44 4.12 Operating the Shredder ................................................................................4-46 (a) Raising/Lowering the Shredder ...........................................................4-46 (b) Running the Shredder .........................................................................4-47 4.13 Machine Components Start-Up Procedure ..................................................4-48 4.14 Machine Shut Down Procedure....................................................................4-50 4.15 Machine Lockout and Tag Out Procedure ....................................................4-50 4.16 Emergency Stop Procedure .........................................................................4-50

Transportation............................................................................................ 5-2 5.5 Preparing Machine for Transport ....................................................................5-3 (1) Placing Tipping Grip in Transport Position .................................................5-3 (2) Folding Auxiliary Conveyor ........................................................................5-3 (3) Folding the Side Conveyor for Transport ...................................................5-5 (4) Placing Screen in Transport Position .........................................................5-7 (5) Folding Tail Conveyor for Transport ...........................................................5-9 (6) Retracting Hopper Landing Legs .............................................................5-12 5.6 Loading Machine to Transport Trailer ...........................................................5-13

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Table of Content (f) Every 500 Service Hours ....................................................................6-10 (g) Every 500 Service Hours or 1 Year .....................................................6-10 (h) Every 1000 Service Hours ..................................................................6-10 (i) Every 1500 Service Hours ..................................................................6-10 (j) Every 2000 Service Hours .................................................................. 6-11 (k) Every 3000 Service Hours .................................................................. 6-11 (l) Every 3000 Service Hours or 2 Years ................................................. 6-11 (m) Every 4000 Service Hours .................................................................. 6-11 (n) Every 6000 Service Hours or 3 Years ................................................. 6-11 (o) Every 12000 Service Hours or 6 Years ............................................... 6-11 6.10 Lubrication ....................................................................................................6-12 (1) Lubrication Points ....................................................................................6-13 6.11 Servicing Conveyors ....................................................................................6-14 (1) Clean & Check the Conveyor Belts .........................................................6-14 (2) Tensioning the Conveyor Belts ................................................................6-14 (3) Conveyor Alignment ................................................................................6-15 6.12 Servicing the Tracks .....................................................................................6-16 6.13 Measuring Track Tension .............................................................................6-16 6.14 Adjusting Track Tension ...............................................................................6-17 6.15 Gearbox Oil Level.........................................................................................6-19 (1) Checking and Filling Gearbox Oil ............................................................6-19 (2) Draining Gearbox Oil ...............................................................................6-20 6.16 Servicing the Hydraulic System....................................................................6-21 (1) Changing Hydraulic Filters ......................................................................6-21 (2) Changing Hydraulic Oil ............................................................................6-22 6.17 Changing Air Filter Elements ........................................................................6-23 6.18 Replacing Screen Media ..............................................................................6-24 (1) Replacing Top (and Middle) Deck Screens .............................................6-24 (2) Replacing Bottom Deck Screens .............................................................6-25 6.19 Checking the Screen Box Running Condition ..............................................6-28 (1) Checking if Screen Box is in Tune ...........................................................6-28

Appendix A Warranty.................................................................................A-1

Appendix B Schematics ............................................................................B-1

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1 Introduction

Introduction

1.1 Operations Manual Guide This operations manual has been designed to help you properly and safely operate and maintain your new machine to ensure many years of safe, reliable and efficient service. Make sure that all owners and operators read and understand this manual fully to learn how to operate your machine. Failure to do so could result in personal injury or equipment damage. Consider this manual a permanent part of your machine. Keep it with the machine at all times. Follow all applicable safety regulations and recommendations in this manual as appropriate to your machine and the situation/conditions prevailing at the time. Federal, State, National and Local laws and safety regulations must be complied with at all times to prevent possible danger to person(s) or property from accidents or harmful exposure. Where supplied as a basic machine only, (with or without optional extras, e.g. drive elements, etc.), the machine is intended for incorporation into a complete processing machine that is NOT designed and/or constructed by McCloskey International Ltd. In these circumstances, or where supplied as a replacement machine, McCloskey International Ltd. will NOT be responsible for addressing environmental issues and/or health and safety protection measures for the machine installation as a whole and will bear NO responsibility for ensuring compliance with any regulations and/or statutory requirements that may apply unless specifically included in the Contract of Sale. INFORMATION AND ADVICE If you need any information or advice regarding your machine please contact: McCloskey International Ltd.

47 Moor Road Coalisland, Co. Tyrone BT71 4QB Telephone: +44 (0) 28 8774 0926 E mail: salesuk@mccloskeyinternational.com

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Optional Equipment

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

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Introduction 1

1.2 Safety Information (1)

Safety Warning Symbol

In conjunction with the text which follows it, this safety warning symbol is used as a “safety warning system” in these operating instructions. The safety warning symbol indicates a risk of personal injury. Follow all instructions which appear after this safety warning symbol in order to avoid injury or fatal accidents.

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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. The safety alert symbol is shown with this danger classification.

CAUTION This indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. The safety alert symbol is shown with this danger classification.

NOTICE This indicates a message related to property damage. The safety alert symbol is not shown with this danger classification.

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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 Machine Designated Use This machine is a portable, self-contained screening plant for screening materials into various sizes. Typical materials include rock, soil, gravel, sand, coal and landfill. If you need to crush any other material not listed please consult with the factory. S Range Operations Manual

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1 Introduction McCloskey International cannot be held liable for any damages resulting from misuse.

1.4 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.

1.5 Warranty Please make sure that you complete the warranty registration form located in the appendix section of this manual and return it to McCloskey International Ltd. Warranty cannot be activated until this form has been completed and returned.

1.6 Copyright The copyright of this operations manual is reserved by McCloskey International Ltd. This operations manual contains information and technical drawings, which may not be copied, distributed, altered, stored on electronic media, revealed to others or used for the purpose of competition, either partially or in its entirety. The right is reserved to alter any details contained in this manual without notice. Copyright 2013 McCloskey International Ltd 47 Moor Road Coalisland, Co. Tyrone BT71 4QB To order additional copies contact your local dealer.

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2 Safety

Safety

Most accidents involving product operation, service and transportation are caused by failure to observe basic safety rules and precautions. Recognizing all possible safety hazards before acting can often prevent accidents. Any person(s) involved in the operation, maintenance or transportation of this machine must observe each situation for potential hazards. The Person(s) must also posses the required knowledge, skill and equipment required to perform these tasks appropriately. The warnings located on the machine and those in this publication are NOT inclusive. McCloskey International Ltd strive to foresee all potential hazardous situations but cannot anticipate every possible situation that can prove potentially hazardous. For any function performed not recommended by McCloskey International Ltd, you must satisfy yourself that it is safe for you and for others and the action most not compromise the safety or function of the product.

2.2 Safety Symbol Classification The following signs and designations are used in the manual to designate instructions of particular importance.

(1)

Safety Warning Symbol

The safety warning symbol indicates a risk of personal injury. Follow all instructions which appear after this safety warning symbol in order to avoid injury or fatal accidents.

(2)

ANSI Hazard Classification System

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. The safety alert symbol is shown with this danger classification.

CAUTION This indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. The safety alert symbol is shown with this danger classification.

NOTICE This indicates a message related to property damage. The safety alert symbol is not shown with this danger classification.

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Description of Safety Symbols

This machine is fitted with a number of safety warning decals to highlight potential risks. These warnings must be obeyed at all times. If one of the decals becomes detached or damaged it must be replaced. The safety decals use pictograms to indicate the relevant risk in line with ISO requirements and pictograms with text in line with ANSI requirements and will be equipped with same dependant on your region. A full list of explanations for each picogram can be found on page 2-4.

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2 Safety 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 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 safe methods to check for hydraulic leaks.

Crush hazard Crushed foot from support leg. Stay clear of support legs and jacks.

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Safety 2 Symbol

Description Falling material hazard Risk 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

Electrocution hazard Electric shock/ electrocution.

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2 Safety Symbol

Description Hearing hazard Risk of loss or degradation of hearing. Wear hearing personal protective equipment.

Explosion hazard Risk of explosion during an operation or service procedure. Burn hazard Risk Of burns from corrosive material. Keep open flame away.

Emergency Stop Press to engage, twist to reset. Flying Material Hazard Risk of being struck by flying objects Wear eye personal protective equipment

Crush Hazard Crush risk from overhead impact. Stay clear of moving conveyors.

Unauthorized persons prohibited.

Flying Material Hazard risk of being struck by flying material. Do not stand on platform while machine is in operation

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Safety 2 Symbol

Description 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.

Burn Hazard Burn from hot surface or liquid

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2 Safety Symbol

Description Stay clear of hot surface or liquid.

Impact Hazard Impact from spring loaded door. Stay clear of spring loaded door while opening.

Safety Harness Safety harness is required when working above ground level.

2.3 Safety Signs on the Machine Table 2.2 lists the safety signs that are on this machine.

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Safety 2 Table 2.2 - Safety Signs Sign Item 1

ISO

ANSI

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2 Safety Sign Item 4

ISO

ANSI

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Safety 2 Sign Item 7

ISO

ANSI

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2 Safety

2.4 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 the 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.

2.5 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. Only authorised and trained personnel involved in the machines operation or maintenance should be in the vicinity of the machine while it is running. All other personnel should be kept at a safe distance. 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.

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Safety 2 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.

(2)

Safety Warnings and Labels

You can be injured if you do not obey the safety instructions as indicated on warning signs. Observe all safety instructions and warnings attached to the equipment. Ensure that safety instructions and warnings attached to the equipment are always complete and perfectly legible. Keep warnings and instruction labels clean and up to date. Replace unreadable or missing labels with new ones before operating the machinery. Make sure replacement parts include warning or instruction labels where necessary. (a)

Modifications

Never make any modifications, additions or conversions which might affect safety without the supplierâ&#x20AC;&#x2122;s approval. In the event of safety relevant modifications or changes in the behavior of the machinery during operation, stop the machine and lock out immediately and report the malfunction to the competent authority/ person.

(3)

Transportation Safety

Before transporting the machine, observe the prescribed transport position, admissible speed and itinerary. Only use appropriate means of transport and lifting gear of adequate capacity. Know the overall height to avoid contacting overhead obstructions such as bridges, power lines etc. The preparations to move equipment by an articulated lorry should be supervised by a minimum of two persons. Ensure persons transporting the machine adhere to all safety signs and procedures. Before transportation on public roads, ensure the machine has been properly secured with no loose material left in or on the machine. Always observe the valid traffic regulations and, if necessary, ensure beforehand that the machine is in a condition compatible with these regulations. Extreme caution is required when transporting machinery on site. Soft or uneven ground may cause accidents. On sloping terrain, always adapt your travelling speed to the relevant ground conditions. Never change to a lower gear on a slope. Always change gear before reaching a slope. S Range Operations Manual

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2 Safety 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 wheel Bogie machines: Ensure wheel nuts are torqued between 800 to 550 Nm (590 - 627 ft.lb) 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 overinflated tire can explode and cause serious injury or death.

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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 belt feeder on conveyor belts or screen box. Starting a machine with a full load will cause strain problems in your machine. S Range Operations Manual

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2 Safety (5)

Hydraulic and Pneumatic Safety

Only persons having special knowledge and experience in hydraulic and pneumatic systems may carry out work on hydraulic and pneumatic equipment. Never disable or alter any hydraulic circuit or component without consulting with McCloskey International Ltd. 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 McCloskey International Ltd distributor. Malfunctioning valves or poor maintenance practices can result in build-up of extremely high hydraulic and/or pneumatic pressures inside the accumulator.

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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.

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Safety 2 â&#x20AC;˘ 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 sulfuric 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. 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.

(7)

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.

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2 Safety 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 safetyoriented ladders and working platforms. Always use any walkway/platforms provided or a safe and secure platform approved by the regional safety enforcing authority. Performing work above ground level make sure to always use an approved (EN/ANSI) safety harness. Always use walkways and platforms provided or a safe secure platform approved by the machine operators management. Do not use any unauthorized or unsafe structures or platforms. 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 McCloskey International Ltd 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. 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 McCloskey International Ltd 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 above ground level. Keep all handles, steps, handrails, platforms, landing and ladders free from dirt, oil, snow and ice.

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Safety 2 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 McCloskey International Ltd 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.

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2 Safety (8)

Gas, Dust, Steam, Smoke

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

(9)

Hazardous Substances

Ensure that correct procedures are formulated to safely handle hazardous materials by correct identification, labelling, storage, use and disposal. All hazardous materials must be handled strictly in accordance with the manufacturers instructions and all applicable regulations observed at all times. Store hazardous materials in restricted access areas and mark them clearly.

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

2.6 Emergency Stop Locations Emergency stops are located at both the left and right hand side of the machine Ref: Figure 2.1 on page 2-21

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Figure 2.1 - Emergency Stop Locations

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Table of Content 3

Technical Data ............................................................................................ 3-2 3.3 S190 General Information ..............................................................................3-2 (1) Fines Conveyor..........................................................................................3-2 (2) Side Conveyors .........................................................................................3-2 (3) Transport Dimensions................................................................................3-2 (4) Working Dimensions ..................................................................................3-2 3.4 S130 General Information ..............................................................................3-3 (1) Fines Conveyor..........................................................................................3-3 (2) Side Conveyors .........................................................................................3-3 (3) Transport Dimensions................................................................................3-3 (4) Working Dimensions ..................................................................................3-3 3.5 S80 General Information ................................................................................3-4 (1) Fines Conveyor..........................................................................................3-4 (2) Side Conveyor ...........................................................................................3-4 (3) Transport Dimensions................................................................................3-4 (4) Working Dimensions ..................................................................................3-4 3.6 General Layout ...............................................................................................3-5 3.7 Machine Measurements ................................................................................3-6 3.8 S190 2 Deck Elevation (Track) .......................................................................3-6 3.9 S190 3 Deck Elevation (Track) .......................................................................3-7 3.10 S190 2 Deck Elevation (Wheel) .....................................................................3-8 3.11 S190 3 Deck Elevation (Wheel) .....................................................................3-9 3.12 S190 2 Deck Plan View ................................................................................3-10 3.13 S190 3 Deck Plan View ................................................................................ 3-11 3.14 S130 2 Deck Elevation (Track) .....................................................................3-12 3.15 S130 3 Deck Elevation (Track) .....................................................................3-13 3.16 S130 2 Deck Elevation (Wheel) ...................................................................3-14 3.17 S130 3 Deck Elevation (Wheel) ...................................................................3-15 3.18 S130 2 Deck Plan View ................................................................................3-16 3.19 S130 3 Deck Plan View ................................................................................3-17 3.20 S80 2 Deck Elevation (Track) .......................................................................3-18 3.21 S80 2 Deck Elevation (Wheel) .....................................................................3-19 3.22 S80 2 Deck Plan View ..................................................................................3-20 3.23 Noise levels ..................................................................................................3-21

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Technical Data

3.3 S190 General Information Machine ................................................................................... Mobile Screening Machine Weight (Track Machine)........................................................... 36,000 kg Weight (Wheel Machine .......................................................... 29,000 kg Additional Weight For Live Head ............................................. +3,500 kg Additional Weight For Three Deck ........................................... +2,500 kg

(1)

Fines Conveyor

Stockpile Height (Track) .......................................................... 4638 mm (15’ - 3’’) Stockpile Height (Wheeled) ..................................................... 4905 mm (16’ - 1’’) Belt Width ................................................................................ 1200 mm (48’’) Belt Type .................................................................................. Three-ply

(2)

Side Conveyors

Stockpile Height (Track) .......................................................... 5100 mm (16’ - 9’) Stockpile Height (Wheel) ......................................................... 5370 mm (17’ - 7’’) Belt Width ................................................................................ 800 mm (32’’) Belt Type ................................................................................. Three-ply

(3)

Transport Dimensions

Transport Height (2 Deck Track).............................................. 3400 mm (11’ 4’’) Transport Height (3 Deck Track).............................................. 3450 mm (11’ - 6’’) Transport Height (2 Deck Wheel) ............................................ 3950 mm (12’ - 11.5’’) Transport Height (3 Deck Wheel) ............................................ 4000 mm (13’ - 1.5’’) Transport Width ....................................................................... 2900 mm (9’ - 6’’) Transport Length (12ft Hopper) ............................................... 17515 mm (57’ - 5’’) Transport Length (15ft Hopper) ............................................... 18430 mm (60’ - 6’’)

(4)

Working Dimensions

Working Height (Track) ............................................................ 6290 mm (20’- 8’’) Working Height (Wheel) .......................................................... 6590 mm (21’ - 6’’) Working Width ......................................................................... 18240 mm (59’ - 10’) Working Length (12ft Hopper) ................................................. 18690 mm (61’ - 4’’) Working Length (15ft Hopper .................................................. 19605 mm (64’ - 4’’)

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3.4 S130 General Information Machine ................................................................................... Mobile Screening Machine Weight (Track Machine)........................................................... 27,000 kg Weight (Wheel Machine .......................................................... 24,000 kg Additional Weight For Live Head ............................................. +3,500 kg Additional Weight For Three Deck ........................................... +2,000 kg

(1)

Fines Conveyor

Stockpile Height (Track) .......................................................... 3871 mm (12’ - 8’’) Stockpile Height (Wheeled) ..................................................... 4139 mm (13’ - 7’’) Belt Width ................................................................................ 1200 mm (48’’) Belt Type .................................................................................. Three-ply

(2)

Side Conveyors

Stockpile Height (Track) .......................................................... 4600 mm (15’ - 1’) Stockpile Height (Wheel) ......................................................... 4870 mm (16’) Belt Width ................................................................................ 800 mm (32’’) Belt Type ................................................................................. Three-ply

(3)

Transport Dimensions

Transport Height (2 Deck Track).............................................. 3400 mm (11’ 4’’) Transport Height (3 Deck Track).............................................. 3450 mm (11’ - 6’’) Transport Height (2 Deck Wheel) ............................................ 3950 mm (12’ - 11.5’’) Transport Height (3 Deck Wheel) ............................................ 4000 mm (13’ - 1.5’’) Transport Width ....................................................................... 2900 mm (9’ - 6’’) Transport Length (12ft Hopper) ............................................... 15420 mm (50’ - 7’’) Transport Length (15ft Hopper) ............................................... 16335 mm (51’ - 9’’)

(4)

Working Dimensions

Working Height (Track) ............................................................ 5060 mm (16’- 7’’) Working Height (Wheel) .......................................................... 5330 mm (17’ - 6’’) Working Width ......................................................................... 15840 mm (51’ - 9’) Working Length (12ft Hopper) ................................................. 16515 mm (54’ - 6’’) Working Length (15ft Hopper) ................................................. 17530 mm (57’ - 6’’)

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3.5 S80 General Information Machine ................................................................................... Mobile Screening Machine Weight (Track Machine)........................................................... 20,000 kg Weight (Wheel Machine .......................................................... 18,000 kg

(1)

Fines Conveyor

Stockpile Height (Track) .......................................................... 3790 mm (12’ - 5’’) Stockpile Height (Wheeled) ..................................................... 4100 mm (13’ - 6’’) Belt Width ................................................................................ 1050 mm (42’’) Belt Type .................................................................................. Three-ply

(2)

Side Conveyor

Stockpile Height (Track) .......................................................... 4100 mm (13’ - 6’) Stockpile Height (Wheel) ......................................................... 4420 mm (14’ - 6’’) Belt Width ................................................................................ 650 mm (26’’) Belt Type ................................................................................. Three-ply

(3)

Transport Dimensions

Transport Height (Track) .......................................................... 3200 mm (10’ 6’’) Transport Height (Wheel) ........................................................ 3690 mm (12’ - 1’’) Transport Width ....................................................................... 2500 mm (8’ - 2’’) Transport Length ..................................................................... 14405 mm (47’ - 3’’)

(4)

Working Dimensions

Working Height (Track) ............................................................ 5010 mm (16’- 5’’) Working Height (Wheel) .......................................................... 5330 mm (17’ - 6’’) Working Width ......................................................................... 14080 mm (46’ - 2’)

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3.6 General Layout

Figure 3.1 - General Layout

NOTICE The left and right of the machine are assigned by standing at the hopper end of the machine and looking towards the main conveyor. 1

Grid – Separates the large un-screenable material from the screenable material and rejects this material to the side of the feeder. The grid may be tipped periodically to clear material which sits on the grid after loading.

Feeder – Consists of a hopper and heavy duty 3 ply belt. Acts as a reserve for raw material and controls the rate at which the material is fed to the screen box.

Main Conveyor–A three-ply belt delivers material from the hopper to the screen box.

Screen box - This is the most important part of the machine. This will screen raw material into three products. Different grades of product can be produced depending on screen meshes fitted. And in the case of a 3 deck four products.

Tail (Fine Product) Conveyor – A three-ply belt and carries the smallest screened material from the screen box to discharge stockpile.

Left Hand (Mid-Product) Side Conveyor – A three-ply belt and carries the mid screened material from the screen box to discharge stockpile.

Right Hand (Oversize Product) Side Conveyor – A three-ply belt and carries the oversize screened material from the screen box to discharge stockpile.

Powerunit – Encloses the engine, hydraulic tank and machine operational controls.

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3.7 Machine Measurements 3.8 S190 2 Deck Elevation (Track)

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3.9 S190 3 Deck Elevation (Track)

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3.10 S190 2 Deck Elevation (Wheel)

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3.11 S190 3 Deck Elevation (Wheel)

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3.12 S190 2 Deck Plan View

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3.13 S190 3 Deck Plan View

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3.14 S130 2 Deck Elevation (Track)

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3.15 S130 3 Deck Elevation (Track)

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3.16 S130 2 Deck Elevation (Wheel)

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3.17 S130 3 Deck Elevation (Wheel)

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3.18 S130 2 Deck Plan View

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3.19 S130 3 Deck Plan View

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3.20 S80 2 Deck Elevation (Track)

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3.21 S80 2 Deck Elevation (Wheel)

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3.22 S80 2 Deck Plan View

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3.23 Noise levels

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Machine Operation 4

Table of Content 4

Operational Procedures ............................................................................ 4-2 4.4 Prior to Use ....................................................................................................4-2 4.5 Prestart Inspection .........................................................................................4-2 4.6 Machine Location ...........................................................................................4-2 4.7 Control Panel Overview..................................................................................4-3 (1) 74kW (100hp) Engine Control Panel .........................................................4-3 (2) 94kW (127hp) Engine Control Panel .........................................................4-5 (3) Tier 4i Engine Control Panel ......................................................................4-7 (4) Tier 4i Control Panel LCD Display Screen.................................................4-9 (5) T4i Control Panel Warning and Shutdown Lights ....................................4-10 4.8 Starting the Engine ....................................................................................... 4-11 (1) Hydraulic Control Valve Operation...........................................................4-12 4.9 Pictorial Decal Descriptions..........................................................................4-13 (1) Machine Operations Decals ....................................................................4-13 (2) Machine Information Decals ....................................................................4-20 4.10 Tracking the Machine ...................................................................................4-24 (1) Tracking with the Umbilical Remote Control ............................................4-25 (2) Tracking with the Radio Transmitter Remote Control ..............................4-28 4.11 Machine Setup .............................................................................................4-30 (1) Unfolding the Side and Tail Conveyors ....................................................4-30 (2) Raising the Screen Box and Main Conveyor ...........................................4-32 (a) Raising Screen Box ............................................................................4-32 (b) Raising Main Conveyor .......................................................................4-36 (3) Raising Tail Conveyor ..............................................................................4-37 (4) Tipping Grid Setup ...................................................................................4-38 (5) Tipping Grid Cycle Time Setup ................................................................4-38 (6) Controlling the Tipping Grid Manually ......................................................4-39 (7) Operating the Tipping Grid Using the Radio Controller ...........................4-39 (8) Vibrating Grid Setup ................................................................................4-40 (9) Hopper Landing Legs Setup ....................................................................4-42 (10) Auxiliary Conveyor Setup ........................................................................4-44 4.12 Operating the Shredder ................................................................................4-46 (a) Raising/Lowering the Shredder ...........................................................4-46 (b) Running the Shredder .........................................................................4-47 4.13 Machine Components Start-Up Procedure ..................................................4-48 4.14 Machine Shut Down Procedure....................................................................4-50 4.15 Machine Lockout and Tag Out Procedure ....................................................4-50 4.16 Emergency Stop Procedure .........................................................................4-50

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4 Machine Operation

Operational Procedures

4.4 Prior to Use Do not attempt to start the machine until you have received the correct training and have read and understood this manual fully. Make sure all precautions are taken so that the machine is operated in a safe and reliable manor. Follow all government laws, codes or bylaws regarding safety matters. Only operate the machine after you have satisfied yourself that all safety devices are in place and working correctly including but not limited to all guards, safety devices, emergency stop switches, safety decals, tank caps and exhaust elements. Always operate internal combustion engine equipped machines in properly ventilated areas. Make sure that all personnel are wearing the correct Personal Protective Equipment (PPE) in accordance with local legislation. Avoid wearing any loose fitting clothing which could became entangled in the machine or other equipment

4.5 Prestart Inspection

WARNING Switch off, tag out and lock out machine before carrying out pre-operation checks or machine maintenance. Wear personal protective equipment at all times. Check bearings have been greased. Before staring the machine thoroughly check for any damage and make sure the machine is in good mechanical condition. Before starting the make sure that no personnel are one the machine or machine walkways. Make sure all guards are in places and all safety devices are working correctly Make sure all fluids and lubrication checks have been completed and that the machine has had all required service procedure carried out in line with the service schedules. Make sure all hydraulic control levers are in the neutral (off) position Do not start up the machine until the inspection is complete.

4.6 Machine Location Prior to setting up the machine, consideration should be given to a suitable layout. Position the machine in a safe and level operating position, make sure both tracks are in full contact with the ground to minimise movement of the Machine. Regularly check the machine is level and stable. Inspect the area around the machine for potential hazards such as overhead electric cables or other structures. Pay attention to access from the loading area and to where material is to be deposited.

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4.7 Control Panel Overview (1)

ID 1

74kW (100hp) Engine Control Panel

Symbol

Name Battery Charging Warning Light

Oil Pressure Warning Light

Coolant Temperature Warning Light

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Description This light should illuminate when the key switch is turned to the ON position. As soon as the engine starts it should go out. If it fails to illuminate when the key is turned on, or if it illuminates when the engine is running, it indicates that there is a fault in the charging circuit. Stop the engine and have the circuit checked. This light should illuminate when the key switch is turned to the ON position. As soon as the engine starts it should go out. If a fault occurs in the oil pressure system the engine will shutdown after 2 seconds. This light will only illuminate if a problem occurs in the coolant system, such as low water level. The engine will shut down 5 seconds after the fault has been detected.

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Symbol

Name Coolant Level Warning Light

Engine Run Light

Air Breather Restriction Warning Light

Fuel On Light

Hydraulic Oil Level Warning Light (Not Shown) E-Stop Activated Light

Engine Pre-Heater Indicator Light

Fuel Contamination Light

Hour Clock

Optional Work Light Switch Key Start Switch

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Description This light will only illuminate if a problem occurs in the coolant system, such as low water level. The engine will shut down 5 seconds after the fault has been detected. This light will only illuminate when the key is turned to the ON position and will remain on at all times. If it goes out then an E-Stop has been pressed and the engine will shut down immediately. This light should illuminate if a problem occurs in the air breather system. After 30 minutes the engine will shut down. The light will remain on until the fault has been repaired. This light should illuminate when the engine starts and will remain on at all times. It will go out when the engine has been shut down. This light will only illuminate if the hydraulic oil level is low. The engine will shut down 5 seconds after the fault has been detected. This light will only illuminate when an E-Stop has been pressed. This will immediately shut down the engine. If the light is flashing after shut down, this indicates that the manual tracking umbilical E-Stop has been pressed. If the light remains on constantly than another E-Stop has been pressed. This light only illuminates when the pre-heat button is operated during start up. This light illuminates if a problem occurs in the fuel system, such as water contamination. The engine will shut down 1 second after the fault has been detected. This will record the number of hours that the engine has been running. This optional light can be switched on to give more light when working at the power unit. This is used to start the engine when required.

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ID 1

94kW (127hp) Engine Control Panel

Symbol

Name Battery Charging warning light

Oil Pressure Warning Light

Coolant Temperature Warning Light

Fuel contamination light

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Symbol

Name Engine Run Light

Air Breather Restriction Warning Light

Fuel On Light

Hydraulic Oil Level Warning Light (not shown) E-Stop Activated Light

Engine PreHeater Indicator Light Engine Warning Light

Description This light will only illuminate when the key is turned to the ON position and will remain on at all times. If it goes out then an E-Stop has been pressed and the engine will shut down immediately. This light should illuminate if a problem occurs in the air breather system. After 30 minutes the engine will shut down. The light will remain on until the fault has been repaired. This light should illuminate when the engine starts and will remain on at all times. It will go out when the engine has been shut down. This light will only illuminate if the hydraulic oil level is low. The engine will shut down 5 seconds after the fault has been detected. This light will only illuminate when an E-Stop has been pressed. This will immediately shut down the engine. If the light is flashing after shut down, this indicates that the manual tracking umbilical E-Stop has been pressed. If the light remains on constantly then another E-Stop has been pressed. This light only illuminates when the pre-heat button is operated during start up.

Engine ECU Warning Light

Hour Clock

Throttle Control

Key Start Switch

This light will only illuminate when the engine or engine component has developed a problem. This can result in an engine shut down. In the event of a fault causing this light to illuminate you should contact your local dealer for further information. This light will only illuminate when the engine control unit detects a problem. This can result in an engine shut down. In the event of a fault causing this light to illuminate you should contact your local dealer for further information. This will record the number of hours that the engine has been running. This is used to control the engine throttle by selecting one of the 3 speeds. This is used to start the engine when required.

Fuel Display

Displays fuel level.

Optional Work Light Switch

This optional light can be switched on to give more light when working at the power unit.

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ID 1

Tier 4i Engine Control Panel

Symbol

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Name Battery Charging warning light

Hydraulic Oil Level Warning Light Air Filter Warning Light Regen

Description This light should illuminate when the key switch is turned to the ON position. As soon as the engine starts it should go out. If it fails to illuminate when the key is turned on, or if it illuminates when the engine is running, it indicates that there is a fault in the charging circuit. Stop the engine and have the circuit checked. This light will illuminate only when the hydraulic oil level is low. If low hydraulic oil level occurs the engine will shutdown after 5 seconds. This light will illuminate if a problem occurs in the air breather system. The light will remain on continuously until the fault has been repaired. This light illuminates if regen is required. To activate regen the regeneration filter button on the keypad must be pressed. To deactivate regen the regeneration disable button on the keypad must be pressed.

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Symbol

Name Handset Stop Activated

Description This light will only illuminate when the handset stop has been pressed. This will immediately shut down the Engine. - Constant light refers to handset stop button. This light will only illuminate when a machine E-Stop has been pressed. This will immediately shut down the engine. - Flashing light indicates one or more of the machine E-Stops has been pressed. This light will illuminate when the machine is started and will remain on at all times. It will go out when ta machine stop has been pressed and the engine will shut down immediately. The engine will not start if this light is not illuminated. This light will illuminate when the ignition key is turned to the start position to indicate that the fuel solenoid circuit has been energized. The engine will not start if this light is not on, Whilst the engine is running this light will remain on. Refer to “T4i Control Panel Warning and Shutdown Lights” on page <OV>.

Machine Stop Activated

Engine Run Light

Fuel On Light

Engine warning Light

Engine Shutdown Refer to “T4i Control Panel Warning and Shutdown Light Lights” on page <OV>.

LCD Panel

Tracks Activate Button

Work Lamp Button

Regen Disable

Regen Enabled

Engine Revs Down

Engine Revs Up

Push this button to increase engine speed.

Scroll Down

Push this button to scroll down through the menus on the LCD panel.

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This panel is used to display engine parameters and fault codes, see “Tier 4i Control Panel LCD Display Screen” on page <OV>. This button must be pressed to activate tracking mode. Handset tracking modes will not function unless this button has been pushed. This button will switch the work lamp on/off. (The work lamp is optional and may not be fitted to all machines). This button will disable the engine regeneration cycle. (Optional, on engines without this function the button will be blank). This button will enable the engine regeneration cycle. (Optional, on engines without this function the button will be blank) Push this button to decrease engine speed.

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Symbol

(4)

Name Scroll Up

Description Push this button to scroll up through the menus on the LCD panel.

Key Start Switch

This is used to start the engine when required.

Tier 4i Control Panel LCD Display Screen

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Home Screen

Home screen displays engine RPM and fuel level.

Screen 1

Screen 1 displays total engine hours and engine speed.

Screen 2

Screen 2 displays soot load and ash load. (Soot load and ash load functions are only available with Regen units, engines without the Regen function will read 0%).

Screen 3

Screen 3 displays engine fault codes.

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T4i Control Panel Warning and Shutdown Lights Engine Engine Warning Shutdown Lamp Lamp

Off

Flashing

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Description When the ignition is switched on both lamps illuminate for 2 seconds them go off. If both light are off while engine is running then there are no active faults.

Engine State Key on but engine yet to be cranked.

Engine running with no active faults.

Off

Flashing

Off

Flashing

Should the light illuminate as shown while the engine is running an active electrical fault has been detected. Should the lights illuminate as shown while the engine is running an active electrical fault is present sufficient to evoke engine derate. Should the lights illuminate as shown while the engine is running one or more of the engines protection values has been exceeded but not to a level that will initiate engine derate or shutdown. Should the lights illuminate as shown while the engine is running one or more of the engines protection values has been exceeded beyond acceptable levels and has initiated an engine derate.

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Engine is running but has one or more active faults with the engine management system. Engine is running but has one or more active faults that have initiated engine derate.

Engine is running normally but has one or more engine parameters outside the acceptable operating range but not sufficient to initiate engine derate or shutdown.

Engine is running but has one or more parameters outside the acceptable operating range which are sufficient to exceeded the range set for engine derate.

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Machine Operation 4

Should both the warning light and the shutdown light illuminate while the engine is running this indicates that either: 1. One or more of the engine protection shutdown values has been exceeded.

Engine is either shutdown or shutdown is imminent, one or more of the monitored engine parameters have gone beyond that of warning or derate and have now exceeded the levels set for engine shutdown.

2. A serious active fault has been detected. This will result in an engine shutdown.

4.8 Starting the Engine

WARNING Wear personal protective equipment at all times. Make sure that no personnel are on the machine. 1.

Observe all safety warnings

Check that control levers are in neutral position, and all emergency stops are released

For machines fitted with the T4i control panel the umbilical control or blanking plug must be fitted before the machine will start. If the umbilical controller is fitted the on/off button must be in the off position see Figure 4.5 before the machine will start.

If equipped with a manual throttle then set throttle lever to idle.

Turn ignition key to position 2, Ref: Figure 4.1.

Figure 4.1 - Ignition Key Positions 6.

The following warning lights on the control panel will illuminate:

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4 Machine Operation Tier 3 Machines Charge light Oil pressure light Emergency stop

Tier 4i Machines Charge light Engine run light Fuel on light 7.

Turn ignition key to position 3 and hold until the safety siren stops, Ref Figure 4.1.

The fuel on light will illuminate and the engine will start Fuel On Light

(1)

Release the ignition key immediately after the engine starts.

Hydraulic Control Valve Operation

All hydraulic control valves operate using levers and each is labelled with their function. Some control valves on the machine are equipped with a flow control dial. These dials control the output flow from the valve which will in turn speed up or slow down (clockwise turn will reduce speed, anti-clockwise will increase speed) the respective component they control Ref Figure 4.2 The neutral (off) position for hydraulic control valves is when the lever is in the centre position.

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Figure 4.2 - Control Valve

4.9 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 tables give short explanations of each operation decal used on the machine. The operations of the levers or controls will remain the same. 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.

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Description

Explanation



Engage screen box



Off position



Raise shredder



Neutral



Lower shredder



Engage shredder



Off position



Engage auxiliary circuit



Off position



Raise main conveyor



Neutral



Lower Main Conveyor

Screen Box

Shredder (Option)

Auxiliary Circuit

Main Conveyor

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Right Hand Side Conveyor

Screen Box

Main Conveyor

Tail Conveyor

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

Fold right hand side conveyor lower section



Neutral



Unfold right hand side conveyor lower section



Fold right hand side conveyor upper section



Neutral



Unfold right hand side conveyor upper section



Raise screen box



Neutral



Lower screen box



Slide main conveyor up



Neutral



Slide main conveyor down



Fold tail conveyor



Neutral



Unfold tail conveyor

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Tail Conveyor

Left Hand Side Conveyor

Support Legs

Tipping Grid

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

Raise tail conveyor



Neutral



Lower tail conveyor



Fold left hand side conveyor lower section



Neutral



Unfold right hand side conveyor lower section



Fold right hand side conveyor upper section



Neutral



Unfold right hand side conveyor lower section



raise support legs



Neutral



Lower support legs



Raise tipping grid



Neutral



Lower tipping grid

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Auxiliary Conveyor

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

Raise auxiliary conveyor



Neutral



Lower auxiliary conveyor



Fold auxiliary conveyor



Neutral



Unfold auxiliary conveyor

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4 Machine Operation Decal

Description

Explanation



Engage feeder plus speed control for conveyor



Off position



Engage left hand side and cross conveyors plus speed control for conveyors



Off position



Engage right hand and auxiliary conveyors plus speed control for conveyors



Off position

Feeder Conveyor

Left Hand Conveyor & Cross Conveyor

Right Hand Conveyor & Auxilairy Conveyor



Engage main conveyors

Main Conveyor 

Off position



Engage main conveyor and vibrating grid



Hold

Main Conveyor and Vibrating Grid

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

Engage tail conveyor and screen box



Off position



Engage left hand side conveyor plus speed control



Off position



Engage right hand side conveyor plus speed control



Off position

Tail Conveyor and Screen Box

Left Hand Side Conveyor

Right Hand Side Conveyor

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4 Machine Operation Decal

(2)

Explanation

Engage main conveyor



Off position

Engage tracks

Engage tail conveyor and screen box



Off position

Engage tracks

Engage main conveyor



Off position

Engage tracks

Machine Information Decals

NOTICE The decals shown below are for illustration only and the actual decal fitted to the machine should be referred to for the correct information. All details are also covered in the corresponding sections of the operations manual which should be read and understood fully before performing any operation with the machine.

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Machine Operation 4 Table 4.2 - Machine Information Decals Decal

Explanation

Fuel tank capacity

Hydraulic oil tank capacity

Screen box greasing schedule. This decal shows that the screen box requires 5 grease gun pumps delivering 1.25 grams of Mobilith SHC220 grease per pump every 24 hours

This decal shows that 2, 1.25 gram grease gun pumps of general purpose grease is required every 40 hours

Vibrating grid greasing schedule. This decal shows that the vibrating grid requires 2 grease gun pumps delivering 1.25 grams of Mobilith SHC220 grease per pump every 24 hours

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4 Machine Operation

Shredder greasing schedule. This decal shows that the shredder bearings require 2 grease gun pumps delivering 1.25 grams of Mobilith SHC220 grease per pump every 40 hours

Make sure that safety pins are removed and replaced as necessary

Make sure that ultra low sulphur fuel only is used

Make sure that conveyor belt is not nipped while folding or unfolding the conveyor

Make sure the locking bolt on the belt adjuster is slackened before adjustment and re-tightened after adjustment

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Risk of impact between the tail conveyor and screen if screen box is raised while the tail conveyor is in the transport position

Make sure that the transport section of the operations manual is read and fully understood before transporting machine.

Battery isolator location

Safety harness securing point

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4.10 Tracking the Machine

DANGER DO NOT stand on any of the platforms or ladders of the machine whilst it is being moved 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 or dangers that may lie in your path.

WARNING Make sure machine is locked out and tagged out before performing any maintenance or checks. Always perform maintenance on a level and solid surface.

NOTICE Make sure that the tracks are free from obstructions and built up material before manoeuvring the machine. Before moving the machine perform the following checks: • Check for loose bolts and nuts on lower rollers, sprockets and track shoes. • Check all tracks links and make sure master pins are correctly located and tight. • Check for oil leaks from the lower rollers and front idlers. • Check for oil leak from the track drive gearbox and motor. • Check track tension is 5mm and 15mm. • Check for general damage and wear to all components. If any issues are found make sure corrective action is taken before attempting to move the machine. When traveling up a gradient, the tracks should be driven forward (i.e. idlers first, drive sprocket to the rear). When traveling down a gradient, tracks should be driven sprocket first Ref: Figure 4.3.

Figure 4.3 - Gradient Direction ALWAYS:• Park the machine on flat, level ground. If it is necessary to park the machine on a gradient, the tracks should be solidly blocked. • Ensure the terrain the machine is working on is firm enough to adequately support the machine.

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Machine Operation 4 • Ensure the machine is tracked at least 10m in either direction on a daily basis, to minimize risk of track chain seizure. • Ensure the track systems are free from debris before moving the machine. • Ensure the tracks are not frozen to the ground before moving the machine.

NEVER:• Attempt to track the machine if there is any build up of material around the tracks and drive sprockets. • Attempt to track the machine if the tracks are frozen to the ground. • Push or tow the machine when unable to free itself.

(1)

Tracking with the Umbilical Remote Control

CAUTION The machine will not stop if the umbilical is removed. The large red button (1) on the umbilical cannot be referred to as an emergency stop. Should an emergency arise and the umbilical is not connected to the machine, pressing the large red button will not stop the machine. Should an emergency arise press an emergency stop on the machine itself.

NOTICE If the machine stop (1) is pressed do not reset it until tracks and surrounding area have been checked and it is safe to move the machine. When the machine stop button has been pressed the engine will cut out and will need to be started after resetting the machine stop button. The umbilical machine stop (1) can be reset by twisting it clockwise one quarter turn. When the remote control unit is not in use, the function buttons must remain in the neutral position. For Tier 4 machines the track activation button on the control panel must be pushed and the on/ off switch on the umbilical controller turned on before the tracks will activate. 1.

Connect the umbilical handset to the hopper end of the machine.

Ensure E-stop button (item 1) is release. Twist to unlock

Make sure all levers are in the neutral (off) position.

Start the engine Ref: 9 on page 4-12.

On Tier 4 machines push the track activate button on the control panel.

Change switch (item 2) Figure 4.5 from AUX to TRACK or Off to On to activate handset, the siren will sound. There will be a 10 second delay before the machine will move.

Push track control levers down to activate track hydraulic circuits see Figure 4.4

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4 Machine Operation

Figure 4.4 - Track Levers 8.

To move machine forward While standing at the hopper end, push both switches (3&4) forward (when holding the controller the stop button (item 1) should be at the bottom). To move in the opposite direction hold the switches in the opposite direction.

To turn machine use either the left hand or right hand tracking switches.

10. To stop engine while using umbilical handset, push red button (Item 1). This will stop the engine but is not an Emergency Stop.

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Figure 4.5 - Umbilical Handset 1

Umbilical machine stop

Tracking On/Off switch (The bottom handset has an L.E.D which will illuminate green when on).

Right hand track forward/reverse

Left hand track forward/reverse

(OPTION) Additional Function Button - operates both tracks at same time.

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4 Machine Operation (2)

Tracking with the Radio Transmitter Remote Control

CAUTION The stop button (1) on the remote control cannot be referred to as an emergency stop. Should an emergency arise and the radio remote is not in connect with the machine, pressing the stop button will not stop the machine. Should an emergency arise press an emergency stop on the machine itself.

Disconnect umbilical cord plug (if connected)

Make sure all levers are in the neutral (off) position.

Start the engine Ref: 9 on page 4-12.

Refer to Figure 4.6 showing the radio transmitter handset.

Push button 2 to activate handset, warning buzzer will be heard when active.

To move left track forward press button 3, release to stop.

To move left track backwards press button 5, release to stop.

To move right track forwards press button 4, release to stop.

To move right track backwards press button 6, release to stop.

10. To move froward straight press button 7, release to stop. 11. To move backward straight press button 8, release to stop 12. Press button 2 to turn off remote, alarm will stop. 13. To stop engine press button 1.

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Figure 4.6 - Radio Transmitter Handset 1

Engine Stop.

Handset Activation.

Track Forward Left.

Track Forward Right.

Track Backward Left.

Track Backward Right.

Track Forward Straight.

Track Backward Straight.

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4.11 Machine Setup

WARNING Make sure all personnel are clear from the machine. When starting the machine always make sure all control levers are in the neutral (off) position. Always observe all safety warnings. Wear personal protective equipment.

(1)

Unfolding the Side and Tail Conveyors

NOTICE All control levers must be in the neutral (non-operational) position. Take care not to nip the conveyor belt between moving parts. 1.

Start engine Ref: 9 on page 4-12.

Run engine at idle speed.

Remove transport stays from tail conveyor (1) and side conveyor pins (2) and (3) see Figure 4.7.

Figure 4.7 - Side and Tail Conveyor Setup 4.

The hydraulic control levers shown in Figure 4.8 are located under the screen pivot point see Figure 4.7. Item 4, the control levers shown in Figure 4.9 are located at the opposite side of the machine.

Right Hand Side Conveyor: Using lever (1) and (2) Ref: Figure 4.8 slowly raise the head section and once clear of the transport bracket unfold, using lever (1), the mid section down toward working position. Then using lever (2) unfold the head section, make sure the belt does not get caught on the wing or return rollers. Replace the pins in the side conveyor.

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Figure 4.8 - Side Conveyor Levers 6.

Tail Conveyor: Push lever in Figure 4.9 (1) to unfold the tail conveyor (ensure transport stays are removed before unfolding)

Left Hand Side Conveyor: Unfold the left hand side conveyor using lever 3 and 4 Figure 4.9 in the same way as the right hand side conveyor.

Figure 4.9 - Side and Tail Conveyor Levers 8.

Once the side conveyors are in the desired working position fit the locking bolt Ref item 1 Figure 4.10

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4 Machine Operation

Figure 4.10 - Side Conveyor Locking Bolts

(2)

Raising the Screen Box and Main Conveyor

(a)

Raising Screen Box

Raise the screen box using lever 3 Figure 4.9 and release the weight on the pins on either side of the screen box support legs, item 1 Figure 4.12.

Remove the pins and raise the screen to the appropriate hole. Replace the pins and lower the screen box to ensure the pins are carrying the load of the screen box.

The pinning holes are explained in Figure 4.13 (S190), Figure 4.14 (S130) and Figure 4.15 (S80).

Figure 4.11 - Screen Box Lever

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Figure 4.12 - Safety Pins

Figure 4.13 - S190 Screen Box Pin Positions • 1 - 30 Degrees. • 2 - 27.5 Degrees. • 3 - 25 Degrees. • 4 - 22.5 Degrees. • 5 - 20 Degrees.

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4 Machine Operation • 6 - Maintenance and loading/unloading from flatbed transporter position. • 7- Wheeled machine transport position. • 8 - Track machine transport position.

Figure 4.14 - S130 Screen Box Pin Positions • 1 - 38 Degrees. • 2 - 35 Degrees. • 3 - 32 Degrees. • 4 - 28 Degrees. • 5 - 25 Degrees. • 6 - Maintenance and loading/unloading from flatbed transporter position. • 7- Wheeled machine transport position. • 8 - Track machine transport position.

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Figure 4.15 - S80 Screen Box Pin Positions • 1 - 37 Degrees. • 2 - 33 Degrees. • 3 - 30 Degrees. • 4 - 27 Degrees. • 5 - Transport and maintenance.

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4 Machine Operation (b) 1.

Raising Main Conveyor Slide the main conveyor forward using lever 4 Figure 4.16. The optimum position of the main conveyor feed in point to the screen will vary with screen angle and material type. (NOT REQUIRED ON S80)

Figure 4.16 - Main Conveyor Sliding Lever 2.

The optimum height for the main conveyor discharge feeding on to the screen can be adjusted using the control valve 1 shown in Figure 4.17. Pin the conveyor in the relevant position using the pin 2 either side Figure 4.17.

Figure 4.17 - Main Conveyor Raise Lever

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Raising Tail Conveyor

NOTICE When the screen is used at max angle the tail conveyor should be in the lowest hole to ensure material is discharged at the maximum rate. 1.

The optimum working angle for the tail conveyor is 24 degrees use valve 2 Figure 4.18. To adjust the conveyor angle. Use pin 2 Figure 4.17 to lock the conveyor in the appropriate hole.

Figure 4.18 - Tail Conveyor Raise Lever

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Tipping Grid Setup

WARNING When working above ground level make sure to use a suitable working platform. Falling material hazard. Wear personal protective equipment. Do not work under unsupported equipment. 1.

Fit the wing plates (item 1 Figure 4.19) to the tipping grid using 10 off M12X35 bolts.

Use tipping grid lever (item 4) to raise the grid to a sufficient angle so that the grid support arm, (item 3), can be raised and pinned using grid leg pin (item 2).

Make sure both support legs are in the same pinning hole position. Using the tipping grid control valve lower the grid until it is resting on the grid leg support.

Figure 4.19 - Tipping Grid Setup

(5)

Tipping Grid Cycle Time Setup

NOTICE This procedure will need to be done each time the grid angle is changed. 1.

Start the engine, Ref: 9 on page 4-12

Set the engine to full throttle.

Press the top button (item 1) on the side of the receiver (located in the power unit) twice and release. Press a third time and hold down. Ref: Figure The grid should start to rise. Once it has reached the required angle (this should be the end of the hydraulic rams stroke) release the button and the grid should stop.

Repeat this exercise for the lowering cycle by pressing the second button on the receiver box (item 2), Ref: Figure 7.33.

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This cycle will be recorded and each time the grid is operated using the remote control the same angle and speed will be achieved.

Figure 4.20 - Tipping Grid Control Pane

(6)

Controlling the Tipping Grid Manually

Start the engine, Ref: 9 on page 4-12.

Set the engine to full throttle and make sure that the grid is fully down

To raise the grid manually press and hold button (3), Ref Figure 4.20. Once the grid has achieved the required height release the button.

To lower the grid manually press and hold button (4), Ref: Figure 4.20. Once the grid is completely down release the button.

(7)

Operating the Tipping Grid Using the Radio Controller

NOTICE The tipping grid is designed to finish the cycle. If the grid is stopped in the rise cycle, once the cycle is restarted it will continue to its highest point before lowering again. The transmitter has an operating range of approximately 100 meters. But longer or shorter distances will be achieved depending on the location of the receiver box in relation to the remote control transmitter. The surroundings will also affect the range of the device. 1.

Start the engine, Ref: Ref: 9 on page 4-12.

Set the engine to full throttle

Make sure that the grid is fully down.

To activate press button 3 (Figure 4.21) twice the red light 4 will flash.

Press button 1 the red light will flash and the grid will cycle. Cycle time for the grid will vary if the grid cycle is not set at full engine throttle it will not operate correctly during normal running conditions.

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Pressing button 2 will stop the grid cycle. By pressing button 1 the cycle will resume.

The radio controller will automatically switch off after 2 minutes of inactivity, to reactivate press button 3 twice as in step 4.

Figure 4.21 - Tipping Grid Radio Controller

(8)

Vibrating Grid Setup

WARNING When working above ground level make sure to use a suitable working platform. Falling material hazard. Wear personal protective equipment. Do not work under unsupported equipment.

NOTICE The vibrating grid most not be used when pinned in its lowest position, the lowest position if for transport only. The correct operating speed of the vibrating grid is 1030 - 1050 rpm with a 5 - 5.5mm throw, 1.

Fit the wing plates (item 1 Figure 4.22) to the tipping grid using 10 off M12X35 bolts

Secure the vibrating grip to a suitable lifting devise/crane using the lifting point (item 2 Figure 4.22).

Making sure that the weight of the chute is supported by the lifting device/crane at all times, remove the transport stays from both sides of the chute (item 3 Figure 4.22).

Lower the chute until the longer support stays (item 1 Figure 4.23) can be fitted.

Remove the pins from the support legs (items 1 Figure 4.24) and raise the grid to the desired angel using the control lever (item 4 Figure 4.19), refit pin on both side to the correct hole to secure grid in desired position.

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The vibrating grid is engaged when the main conveyor is turned on.

Figure 4.22 - Vibrating Grid Transport Stays

Figure 4.23 - Vibrating Grid Chute Supports

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Figure 4.24 - Vibrating Support Legs

(9)

Hopper Landing Legs Setup

CAUTION Crush hazard from lowering jacking legs. Stand clear of support legs when withdrawing the main support pins and when lowering support legs. 1.

Start the engine, Ref: 9 on page 4-12.

Remove jacking leg pins item 1 Figure 4.25.

Use jacking leg control valve, item 2 to lower jacking leg.

Lower the legs until the pin holes line up. If the either or both of the legs are not supporting the hopper, at item 3, place some suitable material under the foot of the jacking leg/legs to support the hopper.

Rotate the side conveyor transport bracket from the transport position to the operating position as shown item 4.

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Figure 4.25 - Landing Legs

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4 Machine Operation (10) Auxiliary Conveyor Setup

NOTICE Make sure the left hand side conveyor is in working position before unfolding auxiliary conveyor. 1.

Remove pins from support leg and transport bracket, Ref: items 1 and 2 Figure 4.26.

Figure 4.26 - Auxiliary Conveyor Transfer Brackets 2.

Raise Auxiliary conveyor just clear of transport bracket, item 2, taking care not to damage belt.

Rotate Auxiliary conveyor clockwise away from the hopper to desired working position.

Raise Auxiliary conveyor to desired working angle.

Pin conveyor in position.

Fit transfer rubber chute to locating holes Ref: Figure 4.27.

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Figure 4.27 - Transfer Chute

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4.12 Operating the Shredder

WARNING When working above ground level make sure to use a suitable working platform.

CAUTION Always fit the safety support and pins when the shredder unit is in the open position. Never work under unsupported equipment (a)

Raising/Lowering the Shredder

Start the engine, Ref: 9 on page 4-12.

To lower the shredder unit remove the safety pins and stays, items 1 and 2 in Figure 4.28.

Press down on the control lever located on the right hand side of the hopper, item 1 Figure 4.29, when the shredder is in the down position return the control lever to the neutral (centre) position.

To raise the shredder unit push up on the control lever until the shredder is raised then return the lever to the neutral (centre) position.

Fit the safety stays and pins, items 1 and 2 in Figure 4.28 to both side of the shredder.

Figure 4.28 - Shredder Safety Pins and Stays

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Figure 4.29 - Shredder Raise/Lower Control Lever (b)

Running the Shredder

WARNING Never attempt to open the shredder unit while it is in operation. When opening the shredder unit make sure the shredder flails have come to a complete stop and the machine has been shut down. Do not attempt to make any adjustments on the shredder while the machine is in operation, make sure the machine has been shut down.

NOTICE The shredder is equipped with a safety device which will prevent it from working while it is in the open position. If the shredder begins to open while it is operating it will divert oil away from the shredder motor resulting in the shredder stopping after its momentum has ceased. 1.

Start the engine, Ref: 9 on page 4-12.

To switch on the shredder push the control lever located in the power unit to the up position, see item 1 Figure 4.30.

The shredder is equipped with a safety device, see Figure 4.31 which will divert oil away from the motor if it opens during use. The amount the shredder can be open before shut down is adjusted by screwing the adjustment bar in or out. Do not attempt to adjust while the machine is in operation, shut the machine down completely.

To switch off the shredder return the control never to the neutral (centre) position.

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Figure 4.30 - Shredder On/Off Control Lever

Figure 4.31 - Shredder Safety Device

4.13 Machine Components Start-Up Procedure

WARNING Wear personal protective equipment. Make sure no personnel are on the machine or machine walkways.

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NOTICE Before starting the machine components make sure you check that all fluid and grease checks have been completed in line with the service schedules contained in Maintenance section of this manual. Make sure all control levers are in the neutral (off) position and the throttle is set to idle. 1.

Make sure all prestart checks have been completed Ref: “4.2 Prestart Inspection” on page 4-2

Make sure the electrical isolator switch is turned on Ref: item 1 Figure 4.32

Figure 4.32 - Isolator Switch 3.

Turn on the engine Ref: 9 on page 4-12.

Increase the throttle speed.

Start the machine components using the hydraulic levers in the power unit in the following order:• Left hand side conveyor (and cross conveyor on 3 deck versions). • RH side conveyor (and auxiliary conveyor in 3 deck options). • Screen box and tail conveyor. • Main conveyor. • Shredder (if fitted). • Feeder.

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4.14 Machine Shut Down Procedure

Make sure that all material has been run off the machine and the screen box is empty.

Stop the machine components in the following order • Feeder. • Main conveyor. • Screen box and tail conveyor. • Right hand side conveyor (and auxiliary conveyor in 3 deck options). • Left hand side conveyor (and cross conveyor on 3 deck versions).

Throttle down the machine and allow engine to run at idle for 5 minutes.

Turn ignition key to the off position and remove key.

Check fuel level and top up if required to avoid build up of condensation in fuel tank.

Secure machine.

4.15 Machine Lockout and Tag Out Procedure 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. 1.

Turn off the machine following the “Machine Shut Down Procedure” on page 4-50.

After 20 seconds, rotate the isolator switch from the “ON” position to the “OFF” position, Ref: Figure 4.32.

Fit the lock out padlock on the main power isolator and keep the key with you.

Release stored energy from the system, such as hydraulic fluid under pressure, so that the machine is in a zero energy state.

Place a tag on the lock that identifies you as well as the date and time you locked it out

Check that the machine can not be started to ensure the lookout is complete.

4.16 Emergency Stop Procedure In an emergency situation stop the machine by pressing the closest emergency stop button located on the machine. The stop button on the remote radio control or umbilical control, if fitted, is not an emergency stop. 1.

Press any emergency stop button located on the machine to stop the engine and machine, Ref: Figure 4.33. Turn the ignition key to the off position as soon as possible, if safe to do so.

Remove the ignition key.

Set the isolator switch to the off position.

When safe, release the emergency stop button(s) by pulling or twisting.

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Figure 4.33 - Emergency Stop Locations

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Table of Content 5

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5 Transportation

Transportation

NOTICE Make sure that all of material has been run off the conveyors and the screen box and hopper are both empty and that the machine has been properly shut down Ref: “Machine Shut Down Procedure” on page 38. Clear the area of all personnel & obstructions before folding the conveyors.

DANGER Do not move the machine without all transportation fitments securely in place and safety pins in position.

CAUTION Prior to transportation always check the machine for loose or damaged components. Make sure all loose items are carefully stowed and secured if these are to be transported on the machine. Check that the travelling dimensions and weight of the machine will be within the regulation limits. 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. 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. Before travelling with the machine, check that the braking and any signalling and lighting systems are fully functional. On wheeled machine: Ensure wheel nuts are torqued between 590 to 627 ft.lb (800Nm to 850Nm) prior to transport. Connect and check the braking system. Check your tires for:• correct pressure • cuts or bulges • nails or spikes • uneven or excessive wear Check your wheels for:• damaged rims • missing or loose wheel nuts or bolts • obvious misalignment

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Transportatipon 5 Wheeled bogie machines are fitted with a tow bar, this should not be used to transport the machine and is only to be used to manoeuver the machine over short distances when on-site. When manoeuvering with the tow bar the ground must be level, firm and free of obstacles. When transporting wheeled bogie machines they must be correctly hitched to a tractor unit using the kingpin.

5.5 Preparing Machine for Transport (1)

Placing Tipping Grip in Transport Position

WARNING When working above ground level make sure to use a suitable working platform. 1.

Remove the wing plates (item 1) Figure 5.1 from the tipping grid by undoing the securing bolts.

Raise the tipping grid slightly using lever (item 4) to allow the support leg pins (item 2) can be removed and the support legs (item 3) lowered.

Replace pins when support legs are lowered.

Figure 5.1 - Tipping Grid

(2)

Folding Auxiliary Conveyor

WARNING When working above ground level make sure to use a suitable working platform.

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5 Transportation

NOTICE Make sure the left hand side conveyor is in working position before folding auxiliary conveyor. 1.

Remove transfer rubber chute Figure 5.2.

Remove pins from conveyor support legs.

Lower auxiliary conveyor anti-clockwise towards the hopper.

Lower the auxiliary conveyor onto the transport bracket, item 2 taking care not to damage belt.

Pin conveyor in transport position Figure 5.3.

Figure 5.2 - Transfer Chute

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Figure 5.3 - Auxiliary Conveyor Transport Brackets

(3)

Folding the Side Conveyor for Transport

To prepare machine for transport the following sequence should be followed. 1.

Loosen the locking bolts on the side conveyors and rotate them back towards the feedboot item 1 Figure 5.4.

Figure 5.4 - Side Conveyor Locking Bolts 2.

Place the transport bracket in to the transport position item 1 Figure 5.5

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Figure 5.5 - Side Conveyor Transport Bracket 3.

Using control valves Ref: â&#x20AC;&#x153;Machine Setupâ&#x20AC;? on page 4-14 fold the conveyor until it can be pinned at the transport bracket. Pin the lower section of the conveyor.

Repeat above steps for the other side conveyor.

Tie up side conveyor belts with straps provided. Ensure the left hand side conveyor belt is not covering or touching the exhaust outlet.

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Placing Screen in Transport Position Using screen ram control valve item 3 Figure 5.6 Raise the screen box slightly to relieve pressure on the pin allowing it to be removed, Figure 5.7.

Figure 5.6 - Screen Box Lever 2.

Lower the screen to the transport position pinning hole and insert pin see Figure 5.7 (S190), Figure 5.8 (S130) and Figure 5.9 (S80)

Figure 5.7 - S190Screen Box Pin Positions â&#x20AC;˘ 1 - 30 Degrees. â&#x20AC;˘ 2 - 27.5 Degrees. S Range Operations Manual

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5 Transportation • 3 - 25 Degrees. • 4 - 22.5 Degrees. • 5 - 20 Degrees. • 6 - Maintenance and loading/unloading from flatbed transporter position. • 7- Wheeled machine transport position. • 8 - Track machine transport position.

Figure 5.8 - S130 Screen Box Pin Positions • 1 - 38 Degrees. • 2 - 35 Degrees. • 3 - 32 Degrees. • 4 - 28 Degrees. • 5 - 25 Degrees. • 6 - Maintenance and loading/unloading from flatbed transporter position. • 7- Wheeled machine transport position. • 8 - Track machine transport position.

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Figure 5.9 - S80 Screen Box Pin Positions • 1 - 37 Degrees. • 2 - 33 Degrees. • 3 - 30 Degrees. • 4 - 27 Degrees. • 5 - Transport and maintenance.

(5)

Folding Tail Conveyor for Transport

NOTICE This machine has two tail conveyor transport configurations position 1 and position 2 shown in Figure 5.12. If the screen box is raised above a certain point while the tail conveyor is in position 2 it will result in an impact between the screen box and the tail conveyor. If it is required to raise the screen box while the tail conveyor is in position 2 then, observe the screen box as it is raised and ensure it does not impact on the tail conveyor. Alternatively place the tail conveyor in transport position 1 where it can not impact the screen box if raised. 1.

Using Valve 1, Figure 5.11 raise the tail conveyor slightly to relieve pressure on the pin, (item 2 Figure 5.10) allowing it to be removed. Raise the tail conveyor and replace pin in lowest hole, the hydraulic ram should be fully retracted.

Using valve 2, Figure 5.11 raise the tail conveyor end section to either position shown in Figure 5.12. Make sure that the tail conveyor does not impact the screen box. Fit Transport stays at both sides.

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Figure 5.10 - Tail Conveyor Pin

Figure 5.11 - Tail Conveyor Lever

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Figure 5.12 - Tail Conveyor Transport Position S Range Operations Manual

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5 Transportation (6)

Retracting Hopper Landing Legs

Remove jacking leg pins item 1 Figure 5.13.

Use jacking leg control valve, item 2 to raise jacking leg.

Raise the legs up to their maximum position until the pin holes line up and refit pins

Figure 5.13 - Landing Legs

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5.6 Loading Machine to Transport Trailer

NOTICE Loading of the machine to the transport trailer should only be undertaken by personnel fully trained and competent to do so.

Make sure machine has been placed into transport position Ref: Section 5.5.

Start the machine.

When loading the machine to the transport trailer it will be necessary to raise the screen box to ensure there is adequate clearance between it and the ground.

Remove pins from screen box support legs and raise screen box, Ref: “Raising the Screen Box and Main Conveyor” on page 4-16. Make sure the tail conveyor does not impact the screen box when raising, Ref: “Folding Tail Conveyor for Transport” on page 5-9.

Make sure transport trailer is free from obstructions and ready to receive machine.

Engage tracking mode making sure that tracks are set to their lowest speed.

Track machine onto transport trailer as recommended in Figure 5.14

Lower the screen box to transport position and refit pins and (transport stays if removed from tail conveyor), Ref: “Placing Screen in Transport Position” on page 5-7

Secure the machine to the transport trailer using to machine tie down points and suitable transport chains.

10. Make sure the machine is correctly loaded and sitting level. 11. Make sure there are no loose parts or items on the machine that could become detached during transport.

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Maintenance 6

Table of Content 6

Maintenance ............................................................................................... 6-3 6.6 Regular Servicing ...........................................................................................6-3 6.7 Fuel System ...................................................................................................6-4 (1) Check Fuel Level and Top up ....................................................................6-4 (a) Machines Without Optional Fuel Pump .................................................6-4 (b) Machines With Optional Fuel Pump ......................................................6-4 6.8 Unscheduled Maintenance .............................................................................6-4 (1) Air Cleaner Elements .................................................................................6-5 (2) Tracks ........................................................................................................6-5 6.9 Maintenance Schedules .................................................................................6-6 (1) Daily or 10 Hour Maintenance Schedule ...................................................6-6 (2) Weekly or 50 Hour Maintenance Schedule ..............................................6-7 (3) 500 Hour Maintenance Schedule ..............................................................6-8 (4) 2500 Hour Maintenance Schedule ............................................................6-8 (5) Engine Maintenance Schedules ................................................................6-9 (6) CAT Engine Maintenance Schedules ........................................................6-9 (a) When Required .....................................................................................6-9 (b) Daily ......................................................................................................6-9 (c) Weekly ..................................................................................................6-9 (d) Every 50 Service Hours or Monthly ......................................................6-9 (e) Every 250 Service Hours ....................................................................6-10 (f) Every 500 Service Hours ....................................................................6-10 (g) Every 500 Service Hours or 1 Year .....................................................6-10 (h) Every 1000 Service Hours ..................................................................6-10 (i) Every 1500 Service Hours ..................................................................6-10 (j) Every 2000 Service Hours .................................................................. 6-11 (k) Every 3000 Service Hours .................................................................. 6-11 (l) Every 3000 Service Hours or 2 Years ................................................. 6-11 (m) Every 4000 Service Hours .................................................................. 6-11 (n) Every 6000 Service Hours or 3 Years ................................................. 6-11 (o) Every 12000 Service Hours or 6 Years ............................................... 6-11 6.10 Lubrication ....................................................................................................6-12 (1) Lubrication Points ....................................................................................6-13 6.11 Servicing Conveyors ....................................................................................6-14 (1) Clean & Check the Conveyor Belts .........................................................6-14 (2) Tensioning the Conveyor Belts ................................................................6-14 (3) Conveyor Alignment ................................................................................6-15 6.12 Servicing the Tracks .....................................................................................6-16 6.13 Measuring Track Tension .............................................................................6-16 6.14 Adjusting Track Tension ...............................................................................6-17 6.15 Gearbox Oil Level.........................................................................................6-19 (1) Checking and Filling Gearbox Oil ............................................................6-19 (2) Draining Gearbox Oil ...............................................................................6-20 6.16 Servicing the Hydraulic System....................................................................6-21

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6 Maintenance (1) Changing Hydraulic Filters ......................................................................6-21 (2) Changing Hydraulic Oil ............................................................................6-22 6.17 Changing Air Filter Elements ........................................................................6-23 6.18 Replacing Screen Media ..............................................................................6-24 (1) Replacing Top (and Middle) Deck Screens .............................................6-24 (2) Replacing Bottom Deck Screens .............................................................6-25 6.19 Checking the Screen Box Running Condition ..............................................6-28 (1) Checking if Screen Box is in Tune ...........................................................6-28

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Maintenance

Refer to Chapter 2 Safety for relevant safety information before attempting to carry out any maintenance on the machine.

WARNING Before undertaking any maintenance, repairs work on the machine, switch off the machine and implement the lockout and tagout procedure.

NOTICE Ensure that only qualified and trained personnel operate and maintain this equipment. Always keep control panels closed to avoid water ingress and dust contamination. Regularly check the control system and connections for any damage.

6.6 Regular Servicing 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. In addition to the lubrication points, the lubrication schedule lists the regular attention required to the machine hydraulic system. The engine oil and coolant also require checking regularly.

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6.7 Fuel System (1)

Check Fuel Level and Top up

DANGER Diesel fuel is highly flammable and is an explosion/burns hazard. NEVER remove the filler cap or refuel, with the engine running. DO NOT smoke while refilling or carrying out maintenance on the fuel system. DO NOT carry out maintenance on the fuel system near naked flames or sources of sparks, such as welding equipment. DO NOT leave the machine unattended during the refuelling process

NOTICE Ultra low sulphur diesel must be used in machines with CAT Tier 4 engines. Preferably re-fuel at the end of each day, where possible, to reduce overnight water condensation within the tank. (a)

Machines Without Optional Fuel Pump

Observe all safety warnings.

Check the fuel level gauge / indicator.

Clean the area around the filler cap.

Remove the filler cap and top up fuel level as required.

Replace the filler cap.

(b)

Machines With Optional Fuel Pump

Observe all safety warnings.

Check the fuel level gauge / indicator.

Clean the area around the filler cap.

Remove the filler cap.

Place refueling hose in fuel container and start refuelling pump.

Replace the filler cap when refuelling is completed.

6.8 Unscheduled Maintenance

WARNING Wear personal protective equipment. Switch off machine and implement the lock out and tagout procedure.

NOTICE We recommend that air cleaner elements are replaced and not reused .

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Air Cleaner Elements

The life span on air cleaner elements is dependant on the environment the machine is used in and as such a maintenance schedule can not be implemented for their replacement. This machine is equipped with an air filter restriction indicator which will illuminate at the control panel highlighting the need for maintenance, Ref:â&#x20AC;?4.4 Control Panel Overviewâ&#x20AC;? on page 4-3.

(2)

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.

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6 Maintenance

6.9 Maintenance Schedules (1)

Daily or 10 Hour Maintenance Schedule

ITEM Defects

Screen Bearings

Electrical System

Hydraulic Power Unit

Conveyor Belt

Guards

Fasteners Track Maintenance Fuel Level Engine oil level Hoses Seals

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OPERATION REMARKS Attend to any defects reported by the operator. a) Grease S190 2-deck screen bearings daily with 2 grease gun strokes. b) Grease S130/S80 screen bearings daily with 1 grease gun Mobilith SHC 220 strokes. c) Grease S190 3-Deck screen bearings daily with 3 grease gun strokes. Examine all visible cables and connections. a) Check oil level and replenish b) Visually inspect for leaks, damaged hoses and fittings. Replace defective items. c) Visually inspect filter indicators. a) Visually inspect for cuts, rips and tears. Report to maintenance manager if necessary. b) Check alignment, adjust as necessary. c) Check tension, adjust as necessary. a) Make sure all guards are securely fitted. b) Report defective guards to maintenance manager. c) Replace defective guards. Visually inspect for loose bolts and capscrews, tighten if necessary. Refer to track section a) Check fuel level and replenish. b) Visually inspect for leaks, damaged hoses and fittings and replace as necessary. Check oil level and replenish Visually inspect for leaks, damaged hoses and fittings and replace as necessary. Visually inspect for damaged seals

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Engine air filter Screen Mesh tension

(2)

Check air breather restriction indicator at control panel and replace filters if necessary. Make sure mesh is tensioned correctly

Weekly or 50 Hour Maintenance Schedule

ITEM Carry out daily or 10 hour maintenance schedule Feeder Gearbox

OPERATION Make sure all work in the daily or 10 hours schedule is carried out Change feeder gearbox oil

Return line hydraulic filters

Change

Diesel pre-filter Belt cleaners Skirting rubbers Bearings

Drain Pre-filter Check / adjust / replace Check / adjust / replace Grease.

Screen mesh Rubber cushions

Check condition of screen mesh Check condition of rubber cushions

REMARKS

After first 50 hour service then every 2500 hours or annually Shell Omala 150 or equivalent After first 50 hour service then every 1000 hours or annually or when indicator turns for green to red

Refer to “6.6 Lubrication” on page 6-12

Monthly or 200 Hour Maintenance Schedule ITEM Carry out daily or 10 hour and weekly or 50 hour maintenance schedules Bearings

Hydraulic oil filters Hydraulic tank Engine air intake pipe

Track

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OPERATION

REMARKS

a) Inspect for loose bolts and tighten if necessary. b) Inspect for loose fit on shaft and any damage, replace if necessary Change return line filters Replace hydraulic tank air filter* Check engine air intake pipe for signs of wear or damage. Replace if necessary. Refer to “6.8 Servicing the Tracks” on page 6-16

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6 Maintenance *Refer to Greasing schedule for quantities.

(3)

500 Hour Maintenance Schedule

ITEM FIRST Carry out daily or 10 hour maintenance schedule Carry out weekly or 50 hour maintenance schedule Carry out 200 hour maintenance schedule Engine

(4)

REMARKS

Change engine oil and oil filter Change fuel filter

2500 Hour Maintenance Schedule

ITEM FIRST Carry out daily or 10 hour maintenance schedule Carry out weekly or 50 hour maintenance schedule Carry out 200 hour maintenance schedule Carry out 500 hour maintenance schedule

OPERATION

Hydraulic oil

a) Analyse oil sample, check for condition and contamination b) Change oil if necessary. Change feeder gearbox oil

Feeder Gearbox

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Maintenance 6

(5) Engine Maintenance Schedules For further engine maintenance information, refer to the engine manufacturerâ&#x20AC;&#x2DC;s operation manual supplied.

(6)

CAT Engine Maintenance Schedules

(a)

When Required

Object Battery Battery or battery cable Engine Engine air cleaner element (Dual element) Engine air cleaner element (single element) Engine air cleaner element (single element) Fuel System Severe service application (b)

Sign

Job Check Inspect Check/Clean Check Drain

Remarks

Sign

Job Inspect/Replace

Remarks

Sign

Remarks

Sign

Inspect/Replace Replace Prime Check

Weekly

Object Hoses and clamps (d)

Remarks

Daily

Object Coolant system coolant level Engine air cleaner service indicator Engine air precleaner Engine oil level Fuel system primary filter / water separator Walk around inspection (c)

Job Replace Disconnect Clean Clean/replace

Every 50 Service Hours or Monthly

Object Fuel tank water and sediment

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Job Drain

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6 Maintenance (e)

Every 250 Service Hours

Object Coolant system coolant sample (Level 1) Engine oil sample Engine oil and filter change

Job Obtain Obtain Change*

Remarks

Sign

* 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

Object Belt Engine oil and filter Fan clearance (g)

Job Check Test/Add

Remarks

Sign

Job Inspect

Remarks

Sign

Job Replace

Remarks

Sign

Clean/Replace Inspect/Replace Replace Replace Replace Clean

Every 1500 Service Hours

Object Engine crankcase breather element

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Sign

Every 1000 Service Hours

Object Water pump (i)

Remarks

Every 500 Service Hours or 1 Year

Object Battery electrolyte Level Cooling System Supplemental Coolant Additive (SCA) Engine air cleaner element (Dual Element) Engine air cleaner element (Single Element) Engine air cleaner element (Single Element) Fuel system primary filter (water separator) element Fuel system secondary filter Radiator (h)

Job Inspect Change Check

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Every 2000 Service Hours

Object Aftercooler Core Engine Mounts Starting Motor Turbocharger (k)

Job Inspect Replace Inspect Clean/Replace

Remarks

Sign

Job Change

Remarks

Sign

Job Clean/Test

Remarks

Sign

Remarks

Sign

Remarks

Sign

Every 4000 Service Hours

Object Aftercooler core (n)

Sign

Every 3000 Service Hours or 2 Years

Object Cooling system coolant (DEAC) (m)

Remarks

Every 3000 Service Hours

Object Alternator Alternator and Fan Belts Belt Tensioner Radiator Pressure Cap (l)

Job Inspect Inspect Inspect Inspect

Every 6000 Service Hours or 3 Years

Object Job Cooling System Coolant Extender (ELC) Add (o)

Every 12000 Service Hours or 6 Years

Object Cooling System Coolant (ELC)

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6 Maintenance

6.10 Lubrication

WARNING Wear personal protective equipment. Switch off machine and implement the lock out and tagout procedure.

NOTICE Do not mix grease types as this can result in the blend having a lower specification than the individual greases. Regular lubrication of this machine in accordance with the maintenance schedules is essential..

NOTICE When changing or topping up hydraulic oil or changing filter elements. The utmost cleanliness must be observed at all times, as impurities in the oil will destroy the system. If the performance of the machine has decreased i.e. conveyors or crusher shaft has slowed down, switch off machine immediately, check hydraulic system before restarting Recommended Lubricants and Fluids • Screen Box Bearings ....................................................................... Mobilith SHC 220 • Feeder Gearbox ............................................................................... Shell Omala 150 • Conveyor Bearings .................................................................................. EP2 Grease • Engine Oil ........................................................................................15W/40 Engine oil • Track Gearbox Oil ...........................................................................Renogear SG320 • Hydraulic Oil .............................................................................................. ISO VG 46 • General Grease .................................................................................................... EP2 Cold Weather Operation (Ambient Temp -4°C (40°F)) • Engine Oil .......................................................................................10W/30 Engine Oil • Hydraulic Oil ............................................................................................... ISO VG 32

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Lubrication Points

The various lubrication points are shown in Figure 6.1, refer to the maintenance schedules above for types and quantities of lubricant.

Figure 6.1 - Lubrication Points

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6 Maintenance

6.11 Servicing Conveyors (1)

Clean & Check the Conveyor Belts

WARNING Wear personal protective equipment. Switch off machine and implement the lock out and tagout procedure. When working above ground level make sure to use a suitable working platform.

CAUTION 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. 1.

Observe all safety warnings.

Stop the machine, Ref: “Machine Shut Down Procedure” on page 4-43.

Implement the lockout and tagout procedure, Ref: “Machine Lockout and Tag Out Procedure” on page 4-43

Open the guard doors where necessary.

Clean the conveyor belts using a high pressure hose.

Check the belts for cuts, tears, rips or any other physical damage.

(2)

Tensioning the Conveyor Belts

DANGER Do not attempt to adjust the belt whilst the machine is running. There is an entanglement hazard and risk of trapping parts of the body.

WARNING Wear personal protective equipment. When working above ground level make sure to use a suitable working platform.

NOTICE Do not over tension the belt as this will damage the drum bearings. 1.

Observe all safety warnings.

Start machine and run conveyor.

Observe conveyor belt from a safe distance to check for belt slippage.

If belt slippage is present switch off machine and lock out and tag out.

Tighten the conveyor belt by adjusting both belt adjusters evenly one turn at a time. Slacken bolt 2 then adjust using bolt 1. Retighten bolt 2 after adjustment Ref: Figure 6.2

Start machine, run conveyor and check is slippage is still present.

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Maintenance 6 7.

If slippage is still present then switch off, lock out and tag out and repeat steps 1-6 until slippage is no longer present.

Figure 6.2 - Conveyor Belt Tensioner

(3)

Conveyor Alignment

DANGER Do not attempt to adjust the belt whilst the machine is running. There is an entanglement hazard and risk of trapping parts of the body.

WARNING Wear personal protective equipment. When working above ground level make sure to use a suitable working platform.

NOTICE Do not over tension the belt as this will damage the drum bearings. 1.

Observe all safety warnings.

Start machine and run conveyor.

Observe the conveyor from a safe distance and determine to which side the conveyor is tracking off.

If belt is tracking off switch off machine and lock out and tag out.

Tighten the conveyor belt by adjusting belt adjuster evenly one turn at a time. Slacken bolt 2 then adjust using bolt 1 Ref: Figure 6.2. Retighten bolt 2 after adjustment

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.

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6 Maintenance 7.

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.

Start machine, run conveyor and check if belt is still tracking off.

If belt is still tracking off then switch off, lock out and tag out and repeat steps 1-7 until tracking correctly.

6.12 Servicing the Tracks

NOTICE Keeping the tracks correctly adjusted will increase the service life of the tracks 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. Always check the tracks prior to manoeuvring the machine 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.

6.13 Measuring Track Tension

WARNING Wear personal protective equipment. Do not push or tow the machine.

NOTICE Prior to attempting any manoeuvring of the machine, the tracks must be free of obstructions, including crushed material and fines. It is important that the track is 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. 1.

Observe all Safety Warnings.

Position the machine on solid and level ground and drive 2 metres (2 yards) minimum in a forward direction, track idler roller leading.

Shut down the machine.

Implement the lockout and tagout procedure.

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.

Measure the maximum amount of track sag from the high point of the track to the bottom of the ‘straight edge’, Ref: Figure 6.3.

Correctly adjusted, the sag should be Between 5mm - 15mm.

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Figure 6.3 - Measuring Track Tension

6.14 Adjusting Track Tension

DANGER Grease coming out of the relief valve under pressure can penetrate the body and any maintenance should only be attempted by fully trained personnel.

WARNING Wear personal protective equipment. Switch off machine and implement the lockout and tagout procedure. 1.

Observe all Safety Warnings.

Shut down the machine, Ref: “4.10 Machine Shut Down Procedure” on page 4-43.

Implement the lockout and tagout procedure, Ref: “4.11 Machine Lockout and Tag Out Procedure” on page 4-43.

Locate the access aperture on the side of the track frame and remove the cover, where fitted, to reveal the relief valve inside.

To Release Track Tension 5.

Loosen the relief valve by turning counter clockwise using gradual increments until the grease begins to be expelled. Care must be taken not to loosen the relief valve too quickly because the grease inside is under high pressure Ref: Figure 6.4.

When the correct track tension has been measured, turn the relief valve clockwise to tighten and then clean away all trace of expelled grease.

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.

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6 Maintenance To Increase Track Tension 8.

Connect the grease gun to the grease fitting and add grease until the track tension is within the specified dimension, see ‘Measuring Track Tension’ and refer to lubricant and fluid specifications.

Re-check Tension 9.

Operate the machine in track mode and drive the machine 50 metres (50 yards) forwards and 50 metres (50 yards) backwards, check track tension and repeat the above steps if it is within the specified dimension, see ‘Measuring Track Tension’.

10. If room for manoeuvring the machine is restricted, drive the machine forwards and backwards several times over a shorter distance.

Figure 6.4 - Track Tensioner

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6.15 Gearbox Oil Level (1)

Checking and Filling Gearbox Oil

NOTICE 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 litres of oil, which should be filtered through a 10 micron filter before entering the gearbox. 1.

Move the machine to a level surface and bring the oil drain holes to the position shown in Figure 6.5.

Ensure machine is switched off, locked out and tagged out. Remove ignition key, carry it with you.

Thoroughly clean around both plugs removing all potential contaminants.

Remove both plugs.

Fill the oil through the upper hole (item 1) until it runs out through the lower hole (item 2), Ref: Figure 6.5.

Wait a few moments until any trapped air has escaped and then re-check the level.

Add more oil if necessary.

Figure 6.5 - Gearbox Oil Level Fill Position

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6 Maintenance (2) 1.

Draining Gearbox Oil Move the machine to a level surface and bring the oil fill (1) and oil drain holes (2) to the position shown in Figure 6.6.

Figure 6.6 - Draining Gearbox Oil 2.

Ensure machine is switched off, locked out and tagged out. Remove ignition key, carry it with you.

Thoroughly clean around both plugs removing all potential contaminants.

Remove both plugs and allow the oil to drain. The oil will drain quickly if it is hot, however care should be taken to avoid burns to the operator.

Move the machine to bring the plugs to the fill position shown in Figure 6.5.

Re-fill the oil as per the procedure in â&#x20AC;&#x153;Checking and Filling Gearbox Oilâ&#x20AC;? on page 6-19).

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6.16 Servicing the Hydraulic System

DANGER Never carry out any maintenance work without ensuring the hydraulic system is locked out and depressurised. In the event of any problems these should only be dealt with by suitably experienced and qualified engineers.

WARNING Wear personal protective equipment. Switch off machine and implement the lockout and tagout procedure.

(1)

Changing Hydraulic Filters

Observe all Safety Warnings.

Shut down the machine, Ref: “1.9 Machine Shut Down Procedure” on page 4-39.

Implement the lockout and tagout procedure, Ref: “1.10 Machine Lockout and Tag Out Procedure” on page 4-39.

Take off filter cap by removing 4 bolts (item 1) Figure 6.7, making sure all times that dirt is prevented from entering the tank.

Remove Hydraulic filter element from inside the filter housing (item 2).

Replace filter element with new one.

The complete filter housing does not have to be removed as shown only the cap and lid.

Figure 6.7 - Hydraulic Filter Housing

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6 Maintenance (2)

Changing Hydraulic Oil

Drain hydraulic oil through bung on bottom of hydraulic tank.

Remove existing return line filters and dispose of.

Fill until oil reaches full level on tank gauge through the filler port (item 5) Figure 6.8, making sure all times that dirt is prevented from entering the tank.

Figure 6.8 - Power Unit 1

Air Filter.

Primary Fuel Filter/Water Separator.

Fuel Filter.

Hydraulic Return Filter.

Oil Filler Cap.

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6.17 Changing Air Filter Elements 1.

Observe all safety warnings.

Ensure machine is switched off, locked out and tagged out.

Release the 4 tension clips holding the air filter housing cover in place.

Remove cover. (Item 4), Ref: Figure 6.9.

Carefully remove outer filter element (Item 5) and inner filter (Item 3).

Discard the elements and replace with new items

Refit filter housing cover.

Reset the air filter button (item 2).

Figure 6.9 - Engine Air Filter 1

Air Filter Housing.

Air Filter Reset Button.

Inner Element.

Air Filter Housing Cover.

Outer Element.

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6 Maintenance

6.18 Replacing Screen Media

DANGER Make sure to use suitable lifting equipment. This task should not be attempt unless there are a minimum of two persons.

WARNING Wear personal protective equipment. When working above ground level make sure to use a suitable working platform.

(1)

Replacing Top (and Middle) Deck Screens

Each mesh is held in place by a clamp on either side. This is in turn held in place by a wedge tensioning system. To release the clamp. 1.

Observe all safety warnings.

Lower screen box to maintenance position Ref: (2) on page 4-16.

Ensure machine is switched off, locked out and tagged out.

Remove retaining split pin (item 1) Figure 6.10.

Tap wedge (item 2) lightly with a suitable hammer.

Remove wedge, pin (item 3), Washer (item 4) and spacer (item 5).

Repeat the above until the mesh is released.

Remove the mesh and replace it with the new mesh.

Replace the clamps and wedge system.

10. Once the wedge system is re-assembled tension the mesh by driving the wedge (2) through the pin using a hammer. Drive each wedge in the same amount to, achieve even pressure on the clamp plate. 11. The meshes must not vibrate separate from the screen box when this is achieved the meshes are tensioned correctly.

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Figure 6.10 - Screen Tension Wedges

(2)

Replacing Bottom Deck Screens

Bottom deck meshes are held in place by tension bars (3). Tension in the mesh is achieved through tension block (2) and tension bolts (3).Lock out machine. 1.

Observe all safety warnings.

Lower screen box to maintenance position Ref: (2) on page 4-16.

Ensure machine is switched off, locked out and tagged out.

Loosen off tension bolts completely (item 1) Figure 6.11.

Push tension bar toward the discharge side of the screen box.

Un-hook screening media from around the tension bar.

Remove screening media.

Fit screening media ensuring each end hook. is seated correctly Ref: Figure 6.12.

During tensioning these hooks must be constantly checked to ensure they are seated correctly.

10. Start tensioning the tension bolts top and bottom and side to side alternatively to keep the tension bar relatively level in the slot. 11. Do not over tension the screening media, Ref: Figure 6.13.

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6 Maintenance

Figure 6.11 - Bottom Deck Tensioner

Figure 6.12 - Screen Mesh Hooks

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Figure 6.13 - Screen Mesh Tension 12. A mesh or speed harp will have the correct tension when the pre-bend in the tension bar is straightened (position 2) Figure 6.13. If the mesh or speed harp is tensioned beyond this point the screening media will be stretched and rendered unusable. 13. When fitting speed harp wire spacers they will fit snugly on top of the screen cushion rubbers as shown in Figure 6.14.

Figure 6.14 - Cushion Rubbers

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6 Maintenance

6.19 Checking the Screen Box Running Condition Checking the screen is in tune. To prevent damage to the screen box, bearings or meshes the box must be running at the correct speed and amplitude. The box must also be running in a circular motion. The screening action of the screen box is achieved by rotating the screen shaft which has an inbuilt out of balance weight. The size of the circular motion achieved by the out of balance weight is controlled by adding or subtracting out of balance weights. These weights are called flywheel weights. These weights are attached to the end of the screen shaft. If the out of balance flywheel weight is not in line with the out of balance screen shaft weight the box will run out of tune. An un-balanced or out of tune box will create enormous stress in the screen box and will cause premature failure. Screen Speed = 930 to 960 rpm Screen Throw = 8mm to 9mm

(1)

Checking if Screen Box is in Tune

DANGER This task should not be attempt unless there are a minimum of two persons, second person should be able to shut down machine in the event of an emergency. This process is conducted while the machine is running, extreme caution should be used at all times.

WARNING Wear personal protective equipment.

Attach to each corner of the screen box with a stroke card.

Run the screen box.

If the box is correctly balanced the dot on each corner will trace a slight ellipse see Figure 6.15.

If the box is out of tune, 2 or more of the corners will trace a pronounced ellipse see Figure 6.15.

If any of the ellipses even a slight elliptical shape are pointing in different directions the screen is running out of balance.

Causes for the fault condition shown in Figure 6.15. • 1.

Over speed.

• 2.

Too much weight on the flywheel.

• 3.

Flywheels misaligned.

If your screen box is showing any of the above faults contact your local McCloskey dealer immediately. The speed of the screen box can only be changed by an authorised McCloskey dealer. Tampering with the screen box speed, by someone other than an authorised McCloskey dealer will invalidate warranty. 05/03/2014 Page 6-28

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Figure 6.15 - Screen Tuning

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Appendix A

Appendix A Warranty

Warranty Registration IMPORTANT: Warranty cannot be activated until this form is returned to the manufacturing site. Please fill out completely and return. Customer Name Company Name Address

Phone Fax Email Federal ID # (US only) Machine purchased from Model Serial # Control Panel Serial # Track Serial # RHS LHS Purchase Date Hour Meter Reading at Delivery Signing OďŹ&#x192;cer Print Name Sign Name Date Return Completed Forms To:

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McCloskey Interna onal Ltd, 1 McCloskey Road, RR 7, Peterborough, Ontario, Canada. McCloskey Interna onal Ltd, Coalisland, K9J 6X8 47Moore Road, Fax: +1 705 295 4777 Co. Tyrone, mail: mccloskey@mccloskeyinternaNorthern Ireland. onal.com BT71 4QB Fax: (+44) 028 8774 7242 Web: www.mccloskeyinterna onal.com

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Appendix A

Intentionally Left Blank

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Appendix B

Appendix B Schematics

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T4i Schematic Wiring Diagrams

JMG

SYSTEMS LTD

RL1

F1 F5

RL2

JMG_ENG1 APRIL 2006

RL5

F10 RL3

F4 F8

S190 ENGINE CONTROLPANEL FITTED WITH CAT 3054C DIT ENGINE

RELAYAND FUSE DESIGNATION

FUELSOLENOID, KSB SOLENOID, FUELPUMP, HOUR METER N/A N/A STARTER MOTOR RELAY

C JMG SYSTEMS LTD 2006

DR NO 102

F1...5A PCB CONTROL F2...10A FUELSOLENOID, KSB SOLENOID, FUELPUMP, HOUR METER F3...15A ALTERNATOR CHARGE LAMP, TRACK CONTROL F4...15A N/A F5...10A START RELAY, START/TRACK SIREN, BEACON F6...10A ENGINE STOPSWITCHES, COOLANT LEVEL, FUELCONTAMINATION, HYDRAULIC LEVELSENSORS F7...10A TIPPING GRID F8...15A OILCOOLING FAN NO 1 F9...NA F10...5A OILCOOLER CONTROL

RLY1 RLY2 RLY3 RLY5

30 15

B+

D+ G

UR J2

F3 15A

F6 5A

F2 10A

F1 5A

RW R

K12

F5 5A

F8 15A

SYSTEMS LTD

JMG

F10 5A

O = ORANGE P= PURPLE

R = RED S = SLATE

Y= YELLOW

B3 ENGINE COOLANT LEVELSENSOR B4 FUELCONTAMINATION SENSOR B5 HYDRAULIC OILLEVELSENSOR H3 ENGINE OILPRESSURE WARNINGLAMP H4 ENGINE TEMPERATURE WARNINGLAMP H5 ENGINE COOLANT LEVELWARNING LAMP H7 AIR FILTER RESTRICTIONWARNINGLAMP H8 HYDRAULIC OILLEVELWARNING LAMP H9 MACHINE STOP/MANUALTRACK STOPONWARNINGLAMP H11 FUELCONTAMINATIONWARNING LAMP

H3 H4 H5 H7 H8 H9 H11

C JMGSYSTEMS LTD 2006

U = BLUE W= WHITE

DR NO102

S9 S10 S11

S15

N UG BR NU UY

A1 CONTROLUNIT K2 RLY2 COOLINGFAN 1 RELAY K5 STARTER MOTOR RELAY M1 STARTER MOTOR M2 HYDRAULIC OILCOOLINGFAN 1 S9 ENGINE OILPRESSURE SWITCH S10 ENGINE TEMPERATURE SWITCH S11 AIR FILTER RESTRICTION SWITCH

WIRE COLOUR CODE B = BLACK K = PINK G = GREEN N = BROWN

G1 12VBATTERY G2 ALTERNATOR H1 BATTERYCHARGE LAMP H2 FUELSOLENOID ON LAMP H6 MACHINE STOPRELEASEDWARNINGLAMP J1 STOPSWITCHJUNCTION BOX K1 RLY1 FUELSOLENOID RELAY P1 ENGINE HOUR METER S1 BATTERYISOLATOR SWITCH S2 IGNITION/START SWITCH S3-S8 ENGINE STOPSWITCHES YI FUELSOLENOID YI KBS SOLENOID

WIRINGDIAGRAMFOR MC CLOSKEYS190 FITTEDWITHTIER 2 CAT3054 ENGINE ISS1 ESC ISS 2

FL1 40A

S10

S13

S16

S15

S14

10 3 8 9 6 5

4 2

JMG

SYSTEMS LTD

K6 PRE HEAT RELAY M2 FUELPUMP R1-R4 PRE HEAT PLUGS

O = ORANGE P= PURPLE

R = RED U = BLUE

A2 MANUALTRACK CONTROLHANDSET J2 TRACKCONTROLJUNCTION BOX S13 TRACK CONTROLON-OFF SWITCH S14 TRACK STOPSWITCH S15 RIGHT HANDTRACK SWITCH S16 LEFT HANDTRACK SWITCH Y3 LEFT HAND FORWARD SOLENOID

WIRE COLOUR CODE K = PINK B = BLACK G = GREEN N = BROWN

1 Y4

1 Y5

W= WHITE Y= YELLOW

DR NO102

BB 46

F1A 5A

K11

K9 TRACK CONTROLRELAY K10 TRACK CONTROLTIMER K11 TRACKSIRENAND BEACON RELAY Y4 LEFT HAND REVERSE SOLENOID Y5 RIGHT HAND REVERSE SOLENOID Y6 RIGHT HAND FORWARD SOLENOID Y7 TIPPINGGRID LOWER SOLENOID Y8 TIPPINGGRID RAISE SOLENOID

E1 ENGINE START/TRACK START BEACON

F5 9

A3 TIPPINGGRID REMOTE CONTROL B6 ENGINE START/TRACK START SIREN

C JMGSYSTEMS LTD 2006

K10

9 6 5

18 A1

3 8

UR NU

RL2

WIRING DIAGRAMFOR MC CLOSKEYS520 FITTEDWITHTIER 2 CAT 3054C DIT ENGINE (ESC ISS 2) 11/10/06

FL2 50A

F7 10A

RL1

30 15