Model: J40v2

Operations Manual

SUBJECT TO CHANGE WITHOUT PRIOR NOTICE

Original Instructions
© McCloskey International Ltd 2015

Issue Date: 17/06/2015

Language: English (en)
Revision No.: 3
 Record of Revisions

Record of Revisions
Revision
Number Reason for Change Date
1 First Release 20/10/2013

2 Updated Tedd Control Panel Information. 15/08/2014

Updated Fixed Jaw Die Information.
3 Correction to Chamber Parameters (chapter 4) 17/06/2015

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 Table of Content

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
2 Safety .......................................................................................................... 2-2
2.1 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
2.2 Safety Signs on the Machine..........................................................................2-8
2.3 Personal Safety ............................................................................................ 2-11
(1) Personal Protective Equipment ............................................................... 2-11
2.4 Work Area Safety .........................................................................................2-12
(1) General Work Area Guidelines ................................................................2-12
(2) Safety Warnings and Labels ....................................................................2-12
(a) Modifications .......................................................................................2-12
2.5 Transportation Safety ...................................................................................2-13
2.6 Operation Safety ..........................................................................................2-14
(1) Hydraulic and Pneumatic Safety .............................................................2-15
(2) Electrical Safety .......................................................................................2-15
2.7 Maintenance Safety......................................................................................2-16
(1) Gas, Dust, Steam, Smoke .......................................................................2-18
(2) Hazardous Substances ...........................................................................2-19
(3) Noise Levels ............................................................................................2-19
2.8 Emergency Stop Locations ..........................................................................2-20
3 Technical Data ............................................................................................ 3-2
3.1 General Information........................................................................................3-2
(1) Tank Capacities .........................................................................................3-2
3.2 Conveyors ......................................................................................................3-2
(1) Main Conveyor...........................................................................................3-2
(2) Side Conveyor ...........................................................................................3-2
(3) Transport Dimensions................................................................................3-2
(4) Working Dimensions ..................................................................................3-2
(5) Crusher Info ...............................................................................................3-2
3.3 General Layout ...............................................................................................3-3
(1) Machine Measurements ...........................................................................3-4

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(2) Transport Position .....................................................................................3-6

3.4 Noise levels ....................................................................................................3-7
4 Operational Procedures ............................................................................ 4-3
4.1 Prior to Use ....................................................................................................4-3
4.2 Prestart Inspection .........................................................................................4-3
4.3 Machine Location ...........................................................................................4-3
4.4 Control Panel Overview..................................................................................4-4
4.5 Control Panel Functions .................................................................................4-5
(1) Starting the Engine ....................................................................................4-5
(2) Engine Monitoring ......................................................................................4-6
(3) Tier 4 Additional Engine Monitoring Screen...............................................4-8
(4) Tracking the Machine with Wired Handset ..............................................4-10
(5) Tracking the Machine with Radio Handset .............................................. 4-11
(6) Wired Handset Test .................................................................................4-12
(7) Control Panel Feeder Functions ..............................................................4-13
(a) Chamber / Feeder Control .................................................................4-13
(b) Manual Feeder Adjustment .................................................................4-16
(c) Chamber Level ...................................................................................4-16
(8) Starting the Crusher ................................................................................4-18
(9) Stopping the crusher ...............................................................................4-19
(10) CSS and Jaw Blockage Auto Clear Features ..........................................4-19
(11) Auxiliary Functions...................................................................................4-20
(12) Error Logging ...........................................................................................4-21
(13) Error Alerts ...............................................................................................4-22
4.6 Tracking Machine .........................................................................................4-23
(1) Machine Radio Control Handsets Overview ............................................4-24
(2) Machine Radio Handset ..........................................................................4-25
(3) Feeder Radio Control Handset Overview ................................................4-26
4.7 Hydraulic Control Levers Overview ..............................................................4-26
(1) Hydraulic Control Valve Operation...........................................................4-26
4.8 Pictorial Decal Descriptions..........................................................................4-27
(1) Machine Operations Decals ....................................................................4-27
(2) Machine Information Decals ....................................................................4-30
(3) Control Bank 1 .........................................................................................4-34
(4) Control Bank 2 .........................................................................................4-35
(5) Control Bank 3 .........................................................................................4-36
4.9 Machine Set Up ............................................................................................4-36
(1) Unfolding the Hopper ...............................................................................4-36
(2) Walkway Setup ........................................................................................4-40
(3) Unfolding the Side Conveyor ...................................................................4-40
(4) Landing Legs Setup .................................................................................4-40
(5) Setting Main Conveyor ............................................................................4-42
(6) Unfolding Crusher Top Cover ..................................................................4-42
(7) Adjusting Crusher Closed Side Settings ..................................................4-43
(8) Adjusting Feed Level in Crusher Chamber ..............................................4-46
(9) Adjust / Monitor Pan Feeder Settings ......................................................4-46

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4.10 Machine Components Start-Up Procedure ..................................................4-46

4.11 Machine Shut Down Procedure....................................................................4-47
4.12 Machine Lockout and Tag Out Procedure ....................................................4-47
4.13 Emergency Stop Procedure .........................................................................4-47
5 Transportation............................................................................................ 5-2
5.1 Preparing Machine for Transport ....................................................................5-2
5.2 Loading Machine to Transport Trailer .............................................................5-2
6 Maintenance ............................................................................................... 6-3
6.1 Regular Servicing ...........................................................................................6-3
6.2 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
(c) Machines With AdBlue Tanks ................................................................6-4
6.3 Unscheduled Maintenance .............................................................................6-5
(1) Tracks ........................................................................................................6-5
6.4 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
(7) Volvo Engine Maintenance Schedules .................................................... 6-11
(a) First Service Inspection ....................................................................... 6-11
(b) Daily ....................................................................................................6-12
(c) Weekly ................................................................................................6-12
(d) Every 50 Service Hours or Monthly ....................................................6-12
(e) Every 250 Service Hours ....................................................................6-13
(f) Every 500 Service Hours ....................................................................6-13

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(g)
Every 500 Service Hours or 1 Year .....................................................6-13
(h)
Every 1500 Service Hours ..................................................................6-13
(i)
Every 2000 Service Hours ..................................................................6-14
(j)
Every 800 Service Hours ...................................................................6-14
(8) Lubrication ...............................................................................................6-15
(a) Greasing Information ..........................................................................6-15
(b) Lubricants and Fluids ..........................................................................6-16
6.5 Servicing Conveyors ....................................................................................6-17
(1) Clean & Check the Conveyor Belts .........................................................6-17
(2) Tensioning the Conveyor Belts ................................................................6-18
(3) Conveyor Alignment ................................................................................6-19
6.6 Servicing the Tracks .....................................................................................6-20
6.7 Measuring Track Tension .............................................................................6-20
6.8 Adjusting Track Tension ...............................................................................6-21
6.9 Gearbox Oil Level.........................................................................................6-23
(1) Checking and Filling Gearbox Oil ............................................................6-23
(2) Draining Gearbox Oil ...............................................................................6-24
6.10 Servicing the Hydraulic System....................................................................6-25
(1) Changing Hydraulic Oil ............................................................................6-25
(2) Changing the Return Line Filter ...............................................................6-27
(3) Changing the Hydraulic Tank Breather Filter ...........................................6-28
6.11 Changing Air Filter Elements ........................................................................6-29
6.12 Replacing Crusher Swing Jaw Die ...............................................................6-30
6.13 Replacing Crusher Fixed Jaw Die ................................................................6-31
6.14 Replacing Crusher Cheek Plates .................................................................6-33
6.15 Replacing Pitman Wear Plate ......................................................................6-35
Appendix A Warranty.................................................................................A-1
Appendix B ................................................................................................B-1
(1) Volvo Engine Fault Codes ........................................................................ B-2
(2) Cat Engine Fault Codes ......................................................................... B-16
(3) Machine Fault Codes .............................................................................. B-19
(4) Schematics ............................................................................................. B-21

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 Introduction 1

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

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1 Introduction

1 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: [email protected]

(1) 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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1.2 Safety Information

(1) Safety Warning Symbol

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

(2) ANSI Hazard Classification System

A multi-tier hazard classification system is used to alert you to potential personal injury hazards.
Signal words used with the safety alert symbol indicate a specific level of severity of the potential
hazard. Signal words used without the safety alert symbol relate to property damage and protection
only. All are used as attention-getting devices throughout this manual as well as on ANSI type
decals and labels fixed to the machine.

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.

(3) California Proposition 65 Warnings

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

1.3 Machine Designated Use

This machine is a portable, self-contained crushing plant for crushing materials into various sizes.
Typical materials include rock, concrete, brick and rubble. If you need to crush any other material
not listed please consult with the factory.
McCloskey International cannot be held liable for any damages resulting from misuse.

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1 Introduction

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 2015
McCloskey International Ltd
47 Moor Road
Coalisland, Co. Tyrone
BT71 4QB
To order additional copies contact your local McCloskey International Ltd dealer.

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Table of Content
2 Safety .......................................................................................................... 2-2
2.1 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
2.2 Safety Signs on the Machine..........................................................................2-8
2.3 Personal Safety ............................................................................................ 2-11
(1) Personal Protective Equipment ............................................................... 2-11
2.4 Work Area Safety .........................................................................................2-12
(1) General Work Area Guidelines ................................................................2-12
(2) Safety Warnings and Labels ....................................................................2-12
(a) Modifications .......................................................................................2-12
2.5 Transportation Safety ...................................................................................2-13
2.6 Operation Safety ..........................................................................................2-14
(1) Hydraulic and Pneumatic Safety .............................................................2-15
(2) Electrical Safety .......................................................................................2-15
2.7 Maintenance Safety......................................................................................2-16
(1) Gas, Dust, Steam, Smoke .......................................................................2-18
(2) Hazardous Substances ...........................................................................2-19
(3) Noise Levels ............................................................................................2-19
2.8 Emergency Stop Locations ..........................................................................2-20

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2 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.

2.1 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

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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 Safety 2

(3) 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 in
“Table 2.1 - Description of Safety Symbols” on page 2-4.

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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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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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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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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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Symbol Description
Stay clear of hot surface or liquid.

Impact Hazard
Impact from spring loaded door.

Stay clear of spring loaded door while opening.

2.2 Safety Signs on the Machine

Table 2.2 lists the safety signs that are on this machine.

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Sign
Item ISO ANSI
1

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Sign
Item ISO ANSI
4

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Sign
Item ISO ANSI
7

2.3 Personal Safety

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

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2 Safety

Protective clothing includes: Hard Hat, Safety Glasses, Ear Protection, Dust Mask, Close fitting
Overalls, Steel Toed Boots and a High Visibility Vest.

2.4 Work Area Safety

(1) General Work Area Guidelines

Operators must have received specific training in all operating and service tasks as required for
the safe operation and service of the machine. Operators must know the location and correct
operation of all controls and safety features such as remote stop buttons and isolator switches.
Operators must be aware of all moving parts on the machine.
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.
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
supplier’s approval.

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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.

2.5 Transportation Safety

Before transporting the machine, observe the prescribed transport position, admissible speed and
itinerary. Only use appropriate means of transport and lifting gear of adequate capacity. Know
the overall height to avoid contacting overhead obstructions such as bridges, power lines etc.
The preparations to move equipment by an articulated lorry should be supervised by a minimum of
two persons. Ensure persons transporting the machine adhere to all safety signs and procedures.
Before transportation on public roads, ensure the machine has been properly secured with no loose
material left in or on the machine. Always observe the valid traffic regulations and, if necessary,
ensure beforehand that the machine is in a condition compatible with these regulations.
Extreme caution is required when transporting machinery on site. Soft or uneven ground may
cause accidents. On sloping terrain, always adapt your travelling speed to the relevant ground
conditions. Never change to a lower gear on a slope. Always change gear before reaching a slope.
The machine is remote controlled and may start without notice. Stay clear of the machine. The
machine must be loaded and transported only in accordance with the operating instructions.
For manoeuvring the machine, observe the prescribed transport position, admissible speed and
itinerary. Use only appropriate means of transport and lifting equipment and where applicable
of adequate capacity. The re-commissioning procedure must be strictly in accordance with the
operating instructions. Before travelling with the machine, check that the braking and any signalling
and lighting systems are fully functional. Before setting the machine in motion always check that
the accessories have been safely stowed away.
On 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 over-
inflated tire can explode and cause serious injury or death.

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2.6 Operation Safety

Before attempting to operate the machine, DO read, fully understand and observe the contents
of this manual. Also any other relevant manual for other equipment incorporated in the machine,
e.g. Engine manual. Study all safety signs on your machine.
It is emphasized that all safety aspects are checked before starting the machinery.
Make sure that you fully understand the operating procedures for the machine before attempting
to start.
Take the necessary precautions to ensure that the machine is used only when in a safe and
reliable state.
Operate the machine only for it’s designed purpose and only if all guarding, protective and safety
orientated devices, emergency shut-off equipment, sound proofing elements and exhausts, are
in place and fully functional.
Before starting the engine ensure it is safe to do so. NEVER leave the machine unattended
whilst it is in operation.
Before starting, walk completely around the machine. Make sure no one is under it, on it or close
to it. Let other workers and bystanders know you are starting up and do not start until everyone
is clear of the machine.
Before moving the machine, ensure that everyone is clear from the surrounding area and that the
warning siren and beacon and the tracking umbilical Machine Stop button are operating correctly
Make certain enough ventilation is present to run engines safely. Do not start an engine in an
enclosed space without properly vented exhaust. Exhaust fumes from gasoline or diesel engines
can kill.
DO NOT allow a build up of solid material or dust in any part of the machine. In the event of
material blockage, any malfunction or operational difficulty, stop the machine immediately and
lockout. Have any defects rectified immediately.
Be alert and watch for pinch points, closing mechanisms, and falling parts when working on or
around any machinery. Keep hands and tools clear. In-running nip points on moving machinery
can cause serious injury or even death. Do not reach into unguarded machinery. Your arm could
be pulled in and amputated. Switch off and lockout the machine before removing any safety
devices or guarding.
Never work or stand beneath machinery or attachments as it is raised or lowered. Never work
or stand beneath machinery as they are being loaded with and/or discharging material. During
operation, do not climb onto, over or under moving conveyor belts and rollers. Always use ladders,
steps and walkways when mounting and dismounting.
Hole alignment on mechanical supports must be checked and secured with pins provided and
in accordance with safety signs.
Follow safe operating practices. Operate the machine controls smoothly. Avoid sudden stops,
starts or changes in direction. Only use emergency stop buttons or emergency stop lines (if fitted)
in emergency situations or during safety drills.
Never check the tension of ‘V’ belts, drive chains and conveyors when machine is running.
DO check frequently the stability of the machine. The chassis SHOULD NOT have undue vibration
during operation.
After each day’s operation, always run the machine dry; never leave material in the beltfeeder
on conveyor belts or screenbox. Starting a machine with a full load will cause strain problems in
your machine.

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(1) 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.

(2) 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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• Have the live wire de-energised.

If provided for in the regulations, the power supply to machines and parts of machines, on which
inspection, maintenance and repair work is to be carried out, must be cut off. Before starting
any work, check the de-energised parts for presence of power and ground or short circuit them
in addition to insulating adjacent live parts and elements.
The electrical equipment of the machine is to be inspected and checked at regular intervals.
Defects such as loose connections or scorched or otherwise damaged cables must be rectified
immediately.
Necessary work on live parts and elements must be carried out only in the presence of a second
person, who can cut off the power supply in the case of danger by actuating the emergency
shut off or main power switch. Secure the working area with a red and white safety chain and a
warning sign. Use insulated tools only.
Before starting work on high voltage assemblies and after cutting out the power supply, the feeder
cable must be grounded and components such as capacitors short-circuited with a grounding rod.
Tracked machines are wired with negative earth. Always observe correct polarity.
Always disconnect battery leads before carrying out any maintenance to the electrical system or
servicing the engine. Never short across the starter terminals of a battery as this can cause a
fire and could also damage the electrical system. If welding is to be carried out on the machine,
it is essential that the powerpack is isolated.
The battery contains sulphuric acid, an electrolyte which can cause severe burns and produce
explosive gases. Wear personal protective equipment and avoid contact with the skin, eyes or
clothing.
Diesel engine exhaust emissions contain products of combustion which may be harmful to your
health. Always operate the machine in a well ventilated area and if operating in an enclosed
area, vent the emissions outside. Do not touch any part of the engine or exhaust system. Allow
the engine and exhaust to cool before performing any repair or maintenance.
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.

2.7 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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 Safety 2

Remove only guards or covers that provide access. Wipe away any excess grease and oil.
Never leave guards off or access doors open when unattended. Keep bystanders away if access
doors are open.
When working beneath raised equipment, always use blocks, jack-stands or other rigid and stable
supports. Make sure that any part of the machine raised for any reason is prevented from falling
by securing in a safe reliable manner. Never work under unsupported equipment.
For carrying out overhead assembly work always use specially designed or otherwise safety-
oriented ladders and working platforms. Always use any walkway/platforms provided or a safe
and secure platform approved by the regional safety enforcing authority.
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 2 m (7ft) or more
above the ground level. Keep all handles, steps, handrails, platforms, landing and ladders free
from dirt, oil, snow and ice.

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2 Safety

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.

(1) 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.

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 Safety 2

(2) 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.

(3) 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.

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2.8 Emergency Stop Locations

Emergency stops are located at both the left hand side and right hand side of the machine Ref:
Figure 2.1 and Figure 2.2.

Figure 2.1 - RHS Emergency Stop Locations

Figure 2.2 - LHS Emergency Stop Locations

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Intentionally Left Blank

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 Technical Data 3

Table of Content
3 Technical Data ............................................................................................ 3-2
3.1 General Information........................................................................................3-2
(1) Tank Capacities .........................................................................................3-2
3.2 Conveyors ......................................................................................................3-2
(1) Main Conveyor...........................................................................................3-2
(2) Side Conveyor ...........................................................................................3-2
(3) Transport Dimensions................................................................................3-2
(4) Working Dimensions ..................................................................................3-2
(5) Crusher Info ...............................................................................................3-2
3.3 General Layout ...............................................................................................3-3
(1) Machine Measurements ...........................................................................3-4
(2) Transport Position .....................................................................................3-6
3.4 Noise levels ....................................................................................................3-7

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3 Technical Data

3.1 General Information

Machine ...............................................Mobile crushing machine
Type .....................................................J40v2
Weight (with magnet and side conveyor) ........... 34,600 kg

(1) Tank Capacities

Diesel Tank ..........................................465L (123 US Gal)
Hydraulic Tank (Tier 4).........................1200L (317 US Gal)

3.2 Conveyors

(1) Main Conveyor

Stockpile Height...................................3054mm (10’)
Belt Width ............................................900mm (36’’)
Belt Type ..............................................Plain 500/3 8+2

(2) Side Conveyor

Stockpile Height...................................2100mm (6’ - 10’ 5’’)
Belt Width ............................................650mm (26’’)
Belt Type .............................................EP400/3 3+1.5

(3) Transport Dimensions

Transport Height ..................................3200mm (10’ 6’’)
Transport Width ...................................2500mm (8’ 2.5’’)
Transport Length .................................13778mm (45’ 2.5’’)

(4) Working Dimensions

Working Height ....................................3710mm (12’ 2.1’’)
Working Width .....................................3840mm (12’ 7.2’)
Working Length ...................................13608mm (44’ 7.7’’)

(5) Crusher Info

Crusher Shaft Speed ...........................300RPM
Crusher Stroke ....................................28mm (1’ 1/8’’)

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3.3 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 Hopper - Receives material and channels this onto the vibrating pan feeder.
2 Pan Feeder - Consists of a heavy duty Hardox lined vibrating pan feeder. Acts as a reserve
for raw material and controls the rate at which the material is fed to the jaw crusher.
3 Jaw Crusher - Consists of a single toggle hydraulic drive jaw crusher.
4 Side Conveyor (Fine Product) - A 3 ply belt that carries the smallest screened material from
the pan feeder to stockpile.
5 Main Conveyor - A 3 ply belt that carries material from the jaw crusher to stockpile.
6 Overband Magnet - A conveyor belt mounted over a magnet to lift metal objects from the
main conveyor and discharge material to the side of the machine.
7 Powerunit - Encloses the engine, hydraulic tank, control panel and hydraulic control levers.

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(1) Machine Measurements

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(2) Transport Position

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 Technical Data 3

3.4 Noise levels

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 Machine Operation 4

Table of Content
4 Operational Procedures ............................................................................ 4-3
4.1 Prior to Use ....................................................................................................4-3
4.2 Prestart Inspection .........................................................................................4-3
4.3 Machine Location ...........................................................................................4-3
4.4 Control Panel Overview..................................................................................4-4
4.5 Control Panel Functions .................................................................................4-5
(1) Starting the Engine ....................................................................................4-5
(2) Engine Monitoring ......................................................................................4-6
(3) Tier 4 Additional Engine Monitoring Screen...............................................4-8
(4) Tracking the Machine with Wired Handset ..............................................4-10
(5) Tracking the Machine with Radio Handset .............................................. 4-11
(6) Wired Handset Test .................................................................................4-12
(7) Control Panel Feeder Functions ..............................................................4-13
(a) Chamber / Feeder Control .................................................................4-13
(b) Manual Feeder Adjustment .................................................................4-16
(c) Chamber Level ...................................................................................4-16
(8) Starting the Crusher ................................................................................4-18
(9) Stopping the crusher ...............................................................................4-19
(10) CSS and Jaw Blockage Auto Clear Features ..........................................4-19
(11) Auxiliary Functions...................................................................................4-20
(12) Error Logging ...........................................................................................4-21
(13) Error Alerts ...............................................................................................4-22
4.6 Tracking Machine .........................................................................................4-23
(1) Machine Radio Control Handsets Overview ............................................4-24
(2) Machine Radio Handset ..........................................................................4-25
(3) Feeder Radio Control Handset Overview ................................................4-26
4.7 Hydraulic Control Levers Overview ..............................................................4-26
(1) Hydraulic Control Valve Operation...........................................................4-26
4.8 Pictorial Decal Descriptions..........................................................................4-27
(1) Machine Operations Decals ....................................................................4-27
(2) Machine Information Decals ....................................................................4-30
(3) Control Bank 1 .........................................................................................4-34
(4) Control Bank 2 .........................................................................................4-35
(5) Control Bank 3 .........................................................................................4-36
4.9 Machine Set Up ............................................................................................4-36
(1) Unfolding the Hopper ...............................................................................4-36
(2) Walkway Setup ........................................................................................4-40
(3) Unfolding the Side Conveyor ...................................................................4-40
(4) Landing Legs Setup .................................................................................4-40
(5) Setting Main Conveyor ............................................................................4-42
(6) Unfolding Crusher Top Cover ..................................................................4-42
(7) Adjusting Crusher Closed Side Settings ..................................................4-43
(8) Adjusting Feed Level in Crusher Chamber ..............................................4-46
(9) Adjust / Monitor Pan Feeder Settings ......................................................4-46

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4.10 Machine Components Start-Up Procedure ..................................................4-46

4.11 Machine Shut Down Procedure....................................................................4-47
4.12 Machine Lockout and Tag Out Procedure ....................................................4-47
4.13 Emergency Stop Procedure .........................................................................4-47

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4 Operational Procedures

4.1 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

4.2 Prestart Inspection

WARNING
Switch off, tag out and lock out machine before carrying out pre-operating checks or machine
maintenance.
Wear personal protective equipment at all times.
Before staring the machine thoroughly check for any damage and make sure the machine is in
good mechanical condition.
Do not stand on the machine or machine walkways while it is in operation
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 position
Do not start up the machine until the inspection is complete.

4.3 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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4.4 Control Panel Overview

Figure 4.1 - Panel Overview

1 Crusher Start / Stop 11 Display Unit

2 Track Speed Enable And Adjust 12. Panel Lock
3 Service Mode Access 13. Keyswitch
4 Language Selection 14. Keyswitch Off Position
5 Escape 15. Keyswitch Power only Position
6 Engine Information Menu Access 16. Keyswitch Heat Position
7 Crusher Function Menu Access 17. Keyswitch Crank Position
8 Feeder Function Menu Access
9 Auxiliary Function Menu Access
10 Cursor Controls

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4.5 Control Panel Functions

(1) Starting the Engine

1. Check that all control levers are in the neutral position, and all emergency stops are released.
2. Make sure that no one is standing within 15m of the machine.
3. Insert the key into the main control ignition switch.
4. Turn the key clockwise to the power position. The display will commence its boot sequence
followed by entry in to the main menu screen.
5. Turn the key clockwise to the heat position, the engine heat lamp will illuminate. Wait until
this lamp goes out before continuing.
6. Turn the key further clockwise to the crank position. The machine alarm will sound to indicate
that the machine is about to start. This will be accompanied by a change of display to the
engine function mode.
7. Hold the key in the crank position for 10 seconds, during which time the alarm will continue
to sound and the display will show time to engine crank.

Figure 4.2 - Display Screen

8. Release the key immediately the engine starts.

9. Prior to operating the machine, allow the engine to run for 5 minutes to allow running
temperature to be reached. This will prolong engine life.
10. Pressing the escape button (5) Ref: Figure 4.1 will return the display to the main start-up
screen.

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(2) Engine Monitoring

1. From the main screen, press the engine information button (6). The display mode will change
to show the important engine parameters as follows
2. To adjust the engine speed, press and hold the appropriate cursor button (10). Holding down
the “up arrow” key will cause an increase in engine speed, while holding down the “down
arrow” key will cause the engine speed to decrease. The rate at which engine speed varies
depends on how long the key is held. This allows the desired speed to be reached quickly.
Note this is only active whilst the crusher is not running.
3. Press key 9 to access the Tier 4 engine monitoring screen if your machine is fitted with a
Tier 4 engine.
4. Press escape (5) to return to the main screen.

Figure 4.3 - Engine Monitoring Screen

1 Fuel Temperature
2 Coolant Temperature
3 Battery Voltage
4 Inlet Pressure kPA
5 Engine RPM
6 Engine Load
7 Oil Temperature
8 Oil Pressure kPA
9 Fuel Level
10 Fuel Pressure kPA
11 Fuel Rate Litre/Hour

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5. The engine function display also contains 6 automotive-style panel indicators, which alert
the user to the crucial engine warnings and stop conditions, see Figure 4.4.

Figure 4.4 - Engine Warning Indicators

1 Engine Coolant Level Warning

2 Engine Pre-heat Active
3 Engine Stop
4 Engine Fault Warning
5 Engine Service Interval
6 Cold Engine Warning. Engine RPM will be limited and functions disabled until the engine
temperature is greater than 15°C.
6. Other useful machine operating parameters are continually displayed, including total engine
running hours, total machine crushing hours and total estimated remaining fuel time

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Figure 4.5 - Operating Parameters

1 Total Engine Running Hours

2 Total Machine Crushing Hours
3 Crank Delay Period / Total Estimated Remaining Fuel Time

(3) Tier 4 Additional Engine Monitoring Screen

1. When key 9 is pressed while in the engine monitoring screen the display mode will change
to show Tier 4 engine parameters, see Figure 4.6.
1 Inlet Pressure kPA.
2 Diesel Particulate Filter.
3 DPF After Treatment Gas Temerature.

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Figure 4.6 - Tier 4 Operating Parameters

2. Press key 7 to inhibit DPF regeneration.

3. Press key 8 to force a manual DPF regeneration cycle.
4. The engine function display also contains 6 automotive-style panel indicators, which alert
the user to the crucial engine warnings and stop conditions, see Figure 4.7.

Figure 4.7 - Tier 4 Engine Warning Indicators

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1 Diesel Particulate Filter

2 DPF Inhibited
3 DPF Regeneration Manual
4 High Exhaust System Temperature
5 Diesel Exhaust Fluid
6 Emission System Failure

(4) Tracking the Machine with Wired Handset

1. Connect the handset to the machine using the cable provided.
2. If the radio handset is being used in track mode, the doglead handset will be ignored.
3. Ensure that the doglead stop button is released and the enable key switch is in the vertical
position.
4. Start the engine. Note that engine speed will be controlled automatically during track mode.
5. Enter track mode by either using the track mode button on the display (2) Ref: Figure 4.8 or
turn the dog lead handset key switch clockwise. The siren will sound for 10 seconds prior to
machine movement being allowed. The display will change to show key tracking parameters,
including the remaining time before tracking is allowed.
6. If the engine is cold then cold engine symbol will illuminate and tracking will be disabled until
the engine warms up.

Figure 4.8 - Tracking Mode

7. The main lower conveyor section will automatically move in to the transport position.
8. The tracking speed will default to the slowest setting (snail). This can be changed using the
up and down cursor buttons (10) Ref: Figure 4.8. The current speed will be indicated by the
large green snail, tortoise or hare symbol, representing slow, intermediate and fast track
rates respectively. The smaller blue icons, located by the cursor button indicate the next
available allowed speed.

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9. Use the four handset buttons to move the associated tracks in the required direction. The
required track will move at the currently set speed for as long as the button is held. The
display will indicate track movement status using arrows, positioned on the main track icon.

Figure 4.9 - Wired Handset Tracking Screen

10. Machine track mode can be terminated by pressing the display escape button, or by turning
the handset key switch counter-clockwise. The display will return to the main machine menu

(5) Tracking the Machine with Radio Handset

1. The radio handset will not enter track mode on its own, the display must be used to enter
track mode using button (2) Ref: Figure 4.10.
2. Once in track mode, the machine function is identical to operation with the wired handset.
3. Use the four handset buttons to move the associated tracks in the required direction. The
required track will move at the currently set speed for as long as the button is held. The
display will indicate track movement status using arrows, positioned on the main track icon.
4. If the radio handset is being used in track mode, the doglead handset will be ignored.
5. To exit track mode, either use the display escape key (5) Ref: Figure 4.10 or switch the radio
handset off using its keyswitch.

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Figure 4.10 - Radio Handset Tracking Screen

(6) Wired Handset Test

1. If the handset connected is not the latest version then the following screens are displayed
to test the connected handset.
2. Follow the on screen instructions and test each function button highlighted by the red pointing
icon.
3. Once the function of a button has been confirmed a green tick will be shown and the next
button in sequence will be highlighted for testing
4. The test is complete when all four button functions are showing green ticks.

Figure 4.11 - Wired Remote Test Sequence

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Figure 4.12 - Wired Remote Test Completed.

(7) Control Panel Feeder Functions

NOTICE
This Machine has an auto feeder control fitted. This auto feeder will attempt to maintain a preset
crushing level in the crushing chamber
The current level of material in the crushing chamber is read by an ultrasonic sensor built into
the jaw.

(a) Chamber / Feeder Control

In addition to material height, feeder speed is also governed by the crusher hydraulic drive
pressure, conveyor pressure, whether a downstream machine is connected and the hydraulic
oil temperature.
If the crusher drive pressure exceeds a preset maximum value, the feeder speed will be reduced
accordingly. Where the feeder has to stop, it will only re-start when the drive pressure drops below
a preset minimum value.
If the conveyor pressure sensor is reading too low (conveyor not running) or too high (conveyor
stalled), the feeder will be disabled.
If a downstream machine requests the feeder on the machine stops, it will do so after a preset
delay. A separate delay controls the feeder restarting after the downstream machine restarts.
If the hydraulic oil temperature is above its warning point the feeder will derated to run at a
maximum of 50% speed.
1. Press the feeder operating menu button (8) Figure 4.1 to access the feeder control screen.

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Figure 4.13 - Feeder Control Screen

2. Key 1 is used to turn the feeder on or off.

3. Key 2 is used to disable or enable the radio control system.
4. Key 3 turns the pre-screen if fitted on or off. Note: Stopping the pre-screen also stops the
feeder.
5. When key 4 is pressed the screen below is displayed showing the current feeder pause
condition state, as an aid to fault finding:

Figure 4.14 - Feeder Condition State

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This screen displays the current feeder pause condition state, as an aid to fault finding. The user
is able to see which processes are preventing the feeder from running. The feeder control valve
will be disabled whenever a ‘cross’ is shown below a particular icon. The following table explains
the meaning for each icon

Table 4.1 - Feeder Condition States

Key Status Icon If Fault Cross Dispalyed
1 Crusher Run Jaw has not reached operating
speed
2 Feeder Run User requested feeder not to run
3 Crusher Speed Crusher RPM below minimum
preset value
4 Engine Run Engine problem of low RPM
5 Conveyor Pressure Conveyor pressure problem
6 Crusher Pressure Crusher pressure problem
7 Chamber Overflow Chamber full for a period of time
(time adjustable in parameters)
8 Downstream Input Downstream inhibit is active
9 Radio Controller Enabled Feeder paused by radio handset
10 Feeder Current Feeder control valve current
fault

6. When key 6 is pressed once the crusher pressure settings (Selection 1) settings are displayed .
7. When Key 6 is pressed twice the down stream settings (Selection 3) are displayed.
8. There is no selection 2 available with this machine.
9. When the crusher pressure settings (Selection 1) are selected.
10. Press key 7 to select feeder off crush pressure adjustment, use the up and down cursor
button to adjust this setting.

Figure 4.15 - Crush Pressure Off Display

11. Press key 8 to select the feeder restart crush pressure adjustment, use the up and down
cursor button to adjust the setting.

Figure 4.16 - Feeder Restart Pressure Display

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12. When the down stream feed settings (Selection 3) are displayed.
13. Press key 7 to select the down stream feeder off time adjustment, use the up and down
cursor button to adjust this setting.

Figure 4.17 - Feeder Off Time Adjustment Display

14. Press key 8 to select the downstream feeder restart time adjustment, use the up and down
cursor button to adjust this setting.

Figure 4.18 - Feeder Restart Time Adjustment Display

15. Press escape to return to the main menu.

(b) Manual Feeder Adjustment

1. The lower bar graph on the display Ref: (c) shows the current feeder speed as well as the
maximum feeder speed limit (represented by a vertical orange line).
2. In the event that the operator wants to limit the maximum allowable feeder speed, press the
left or right arrow keys on button (10) to move the vertical white line. This is used to slow
down the amount of material being fed into a machine downstream.
3. If the ultrasonic sensor has been disabled then adjusting this maximum will allow the operator
to run the feeder at a constant speed.

Figure 4.19 - Manual Feeder Control Display

(c) Chamber Level

Adjust the desired material level in the crusher chamber prior to commencing crushing operation.
The feeder rate will be controlled accordingly to maintain the required feed height in the crusher
chamber, this will maximize the potential crushing throughput.
1. Press the crusher operating menu button (7) to access the required parameters. The display
will show the current feed height as a percentage, along with the associated bar graph.
2. Use the Up and Down arrows on button (10) to adjust the feed height.

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3. A good starting point is to set the desired material height to 70 percent. The current material
height in the crushing chamber can be monitored by observing the display, as shown in Figure
4.21 which shows desired material height set to 70 percent with no material in the chamber.

Figure 4.20 - Control Screen

Figure 4.21 - Chamber Level Display

4. In Figure 4.21 the indicator is showing that the desired material height is set to 70 percent
with no material in the chamber.

Figure 4.22 - Chamber Level Display

5. In Figure 4.22 the indicator is showing that the desired material height is set to 70 percent
with material in the chamber. The level is currently below the desired height which will allow
the feeder to operate at maximum speed

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Figure 4.23 - Chamber Level Display

6. In Figure 4.23 the indicator is showing that the Desired material height set to 70 percent
with material shown in the chamber. The level in the chamber is currently above the desired
height, such that the feeder will slow or stop in order to maintain the correct material height
7. If the chamber level sensor does not see the material height start to drop for longer than a
preset time, then the feeder will stop.
8. The auto feeder system can be disabled by setting the desired material height to 101%.

(8) Starting the Crusher

1. Press the crusher start / stop button (1) from the main menu Ref: Figure 4.1. The display will
enter the crusher start / stop screen.
If the engine is cold symbol 11 will illuminate, the engine must reach operating temperature before
the crusher will run. If the conveyor 12 is illuminated the conveyor is not running.
2. Press button (6) Ref: Figure 4.24 to start jaw in forward operation.
3. Press Button (8) Ref: Figure 4.24 to start jaw in reverse operation.
4. A timer will appear counting down 8 seconds as an audible warning before the jaw will start.
Siren will also sound for this period.
5. Once the crusher has been started, the red power bar graph display will indicate the current
speed ramp level as a percentage.
6. Press escape to exit back to the main menu.

Figure 4.24 - Starting Crusher

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(9) Stopping the crusher

1. Press the crusher start / stop button (1) from the main menu Ref: Figure 4.1. The display will
enter the crusher start / stop screen.
2. Press button (7) Ref: Figure 4.24. The display will enter the crusher stop mode.
3. The red bar graph display will indicate that the crusher is ramping down to a stop condition

(10) CSS and Jaw Blockage Auto Clear Features

This machine is fitted with a feature to attempt to clear a blocked jaw. This feature will build up
engine RPM and then briefly pulse the jaw in the desired direction to attempt to clear the blockage.
1. Press the crusher operating menu button (7) Ref: Figure 4.1 to access the jaw jog function.

Figure 4.25 - Auto Blockage Removal

2. Press and hold Key 2 to run the jaw in a forwards direction. This button is momentary acting,
i.e. the service is active only while the button is held. The engine will build up rpms before
engaging the jaw to attempt to clear the blockage.
3. Press and hold Key 3 to in run the jaw in a reverse direction. This button is momentary acting,
i.e. the service is active only while the button is held. The engine will build up rpms before
engaging the jaw to attempt to clear the blockage.
4. Press Key 1 to access the CSS screen Figure 4.26 below

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Figure 4.26 - Closed Side Settings

5. Keys 1 and 2 are used to adjust the CSS, keys 3 and 4 are used to calibrate the css zero
point. The zero point will change with wear.
6. Procedure to zero CSS point for sensor is, press and hold key 3 for 3 seconds. Only valid
if jaw not already running.
7. Siren will sound followed by jaw rotating at low rpm.
8. Purpose of jaw rotating is so that when you close the jaw up its easier to tell the point at
which plates make contact. ie zero point.
9. Once jaw is rotating slowly, close jaw CSS by pressing key 1. keep button pressed till jaw
touches plate. Ie no gap / zero CSS. You can hear this as well as see pump pressure
increase on screen.
10. Press and hold key 4 to zero CSS point for sensor. The hold time is to prevent someone
zeroing CSS accidentally by hitting key 4.
11. Once CSS has been zeroed, CSS will automatically open to previous setpoint, ie if CSS was
set to 75.0mm before starting the zeroing procedure then CSS will open to 75.0mm now.

(11) Auxiliary Functions

1. Press the auxiliary function button (9) from the main menu Ref: Figure 4.1. The display will
change to display the available options.
2. Press button (1) Ref: Figure 4.1 to turn the dust suppression water pump on or off. The
associated lamp icon will change from red to green when the service is active.
3. Press button (2) Ref: Figure 4.1 to turn the fuelling pump on or off. The associated lamp icon
will change from red to green when the service is active.
4. Press button (3) Ref: Figure 4.27 to turn the work lights on or off. The associated lamp icon
will change from red to green when the service is active.
5. Press button (4) Ref: Figure 4.27 to access the fault log.

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6. Press button (6) Ref: Figure 4.1 to raise the main conveyor feed boot. This button is momentary
acting, i.e. the service is active only while the button is held.
7. Press button (7) to lower the main conveyor feed boot. This button is momentary acting, i.e.
the service is active only while the button is held.
8. Press escape button (5) to exit back to the main menu.

Figure 4.27 - Auxiliary Functions

(12) Error Logging

This control system incorporates comprehensive error logging facilities which allow errors
generated by the engine or crusher control system to be logged, saved to a USB memory stick
and recalled on-screen. All error codes are translated to descriptive text which is recorded along
with a time and date stamp.
1. Press the auxiliary function button (9) Ref: Figure 4.1 from the main menu. The display will
change to display the available options.
2. Press Key (4) Ref: Figure 4.27 to access the fault log display.
3. Press the up and down cursor buttons (10) Ref Figure 4.28 to scroll through the error display
list.
4. Press escape button (5) to exit back to the auxiliary function screen.
5. The display is fitted with a rear-mounted type-A USB socket, designed to accept a memory
stick device. Access to this is gained by removing two hex bolts which hold the cover in place.
6. Insert the USB memory device into the socket. The display will recognise that the USB device
has been connected.
7. Press button (6) Ref: Figure 4.29 to copy the current error log file to the USB memory device.
Note that an existing file will be overwritten by this action. The resulting text file (error_log.
txt) can be imported into an Excel spreadsheet and manipulated accordingly.
8. Press button (1) to safely eject the USB device.

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Figure 4.28 - Error Log Screen

Figure 4.29 - Error Log Screen (USB)

(13) Error Alerts

NOTICE
If an operator dismisses an error from the display, the error will be re-displayed if the operator
attempts to track or start the jaw.
There are two types of error on the machine, those relating to the engine and those relating to the
control electronics. The engine symbol as shown in Figure 4.30 will be visible for engine faults. A
complete list of fault codes is shown in the Appendix section at the back of this manual.

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1. Press the OK cursor button (10) to view the next error alert or to exit.

Figure 4.30 - Error Alert

4.6 Tracking 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.

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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 4.31.

Figure 4.31 - 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.
• 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) Machine Radio Control Handsets Overview

This machine is available with an option two way radio control handsets.

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(2) Machine Radio Handset

Figure 4.32 - Machine Control Radio Handset

1 Key Switch - On / off switch. When not in use keep the radio remote turned off to prolong
battery life.
2 Transmitting LED - Will flash continuously when button is pressed or intermittently if no
buttons are pressed.
3 Track Forward Right - Used to track the machine once track mode has been selected on the
control panel. (Operates right hand side track only)
4 Track Reverse Right - Used to track the machine once track mode has been selected on the
control panel. (Operates right hand side track only)
5 Coding LED - Used when coding a spare handset to the machine.
6 Charging Socket - this handset is fitted with a Lo-ion rechargeable battery. To charge the
unit connect the handset to the charging socket fitted to the machine using the adaptor plug
provided. Alternatively the unit can be charged using a 12Vdc charger.
7 Track Reverse Left - Used to track the machine once track mode has been selected on the
control panel. (Operates left hand side track only)
8 Track Forward Left - Used to track the machine once track mode has been selected on the
control panel. (Operates left hand side track only)
9 Radio Stop Request - Transmits an engine stop request to the panel. If within range the
machine will stop the engine immediately. This IS NOT an emergency stop and should not
be relied upon as such.

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(3) Feeder Radio Control Handset Overview

Figure 4.33 - Feeder Control Radio Handset

1 Radio Stop Request - Transmits an engine stop request to the panel. If within range the
machine will stop the engine immediately. This IS NOT an emergency stop and should not
be relied upon as such.
2 Feeder Speed Up - Use this button to speed up the feeder when it is set to manual control.
3 Transmit LED - Will flash continuously when button is pressed or intermittently if no buttons
are pressed.
4 Coding LED - Used when coding a spare handset to the machine.
5 Sound Siren - Use this button to sound the siren on the machine, siren will sound while button
is held down.
6 Feeder Slow Down - Use this button to slow down the feeder when it is set to manual control.
7 Feeder Stop - Use this button to stop the feeder. Feeder will not restart until feeder star button
is pressed.
8 Feeder Start - Use this button to start the feeder (all other condition must be met such as
jaw already running etc.).

4.7 Hydraulic Control Levers Overview

The hydraulic control levers are located inside the engine control cabinet Ref: Figure 4.35.

(1) 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 4.34

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The neutral (off) position for hydraulic control valves is when the lever is in the centre position.

Figure 4.34 - Control Valve

4.8 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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Table 4.2 - Pictorial Decals

Decal Description Explanation

 Off position

Feeder

Engage vibrating feeder

 Off position

Main Conveyor)

Engage main conveyor

 Off position

Side Conveyor
Engage side conveyor plus side conveyor speed
control dial

 Off position

Magnet

Engage magnet conveyor plus speed control dial

 Raise rear support legs

Rear Support
 Neutral
Legs

 Lower rear support legs

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 Raise front support legs

Front Support
 Neutral
Legs

 Lower front support legs

 Raise feed boot section

Main Conveyor
 Neutral
Feed Boot

 Lower feed boot section

 Raise main conveyor height

Main Conveyor  Neutral

 Lower main conveyor height

 Raise hopper back plate

Hopper Back
 Neutral
Plate

 Lower hopper back plate

 Raise right hand side hopper plate

Hopper Right
 Neutral
Hand Side Plate

 Lower right hand side hopper plate

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 Raise left hand side hopper plate

Hopper Left Hand

 Neutral
Side Plate

 Lower left hand side hopper plate

 Raise side conveyor height

Side Conveyor  Neutral

 Lower side conveyor height

 Decrease material size

Crushing
 Neutral
Chamber

 Increase material size

(2) 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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Table 4.3 - Machine Information Decals

Decal Explanation

Fuel tank capacity

Hydraulic oil tank capacity

Crusher greasing schedule, this decal

shows the frequency (every 8 hours),
amounts and type of grease to be used
and that the grease nipples and hoses
should be inspected for damage.

This decal shows that 2, 1.25 gram

grease gun pumps of general purpose
grease is required every 40 hours

Make sure that safety pins are removed

and replaced as necessary

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Make sure that ultra low sulphur fuel only

is used

Make sure that ultra low sulphur fuel only

is used

Make sure that conveyor belt is not

nipped while folding or unfolding the
conveyor

Battery isolator location

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Figure 4.35 - Hydraulic Control Levers

• Control Bank 1 Ref: Figure 4.36.

• Control Bank 2 Ref: Figure 4.37
• Control Bank 3 Ref: Figure 4.38

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(3) Control Bank 1

Figure 4.36 - Control Bank 1

1 Pan Feeder Control Lever

2 Main Conveyor Control Lever
3 Overband Magnet Control Lever
4 Side Conveyor Control Lever

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(4) Control Bank 2

Figure 4.37 - Control Bank 2

1 Raise/Lower Hopper Back Plate

2 Raise/Lower Hopper Right Hand Side Plate
3 Raise/Lower Hopper Left Hand Side Plate
4 Fold/Unfold Side Conveyor
5 Increase/Decrease Jaw Setting

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(5) Control Bank 3

Figure 4.38 - Control Ban 3

1 Extend/Retract Side Conveyor Telescopic Section

2 Raise/Lower Rear Jacking Legs
3 Raise/Lower Front Jacking Legs
4 Raise/Lower Feedboot
5 Raise/Lower Main Conveyor

4.9 Machine Set Up

WARNING
Wear personal protective equipment.
Make sure non essential personnel are outside machine exclusion zone when setting up machine.
When working above ground level make sure to use suitable work platforms.

(1) Unfolding the Hopper

1. Start engine Ref: “Starting the Engine” on page 4-5.
2. Access the hydraulic control levers located inside the engine cabinet Ref: “Hydraulic Control
Levers Overview” on page 4-26
3. Raise the hopper left and right hand side plates Ref: Figure 4.39
4. Raise the hopper back plate. Lock in position using the supplied wedges Ref: Figure 4.40.
Additional M20x65 bolts can be fitted if desired.

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Figure 4.39 - Control Levers

• 1 Raise/Lower Hopper Back Plate

• 2 Raise/Lower Hopper Right Hand Side Plate
• 3 Raise/Lower Hopper Left Hand Side Plate
• 4 Fold/Unfold Side Conveyor
• 5 Increase/Decrease Jaw Setting
5. Install the hopper crossbeam using the supplied pins Ref Figure 4.41

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Figure 4.40 - Hopper Wedges

Figure 4.41 - Hopper Crossbeam

• 1 Crossbeam
• 2 Pin

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6. Lock both hopper sides in position using the toggle bolts Ref: Figure 4.42

Figure 4.42 - Toggle Bolts

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(2) Walkway Setup

WARNING
When working above ground level make sure to use suitable work platforms.

1. Install the right and left hand side removable handrails to the upper walkway platforms. These
are simply dropped into sockets on the walkway Ref: Figure 4.43.

Figure 4.43 - Walkway Handrails

(3) Unfolding the Side Conveyor

NOTICE
Before the side conveyor can be unfolded the right hand side hopper plate must first be unfolded.

1. Lower the side conveyor to working position using the hydraulic control level Ref: Figure 4.39.

(4) Landing Legs Setup

WARNING
Crushing hazard from landing legs. Make sure to keep clear while legs are lowered / raised.

NOTICE
The crusher must not be operated without sufficient support under the landing legs.

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1. Remove the front and rear landing leg pins and lower the leg into place Ref: Figure 4.44
and Figure 4.45.
2. Make sure machine is level.
3. Replace leg pin once leg has been lowered to desired level Ref: Figure 4.45.

Figure 4.44 - Hydraulic Controls

• 1 Extend/Retract Side Conveyor Telescopic Section

• 2 Raise/Lower Rear Jacking Legs
• 3 Raise/Lower Front Jacking Legs
• 4 Raise/Lower Feedboot
• 5 Raise/Lower Main Conveyor

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Figure 4.45 - Landing Legs

(5) Setting Main Conveyor

1. The main conveyor and main conveyor feedboot can be raised or lowered using the hydraulic
control lever Ref: Figure 4.44.

(6) Unfolding Crusher Top Cover

WARNING
When working above ground level make sure to use suitable work platforms.

NOTICE
The crusher must not be operated with the crusher cover in the transport position.

1. Place the crusher top cover into the position shown in Figure 4.46.

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 Machine Operation 4

Figure 4.46 - Crusher Cover

(7) Adjusting Crusher Closed Side Settings

NOTICE
Before operating the crusher the closed side settings (CCS) should be set to suit the application
the machine will be used in.
Do not set the closed side setting (CSS) to below the 63.5mm (2 ½”) minimum
To calculate the closed side settings (CSS) then the open side settings (OSS) measurement
must be taken when the jaw is at rest, measured peak to peak on the jaw dies Ref: Figure 4.47

Figure 4.47 - OSS Measurement Peak to Peak

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4 Machine Operation

Equation used for calculation the CSS is:

• OSS - [Crusher Throw + 6mm] = CSS
Table of CSS and corresponding OSS measurements for the J40 crusher (throw = 28mm)

CSS OSS
(mm) (mm)
50 84
55 89
60 94
65 99
70 104
75 109
80 114
90 124
100 134
110 144
120 154
130 164
140 174
150 184

Table 4.4 - CSS and OSS Settings

NOTICE
It is highly recommended that the CSS adjust wedges are cycled in and out daily to prevent
them form sticking.
Re-calerbration of the CSS is required over time as the jaw dies wear or are replaced.
1. The crusher CSS is controlled by a dual wedge system activated by hydraulic rams Ref:
item 1, Figure 4.48
2. The crusher is adjusted using a hydraulic control valve Ref: Figure 4.39.
3. Hydraulic rams will automatically lock in position after adjustment.
The machine has an auto adjust mechanism on the toggle tension rod. When the Close Side
Setting is changed the toggle tension rod ram Item 2, Figure 4.49 automatically adjusts to maintain
constant tension on toggle plate seats. The spring Item 1, Figure 4.49 moves during normal
operation to prevent excess wear inside the hydraulic cylinder.

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 Machine Operation 4

Figure 4.48 - CSS Dual Wedge System

Figure 4.49 - Tension Rod

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(8) Adjusting Feed Level in Crusher Chamber

Refer to “Chamber Level” on page 4-16.

(9) Adjust / Monitor Pan Feeder Settings

Refer to “Control Panel Functions” on page 4-5

4.10 Machine Components Start-Up Procedure

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 the main conveyor feedboot is in the working position.
Make sure all control levers are in the neutral (off) position.
1. Make sure all prestart check have been completed Ref: “Prestart Inspection” on page 4-2
2. Make sure the electrical isolator switch is turned on Ref: item 1 Figure 4.50

Figure 4.50 - Isolator Switch

3. Start the machine components in the following order:

• Main Conveyor Ref:
• Side Conveyor Ref:
• Overband Magnet:
• Crusher
• Pan Feeder

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 Machine Operation 4

4.11 Machine Shut Down Procedure

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.
1. Make sure that all material has been run off the machine and the crusher chamber is empty.
2. Stop the machine components in the following order
• Pan Feeder
• Crusher
• Overband Magnet
• Side Conveyor
• Main Conveyor
3. Throttle down the machine at the control panel and allow engine to run at idle for 5 minutes.
4. Turn ignition key to the off position and remove key.
5. Check fuel level and top up if required to avoid build up of condensation in fuel tank.
6. Secure machine.

4.12 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 4-47.
2. After 20 seconds, rotate the isolator switch from the “ON” position to the “OFF” position,
Ref: Figure 4.50.
3. Fit the lock out padlock on the main power isolator and keep the key with you.
4. Release stored energy from the system, such as hydraulic fluid under pressure, so that the
machine is in a zero energy state.
5. Place a tag on the lock that identifies you as well as the date and time you locked it out
6. Check that the machine can not be started to ensure the lookout is complete.

4.13 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, 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 4.51 and Figure 4.52. Turn the ignition key to the off position as soon as possible,
if safe to do so.
2. Remove the ignition key.
3. Set the isolator switch to the off position.
4. When safe, release the emergency stop button(s) by pulling or twisting.

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Figure 4.51 - RHS Emergency Stop Locations

Figure 4.52 - LHS Emergency Stop Locations

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Intentionally Left Blank

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 Transportatipon 5

Table of Content
5 Transportation............................................................................................ 5-2
5.1 Preparing Machine for Transport ....................................................................5-2
5.2 Loading Machine to Transport Trailer .............................................................5-2

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5 Transportation
NOTICE
Make sure that all of material has been run off the conveyors and the screen box and hopper
are both empty.
Make sure that the machine has been properly shut down Ref: “Machine Shut Down Procedure”
on page 4-47.
Always perform machine pre-start check starting the machine Ref: “Prestart Inspection” on page
4-2.
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.

5.1 Preparing Machine for Transport

To Prepare the machine for transport the following sequence should be followed
1. Start the machine.
2. Fold the crusher top conveyor to transport position.
3. Remove upper walkway pull-out handrails.
4. Retract side conveyor head section then fold side conveyor to vertical position.
5. Remove wedge and bolts then fold down hopper back plate.
6. Remove hopper crossbeam.
7. Remove toggle bolts and fold down hopper right and left hand sides.
8. Raise jacking legs.
9. Lower main conveyor head section to lower position.

NOTICE
Make sure no parts of the machine are above the level of the powerunit canopy when folded in
the transport position.

5.2 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.
1. Make sure machine has been placed into transport position Ref: Section 5.1.
2. Make sure transport trailer is free from obstructions and ready to receive machine.
3. Start machine.
4. Engage tracking mode making sure that tracks are set to their lowest speed.
5. Track machine onto transport trailer as recommended in Figure 5.1

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 Transportatipon 5
6. Once the machine is located on the transport trailer make sure the main conveyors highest
point is not above the level of the power unit Ref: Figure 5.1.
7. Secure the machine to the transport trailer using to machine tie down points and suitable
transport chains.
8. Make sure the machine is correctly loaded and sitting level.
9. Make sure there are no loose parts or items on the machine that could become detached
during transport.

Figure 5.1 - Recommended Transport Position

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 Maintenance 6

Table of Content
6 Maintenance ............................................................................................... 6-3
6.1 Regular Servicing ...........................................................................................6-3
6.2 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
(c) Machines With AdBlue Tanks ................................................................6-4
6.3 Unscheduled Maintenance .............................................................................6-5
(1) Tracks ........................................................................................................6-6
6.4 Maintenance Schedules .................................................................................6-7
(1) Daily or 10 Hour Maintenance Schedule ...................................................6-7
(2) Weekly or 50 Hour Maintenance Schedule ..............................................6-8
(3) 500 Hour Maintenance Schedule ..............................................................6-9
(4) 2500 Hour Maintenance Schedule ............................................................6-9
(5) Engine Maintenance Schedules ..............................................................6-10
(6) CAT Engine Maintenance Schedules ......................................................6-10
(a) When Required ...................................................................................6-10
(b) Daily ....................................................................................................6-10
(c) Weekly ................................................................................................6-10
(d) Every 50 Service Hours or Monthly ....................................................6-10
(e) Every 250 Service Hours .................................................................... 6-11
(f) Every 500 Service Hours .................................................................... 6-11
(g) Every 500 Service Hours or 1 Year ..................................................... 6-11
(h) Every 1000 Service Hours .................................................................. 6-11
(i) Every 1500 Service Hours .................................................................. 6-11
(j) Every 2000 Service Hours ..................................................................6-12
(k) Every 3000 Service Hours ..................................................................6-12
(l) Every 3000 Service Hours or 2 Years .................................................6-12
(m) Every 4000 Service Hours ..................................................................6-12
(n) Every 6000 Service Hours or 3 Years .................................................6-12
(o) Every 12000 Service Hours or 6 Years ...............................................6-12
(7) Volvo Engine Maintenance Schedules ....................................................6-12
(a) First Service Inspection .......................................................................6-12
(b) Daily ....................................................................................................6-13
(c) Weekly ................................................................................................6-13
(d) Every 50 Service Hours or Monthly ....................................................6-13
(e) Every 250 Service Hours ....................................................................6-14
(f) Every 500 Service Hours ....................................................................6-14
(g) Every 500 Service Hours or 1 Year .....................................................6-14
(h) Every 1500 Service Hours ..................................................................6-14
(i) Every 2000 Service Hours ..................................................................6-15
(j) Every 800 Service Hours ...................................................................6-15
(8) Lubrication ...............................................................................................6-16
(a) Greasing Information ..........................................................................6-16

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6 Maintenance

(b) Lubricants and Fluids ..........................................................................6-17

6.5 Servicing Conveyors ....................................................................................6-18
(1) Clean & Check the Conveyor Belts .........................................................6-18
(2) Tensioning the Conveyor Belts ................................................................6-19
(3) Conveyor Alignment ................................................................................6-20
6.6 Servicing the Tracks .....................................................................................6-21
6.7 Measuring Track Tension .............................................................................6-21
6.8 Adjusting Track Tension ...............................................................................6-22
6.9 Gearbox Oil Level.........................................................................................6-24
(1) Checking and Filling Gearbox Oil ............................................................6-24
(2) Draining Gearbox Oil ...............................................................................6-25
6.10 Servicing the Hydraulic System....................................................................6-26
(1) Changing Hydraulic Oil ............................................................................6-26
(2) Changing the Return Line Filter ...............................................................6-28
(3) Changing the Hydraulic Tank Breather Filter ...........................................6-29
6.11 Changing Air Filter Elements ........................................................................6-30
6.12 Replacing Crusher Swing Jaw Die ...............................................................6-31
6.13 Replacing Crusher Fixed Jaw Die ................................................................6-32
6.14 Replacing Crusher Cheek Plates .................................................................6-34
6.15 Replacing Pitman Wear Plate ......................................................................6-36

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 Maintenance 6

6 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.

6.1 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 Maintenance

6.2 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

1. Observe all safety warnings.
2. Check the fuel level gauge / indicator.
3. Clean the area around the filler cap.
4. Remove the filler cap and top up fuel level as required.
5. Replace the filler cap.

(b) Machines With Optional Fuel Pump

1. Observe all safety warnings.
2. Check the fuel level gauge / indicator.
3. Clean the area around the filler cap.
4. Remove the filler cap.
5. Place refueling hose in fuel container and start refuelling pump.
6. Replace the filler cap when refuelling is completed.

(c) Machines With AdBlue Tanks

NOTICE
It is recommended to use AdBlue - DIN70070 diesel exhaust fluid (DEF), if using a different
supplier ensure that the def complies with this standard.
If flushing or cleaning associated AdBlue parts do not use diesel or any other cleaning fluids.
Use only clean water or AdBlue to carry out the procedure.
Do not use fuel pump to fill AdBlue tank. Diesel and AdBlue must not be mixed.
1. Observe all safety warnings.
2. Check the fuel level gauge / indicator.

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 Maintenance 6

3. Clean the area around the filler cap.

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

6.3 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 .

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 highlight the need for maintenance,
Ref: item 1 Figure 6.1

Figure 6.1 - Blockage Indicator

(1) 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

6.4 Maintenance Schedules

(1) Daily or 10 Hour Maintenance Schedule

ITEM OPERATION REMARKS
Attend to any defects reported by the
Defects
operator.
Check auto greaser (if fitted) has
Crusher Bearings sufficient grease in reservoir and fill is Mobilith SHC 460
necessary.
Examine all visible cables and
Electrical System
connections.
a) Check oil level and replenish
b) Visually inspect for leaks, damaged
Hydraulic Power
hoses and fittings. Replace defective
Unit
items.
c) Visually inspect filter indicators.
a) Visually inspect for cuts, rips and
tears. Report to maintenance manager if
necessary.
Conveyor Belt
b) Check alignment, adjust as
necessary.
c) Check tension, adjust as necessary.
a) Make sure all guards are securely
fitted.
Guards b) Report defective guards to
maintenance manager.
c) Replace defective guards.
Visually inspect for loose bolts and
Fasteners
capscrews, tighten if necessary.
Track Maintenance Refer to track section
a) Check fuel level and replenish.
Fuel Level b) Visually inspect for leaks, damaged
hoses and fittings and replace as
necessary.
Engine oil level Check oil level and replenish
Visually inspect for leaks, damaged
Hoses hoses and fittings and replace as
necessary.
Seals Visually inspect for damaged seals
Check blockage indicator and replace
Engine air filter
filters if necessary.
a) Check oil level and replenish
Pan Feeder Shell Omala 220
b) Visually inspect for leaks.
Cycle wedges in and out to prevent
Adjust Wedge
jamming.

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 Maintenance 6

(2) Weekly or 50 Hour Maintenance Schedule

ITEM OPERATION REMARKS
Carry out daily or 10 hour Make sure all work in the daily or
maintenance schedule 10 hours schedule is carried out
Pan Feeder Change feeder gearbox oil After first 50 hour service
only then every 500 hours
there after.
Shell Omala 220 or
equivalent
Return line hydraulic Change After first 50 hour service
filters only then every 1000 hours
there after or when indicator
turn for green to red.
Diesel pre-filter Drain Pre-filter
Belt cleaners Check / adjust / replace
Skirting rubbers Check / adjust / replace
Bearings Grease Refer to “(7) Lubrication” on
page 6-12

Monthly or 200 Hour Maintenance Schedule

ITEM OPERATION REMARKS
Carry out daily or 10 hour and
weekly or 50 hour maintenance
schedules
Bearings a) Inspect for loose bolts and
tighten if necessary.
b) Inspect for loose fit on shaft
and any damage, replace if
necessary.
Hydraulic oil filters Change return line filters
Hydraulic tank Replace hydraulic tank air
filter*
Engine air intake pipe Check engine air intake pipe
for signs of wear or damage.
Replace if necessary.
Track Refer to “6.6 Servicing the
Tracks” on page 6-17
*Refer to Greasing schedule for quantities.

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6 Maintenance

(3) 500 Hour Maintenance Schedule

ITEM OPERATION REMARKS
FIRST
Carry out daily or 10 hour
maintenance schedule
Carry out weekly or 50 hour
maintenance schedule
Carry out 200 hour maintenance
schedule
Pan feeder Change gear box oil Shell Omala 220 or
equivalent
Engine Change engine oil and oil filter.
Change fuel filter.

(4) 2500 Hour Maintenance Schedule

ITEM OPERATION REMARKS
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

Hydraulic oil a) Analyse oil sample,

check for condition and
contamination.
b) Change oil if necessary.

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 Maintenance 6

(5) Engine Maintenance Schedules

For further engine maintenance information, refer to the engine manufacturer‘s operation manual
supplied.

(6) CAT Engine Maintenance Schedules

(a) When Required

Object Job Remarks Sign
Battery Replace
Battery or battery cable Disconnect
Engine Clean
Engine air cleaner element (Dual Clean/replace
element)
Engine air cleaner element (single Inspect/Replace
element)
Engine air cleaner element (single Replace
element)
Fuel System Prime
Severe service application Check

(b) Daily
Object Job Remarks Sign
Coolant system coolant level Check
Engine air cleaner service indicator Inspect
Engine air precleaner Check/Clean
Engine oil level Check
Fuel system primary filter / water Drain
separator
Walk around inspection

(c) Weekly
Object Job Remarks Sign
Hoses and clamps Inspect/Replace

(d) Every 50 Service Hours or Monthly

Object Job Remarks Sign
Fuel tank water and sediment Drain

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6 Maintenance

(e) Every 250 Service Hours

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

(f) Every 500 Service Hours

Object Job Remarks Sign
Belt Inspect
Engine oil and filter Change
Fan clearance Check

(g) Every 500 Service Hours or 1 Year

Object Job Remarks Sign
Battery electrolyte Level Check
Cooling System Supplemental Coolant Test/Add
Additive (SCA)
Engine air cleaner element (Dual Clean/Replace
Element)
Engine air cleaner element (Single Inspect/Replace
Element)
Engine air cleaner element (Single Replace
Element)
Fuel system primary filter (water Replace
separator) element
Fuel system secondary filter Replace
Radiator Clean

(h) Every 1000 Service Hours

Object Job Remarks Sign
Water pump Inspect

(i) Every 1500 Service Hours

Object Job Remarks Sign
Engine crankcase breather element Replace

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 Maintenance 6

(j) Every 2000 Service Hours

Object Job Remarks Sign
Aftercooler Core Inspect
Engine Mounts Inspect
Starting Motor Inspect
Turbocharger Inspect

(k) Every 3000 Service Hours

Object Job Remarks Sign
Alternator Inspect
Alternator and Fan Belts Replace
Belt Tensioner Inspect
Radiator Pressure Cap Clean/Replace

(l) Every 3000 Service Hours or 2 Years

Object Job Remarks Sign
Cooling system coolant (DEAC) Change

(m) Every 4000 Service Hours

Object Job Remarks Sign
Aftercooler core Clean/Test

(n) Every 6000 Service Hours or 3 Years

Object Job Remarks Sign
Cooling System Coolant Extender (ELC) Add

(o) Every 12000 Service Hours or 6 Years

Object Job Remarks Sign
Cooling System Coolant (ELC) Change

(7) Volvo Engine Maintenance Schedules

(a) First Service Inspection

* After first 100 hours of service or within 180 days of the date of delivery, whichever comes first.

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6 Maintenance

Object Job Remarks Sign

Inspect with VODIA (diagnostic tool) Check
Coolant level and antifreeze mixture Check
Drive belts, belt tensioner and idler Check
wheels
Batteries, electrolyte level Check
Air filter Check
Fuel filter / water trap Check
Start and warn up engine
Engine, abnormal noises Check
Engine, oil / fuel / water leakage Check

(b) Daily
Object Job Remarks Sign
Coolant system coolant level Check
Engine air cleaner service indicator Inspect
Engine air precleaner Check/Clean
Engine oil level Check
Fuel system primary filter / water Drain
separator
Walk around inspection

(c) Weekly
Object Job Remarks Sign
Hoses and clamps Inspect/Replace

(d) Every 50 Service Hours or Monthly

Object Job Remarks Sign
Fuel tank water and sediment Drain

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 Maintenance 6

(e) Every 250 Service Hours

Object Job Remarks Sign
Coolant system coolant sample Obtain
Engine oil sample Obtain
Engine oil and filter change** Change*
** Due to the severe environment that most crushers and screens operate in the engine oil and
filter change should be every 250 hours of service. However if oil sampling and analysis is carried
out it is possible to increase the engine oil and filter change to every 500 hours of service.

(f) Every 500 Service Hours

Object Job Remarks Sign
Belt Check
Engine oil and filter Change
Fan clearance Check

(g) Every 500 Service Hours or 1 Year

Object Job Remarks Sign
Inspect with VODIA (diagnostic tool) Check
Coolant level and antifreeze mixture Check
Drive belts, belt tensioner and idler Check
wheels
Batteries, electrolyte level Check
Air filter Check
Fuel filter / water trap Check
Start and warn up engine
Engine, abnormal noises Check
Engine, oil / fuel / water leakage Check
Engine oil and oil filters Change
Engine, inspect hoses and cable Check
clamping
Engine, cleaning / painting Check

(h) Every 1500 Service Hours

Object Job Remarks Sign
Engine crankcase breather element Replace

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6 Maintenance

(i) Every 2000 Service Hours

Object Job Remarks Sign
Valve clearance Check
Drive belts Check
AdBlue DEF filter Replace
Turbocharger Inspect

(j) Every 800 Service Hours

Object Job Remarks Sign
Coolant VCS (Yellow)*** Change
*** Do not mix different types of coolant with each other.

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 Maintenance 6

(8) Lubrication
(a) Greasing Information

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..

Crusher Bearings
Grease the swing jaw and eccentric shaft bearings while the unit is still warm. Apply five strokes of
a standard grease gun to the grease nipples at the central greasing point. Use NGLI 02 grease with
EP additives if the crusher is operating in a temperature range from 4°C (40°F) to 38°C (100°F).
If the crusher is used for more than one 8 hour shift per day, grease amounts will need to be
adjusted accordingly. A properly greased crusher should show a slight amount of grease seepage
at the grease seal/shaft junction behind the flywheel after eight hours of use
Layshaft Bearings
• Layshaft bearings must be greased daily before machine is started.
• Layshaft bearings are greased from the central grease point located on the walkway.
• Layshaft bearings require 2 grease gun strokes daily.
Layshaft Internal Spline
• The layshaft internal spline is greased from the central grease point located on the walkway.
• The layshaft internal spline requires 1 grease gun stroke daily.
Conveyor Bearings
• Conveyor bearings require 2 grease gun strokes every 40 hours (weekly).

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6 Maintenance

(b) Lubricants and Fluids

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

• Pan Feeder Bearings ....................................................................... Shell Omala 220
• Crusher Bearings ............................................................................ Mobilith SHC 460
• Layshaft Bearings ............................................................................ Mobilith SHC 460
• Conveyor Bearings .................................................................................. EP2 Grease
• Engine Oil ........................................................................................15W/40 Engine oil
• Track Gearbox Oil ...........................................................................Renogear SG320
• Hydraulic Oil .............................................................................................. ISO VG 68
• General Grease .................................................................................................... EP2
Cold Weather Operation (Ambient Temp -4°C (40°F))
• Engine Oil .......................................................................................10W/30 Engine Oil
• Hydraulic Oil ............................................................................................... ISO VG 68
• Crusher Bearings ............................................................................. Mobilith SHC 007
• Layshaft Bearings............................................................................ Mobilith SHC 007.

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 Maintenance 6

6.5 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.
2. Stop the machine, Ref: “Machine Shut Down Procedure” on page 4-43.
3. Implement the lockout and tagout procedure, Ref: “Machine Lockout and Tag Out Procedure”
on page 4-43
4. Open the guard doors where necessary.
5. Clean the conveyor belts using a high pressure hose.
6. Check the belts for cuts, tears, rips or any other physical damage.

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6 Maintenance

(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.

2. Start machine and run conveyor.
3. Observe conveyor belt from a safe distance to check for belt slippage.
4. If belt slippage is present switch off machine and lock out and tag out.
5. 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
6. Start machine, run conveyor and check is slippage is still present.
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

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 Maintenance 6

(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.

2. Start machine and run conveyor.
3. Observe the conveyor from a safe distance and determine to which side the conveyor is
tracking off.
4. If belt is tracking off switch off machine and lock out and tag out.
5. If the conveyor is tracking off to the right side, operate the right side adjuster one turn at a
time until the belt tracks correctly.
6. If the conveyor is tracking off to the left side, operate the left side adjuster one turn at a time
until the belt tracks correctly.
7. Start machine, run conveyor and check if belt is still tracking off.
8. If belt is still tracking off then switch off, lock out and tag out and repeat steps 1-7 until
tracking correctly..

Figure 6.3 - Conveyor Belt Tensioner

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6 Maintenance

6.6 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.

6.7 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.
2. Position the machine on solid and level ground and drive 2 metres (2 yards) minimum in a
forward direction, track idler roller leading.
3. Shut down the machine.
4. Implement the lockout and tagout procedure.
5. 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.
6. Measure the maximum amount of track sag from the high point of the track to the bottom of
the ‘straight edge’, Ref: Figure 6.4.
7. Correctly adjusted, the sag should be Between 5mm - 15mm.

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 Maintenance 6

Figure 6.4 - Measuring Track Tension

6.8 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.
2. Shut down the machine, Ref: “4.10 Machine Shut Down Procedure” on page 4-43.
3. Implement the lockout and tagout procedure, Ref: “4.11 Machine Lockout and Tag Out
Procedure” on page 4-43.
4. 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 6.5.
6. When the correct track tension has been measured, turn the relief valve clockwise to tighten
and then clean away all trace of expelled grease.
7. 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 6.5 - Track Tensioner

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 Maintenance 6

6.9 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 6.6.
2. Ensure machine is switched off, locked out and tagged out. Remove ignition key, carry it
with you.
3. Thoroughly clean around both plugs removing all potential contaminants.
4. Remove both plugs.
5. Fill the oil through the upper hole (item 1) until it runs out through the lower hole (item 2),
Ref: Figure 6.6.
6. Wait a few moments until any trapped air has escaped and then re-check the level.
7. Add more oil if necessary.

Figure 6.6 - Gearbox Oil Level Fill Position

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6 Maintenance

(2) Draining Gearbox Oil

1. Move the machine to a level surface and bring the oil fill (1) and oil drain holes (2) to the
position shown in Figure 6.7.

Figure 6.7 - Draining Gearbox Oil

2. Ensure machine is switched off, locked out and tagged out. Remove ignition key, carry it
with you.
3. Thoroughly clean around both plugs removing all potential contaminants.
4. 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.
5. Move the machine to bring the plugs to the fill position shown in Figure 6.6.
6. Re-fill the oil as per the procedure in “Checking and Filling Gearbox Oil” on page 6-20).

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 Maintenance 6

6.10 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 Oil

1. Drain hydraulic oil through bung on bottom of hydraulic tank.
2. Remove existing return line filters and dispose of.
3. Fit temporary 5 micron return line filters for oil cleansing.
4. Check and replace hydraulic tank air filter / dryer if required.
5. Connect filling pipe direct to filling port on return manifold Ref: item 2, Figure 6.8.
6. NOTE: This is highest point on hydraulic system and will ensure that all oil is pre-filtered
through return line filters. Filling through the filling port also ensures that the main pump
suction lines are filled.
7. Temporarily remove test point on pump connector block Ref: item 1, Figure 6.8 during filling
process to let out trapped air. This prevents cavitation and damage to main pump on startup.
8. Fill until oil level reaches full level on tank gauge.
9. Startup up machine and operate all conveyors and feeder for 1 hour to flush hydraulic system.
10. NOTE: Do not operate crusher drive during flushing process as excessive back pressure is
caused by 5 micron flushing filters which can damage crusher drive pump and motor.
11. Remove 5 micron flushing filters and store for re-use. (Flushing filters may be used 5 times).
12. Fit regular 10 micron return line filters.
13. Check and top up hydraulic tank as required.
14. Machine can now be operated as normal.

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6 Maintenance

Figure 6.8 - Filling Hydraulic Oil

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 Maintenance 6

(2) Changing the Return Line Filter

WARNING
Wear personal protective equipment.
Switch off machine and implement the lockout and tagout procedure.
Allow engine to cool before beginning filter change.

NOTICE
Cleanliness is essential when checking, filling or replacing the hydraulic oil. Only use new clean
oil in clean containers and fillers and ensure area is free from dirt before beginning work.
1. Observe all safety warnings.
2. Remove hydraulic filter cap by undoing the 4 securing bolts Ref: items 1 Figure 6.9
3. Remove the hydraulic filter element located inside the filter housing Ref: item 2 Figure 6.9
4. Replace filter element.
5. Refit filter cap with securing bolts.

Figure 6.9 - Hydraulic Filter

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6 Maintenance

(3) Changing the Hydraulic Tank Breather Filter

WARNING
Wear personal protective equipment.
Switch off machine and implement the lockout and tagout procedure.
Allow engine to cool before beginning filter change.
The hydraulic tank air filter is mounted on top of hydraulic tank inside powerunit Ref: Figure 6.10.
This filter is used to dry the air entering the hydraulic system.
1. The crystals inside filter will change from yellow to green to indicate the filter needs to be
replaced.
2. To remove filter pull it vertically out of its mounting socket.
3. Replace with new filter.

Figure 6.10 - Hydraulic Tank Breather

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 Maintenance 6

6.11 Changing Air Filter Elements

1. Observe all safety warnings.
2. Ensure machine is switched off, locked out and tagged out.
3. Release the 4 tension clips. (Item 4), Ref: Figure 6.11.
4. Remove cover. (Item 5), Ref: Figure 6.11.
5. Carefully remove outer filter (Item 3) and inner filter (Item 2).
6. Discard the elements and replace with new items
7. Reset the air filter blockage indicator Ref: Figure 6.1

Figure 6.11 - Engine Air Filter

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6 Maintenance

6.12 Replacing Crusher Swing Jaw Die

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.

NOTICE
If the jaw die is only worn on one end it can turned through 180° and reused in the crusher. If
wear is present on both ends, replace the die.
1. Retract the swing jaw completely using the hydraulic controls see Chapter 4.
2. Ensure that engine is switched off, locked out and tagged out ref; “Machine Lockout and Tag
Out Procedure” on page 4-43.
3. Install 2 jaw die lift hooks Ref: item 1 Figure 6.12 in to the upper pockets of the manganese die.
4. Attach lift chains or harness capable of lifting at least 1000Kgs (2200 lbs) total.
5. Apply slight lift pressure to the hooks to maintain die and hooks in position while the retaining
wedge is removed.
6. Remove the 3 bolts Ref: item 2 Figure 6.12 holding the die clamp to the swing jaw.
7. Install a lift strap through the outer 2 bolt holes on the clamp to lift it clear. Note that clamp
weighs 58Kgs (128lbs).
8. If the clamp or retaining bolts show signs of substantial wear, replace the parts.
9. Examine the back side of the new jaw die for any damage. Clean the mating surfaces and
remove any nicks or burrs. Remove any obvious high spots with a grinder.
10. Lift the new jaw die back into place using the lift hooks.
11. Reinstall the die clamp. If the mounting holes do not line up, check the jaw die is seated
properly.
12. Lube the threads of the retaining bolts with anti seize compound and install.
13. Working in an alternating pattern torque retaining bolts to 2002Nm (1477 Ft lbs).

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 Maintenance 6

Figure 6.12 - Crusher Swing Jaw

6.13 Replacing Crusher Fixed Jaw Die

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.

NOTICE
If the jaw die is only worn on one end it can turned through 180° and reused in the crusher. If
wear is present on both ends, replace the die.
1. Retract the swing jaw completely using the hydraulic controls see Chapter 4
2. Ensure that engine is switched off, locked out and tagged out ref; “Machine Lockout and Tag
Out Procedure” in section 4.
3. Slacken and remove the 2 bolts, washer and sleeve from both side of the jaw die securing
bar, see figure Figure 6.13.
4. Fit the die removal tool (item 1) to the end of the die securing bar, see figure Figure 6.14.
5. With the die removal tool fitted to the bar use a hammer to tap the removal tool and drive
out the jaw die securing wedge (items 1, Figure 6.15) on the opposite side.

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6 Maintenance

6. Remove the tool and fit to opposite side of die securing bar and repeat to remove second
wedge.
7. Install 2 jaw die lift hooks in to the upper pockets of the jaw die.
8. Attach lift chains or harness capable of lifting at least 1000Kgs (2200 lbs) total and carefully
remove jaw die.
9. When reinstalling the jaw die set the wedges to their greatest distance apart then carefully
lower jaw die into position.
10. When jaw die is in position refit the sleeves washers and bolts to both sides of the die
securing bar.
11. Tighten the bolts at both side of the bar in increments to drive the securing wedges into
position. Do not fully tighten one side then the other, work in increments on both side to make
sure the wedges are tightened evenly

Figure 6.13 - Crusher Fixed Jaw Hardware

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 Maintenance 6

Figure 6.14 - Die Removal Tool

Figure 6.15 - Die Wedges

6.14 Replacing Crusher Cheek Plates

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

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6 Maintenance

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

NOTICE
Due to clearance issues it is easier to remove and replace side cheek plates when the fixed jaw
die is removed.
Cheek plates on 44x26 jaw crusher are NOT reversible.
Cheek plates should be checked at each swing and stationary jaw die change.
Check head of retaining bolts for excessive wear, replace if necessary.
If Cheek plate thickness is worn to less than 12mm ( ½”) at any point, replace the cheek plates
1. Retract the swing jaw completely using the hydraulic controls see Chapter 4
2. Ensure that engine is switched off, locked out and tagged out ref; “Machine Lockout and Tag
Out Procedure” on page 4-43.
3. Completely remove the upper bolts Ref: item 2 Figure 6.16 holding cheek plates item 3 Fig.
44 to the crusher frame sides.
4. Loosen, but do not remove the lower bolt on the cheek plate. Tip the top of the plate away
from the crusher chamber side to allow access for lift strap.
5. Install a lift strap Ref: item 1 Figure 6.16 through the top bolt holes on the cheek plate to lift
it clear. Note that larger cheek plate weighs 79Kgs (174lbs).
6. Support the cheek plate weight on the lifting sling then remove the lower bolt.
7. Lift cheek plate clear of crusher.
8. Reverse steps 4 to 8 to reinstall the new cheek plate.
9. Use anti seize compound on all bolt threads.
10. Alternately torque cheek plate mounting bolts to 571Nm (425 Ft. lbs)
11. Re torque all nuts after first 3 days of operation.
12. Use same procedure to remove lower cheek plates.

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 Maintenance 6

Figure 6.16 - Crusher Cheek Plates

6.15 Replacing Pitman Wear Plate

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.

NOTICE
If the Pitman wear plate is damaged or excessively worn on the bottom edge, it should be replaced
at the same time as the swing jaw die.
1. Retract the swing jaw completely using the hydraulic controls see Chapter 4
2. Ensure that engine is switched off, locked out and tagged out ref; “Machine Lockout and Tag
Out Procedure” on page 4-43.
3. Loosen the 6 retaining bolts Ref: Item 2 Figure 6.17 but do not remove.
4. Using a pry bar, pry the wear plate forward until it separates from the face of the Pitman.
Replace the outer 2 mounting bolts with lift hooks or eye bolts Ref: item 3 Figure 6.17.

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6 Maintenance

5. Install a lift strap Ref: item 4 Figure 6.17 through the top bolt holes on the cheek plate to lift
it clear. Note that pitman wear plate weighs 85Kgs (187lbs).
6. Ensure mating surfaces are clean and free of nick or burrs. Check internal threads on mounting
holes for damage or dirt. Clean and re-tap if necessary
7. Lift new pitman wear plate into position.
8. Coat the retaining bolts with medium thread lock and install
9. Torque all bolts to 330Nm (246 Ft. lbs)
10. Re torque all bolts after first 3 days of operation

Figure 6.17 - Crusher Pitman Plate

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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 Officer Print Name
Sign Name
Date

Return Completed Forms To: McCloskey Interna onal Ltd,

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

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Appendix A

Intentionally Left Blank

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 Appendix B

Appendix B

Table of Content
(1) Volvo Engine Fault Codes ........................................................................ B-2
(2) Cat Engine Fault Codes ......................................................................... B-16
(3) Machine Fault Codes .............................................................................. B-19
(4) Schematics ............................................................................................. B-21

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Appendix B

(1) Volvo Engine Fault Codes

SPN Description FMI J1939 Fault
J1939 J1939 SPN FMI J1939 Description Error
Engine Throttle
51 Position 3 Voltage Low SC+
Engine Throttle
51 Position 5 Current Low OC, SC-
Engine Throttle Not Responding
51 Position 7 Properly Mechanical fault
Engine Throttle Only J2012-WWH:
51 Position 12 Failure Incorrect sensor mounted
Engine Throttle
51 Position 13 Calibration Required Out of calibration
Engine Fuel
94 Delivery Pressure 1 Severe Low Range Pressure critically low
Engine Fuel
94 Delivery Pressure 3 Open Circuit SC+M, OCG
Engine Fuel
94 Delivery Pressure 5 Current Low OC5S, SC-M, OCM
Engine Fuel Only J2012-WWH:
94 Delivery Pressure 12 Failure Incorrect sensor mounted
Engine Fuel
94 Delivery Pressure 18 Shutdown Low pressure
Water In Fuel
97 Indicator 1 0 Severe High Range Water in fuel
98 Engine Oil Level 1 Severe Low Range Critically below range
98 Engine Oil Level 4 Short To Ground SC-pos, OCpos
98 Engine Oil Level 5 Current Low SC+pos, OCneg
98 Engine Oil Level 18 Shutdown Moderately below range
Engine Oil
100 Pressure 1 Severe Low Range Critically below range
Engine Oil
100 Pressure 3 Open Circuit SC+M, OCG
Engine Oil
100 Pressure 4 Short To Ground SCL
Engine Oil
100 Pressure 5 Current Low OC5S, SC-M, OCM
Engine Oil Only J2012-WWH:
100 Pressure 12 Failure Incorrect sensor mounted
Engine Oil
100 Pressure 18 Shutdown Moderately below range
Engine Crankcase
101 Pressure 0 severe high range Critically Above Range
Engine Crankcase
101 Pressure 3 voltage high SC+M, OCG
Engine Crankcase
101 Pressure 4 voltage low SC-

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 Appendix B

Engine Crankcase
101 Pressure 5 Current Low OC5S, SC-M, OCM
Engine Crankcase Only J2012-WWH:
101 Pressure 12 Failure Incorrect sensor mounted
Engine Intake
Manifold #1
102 Pressure 0 severe high range Critically above range
Engine Intake
Manifold #1
102 Pressure 3 Open Circuit SC+M, OCG
Engine Intake
Manifold #1
102 Pressure 4 Short To Ground SC-
Engine Intake
Manifold #1
102 Pressure 5 Current Low OC5S, SC-M, OCM
Engine Intake
Manifold #1 Only J2012-WWH:
102 Pressure 12 Failure Incorrect sensor mounted
Engine Intake
Manifold #1
102 Pressure 16 moderate high range Moderately above range
Engine
Turbocharger 1 Missing sensor signal
103 Speed 9 abnormal update rate (SC+,SC-,OC)
Engine Intake
Manifold 1
105 Temperature 0 severe high range Critically above range
Engine Intake
Manifold 1
105 Temperature 3 Open Circuit SC+
Engine Intake
Manifold 1
105 Temperature 4 Short To Ground SC-M
Engine Intake
Manifold 1
105 Temperature 5 Current Low SC+M, OC
Engine Intake
Manifold 1 Only J2012-WWH:
105 Temperature 12 Failure Incorrect sensor mounted
Engine Intake
Manifold 1
105 Temperature 16 moderate high range Moderately above range
Engine Air Filter
1 Differential
107 Pressure 0 severe high range Critically Above range
Engine Air Filter
1 Differential
107 Pressure 3 voltage high SC+M

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Appendix B

Engine Air Filter

1 Differential
107 Pressure 4 voltage low SC-M
Engine Air Filter
1 Differential Only J2012-WWH:
107 Pressure 5 Current Low Incorrect sensor mounted
Engine Air Filter
1 Differential Only J2012-WWH:
107 Pressure 12 Failure Incorrect sensor mounted
Barometric
108 Pressure 3 Open Circuit SC+M
Barometric
108 Pressure 5 Current Low OC
Barometric Only J2012-WWH:
108 Pressure 12 Failure Incorrect sensor mounted
Engine Coolant
110 Temperature 0 shutdown Critically above range
Engine Coolant
110 Temperature 3 Open Circuit SC+
Engine Coolant
110 Temperature 4 Short To Ground SC-M
Engine Coolant
110 Temperature 5 Current Low SC+M,OC
Engine Coolant Only J2012-WWH:
110 Temperature 12 Failure Incorrect sensor mounted
Engine Coolant
110 Temperature 16 Derate Moderately above range
Engine Coolant SC-M, Critically below
111 Level 1 Shutdown Range
Engine Coolant
111 Level 3 Open Circuit SC+M
Engine Coolant
111 Level 4 Short To Ground SC-M
Engine Coolant
111 Level 5 Current Low OC
Engine Coolant Only J2012-WWH:
111 Level 12 Failure Incorrect sensor mounted
Engine Coolant
111 Level 18 Derate Moderately below range
Engine Exhaust
131 Back Pressure 3 voltage high SC+
Engine Exhaust
131 Back Pressure 5 current low OC, SC-
Engine Exhaust Only J2012-WWH:
131 Back Pressure 12 failure Incorrect sensor mounted
Engine Injector
Metering Rail 1 Rail Pressure Critically
157 Pressure 0 severe high range High

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 Appendix B

Engine Injector
Metering Rail 1 Rail Pressure Critically
157 Pressure 1 Severe Low Range Low
Engine Injector
Metering Rail 1 OCM, OC5S, OCG,
157 Pressure 5 current low SC+M
Engine Injector
Metering Rail 1 Not Responding Stuck/Change or rate too
157 Pressure 7 Properly low
Engine Injector
Metering Rail 1 Rail Pressure build up
157 Pressure 14 Special Instruction failure
Engine Injector
Metering Rail 1 Rail Pressure Moderately
157 Pressure 16 moderate high range High
Engine Air Inlet
172 Temperature 4 voltage low SC-M
Engine Air Inlet
172 Temperature 5 Current Low SC+M, OC
Engine Exhaust
173 Gas Temperature 0 severe high range Critically Above range
Engine Exhaust
173 Gas Temperature 16 moderate high range Moderately Above range
Engine Oil
175 Temperature 1 0 shutdown Critically Above range
Engine Oil
175 Temperature 1 3 voltage high SC+
Engine Oil
175 Temperature 1 4 voltage low SC-M
Engine Oil
175 Temperature 1 5 current low SC+M, OC
Engine Oil
175 Temperature 1 12 Failure Plausibility
Engine Oil
175 Temperature 1 16 moderate high range Moderately Above range
190 Engine Speed 0 shutdown Above range
Engine Exhaust
Gas Recirculation
Differential
411 Pressure 3 voltage high SC+M, OCG
Engine Exhaust
Gas Recirculation
Differential
411 Pressure 5 current low OC5S, SC-M, OCM
Engine Exhaust
Gas Recirculation
412 Temperature 4 voltage high SC-M

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Appendix B

Engine Exhaust
Gas Recirculation
412 Temperature 5 current low SC+M, OCM, OCG
Engine Start
626 Enable Device 1 4 voltage low SC-
ECU internal memory
628 Program Memory 2 signal erratic checksum error
628 Program Memory 14 Special Instruction Special instruction
Engine Position Not Responding
636 Sensor 7 Properly Phase error
Engine Position
636 Sensor 8 signal abnormal Noicy, OC
Engine Position MS from cam sensor
636 Sensor 9 abnormal update rate (SC+,SC-,OC)
Engine Timing Intermittent or weak
637 Sensor 2 signal erratic signal
Engine Timing
637 Sensor 8 signal abnormal Noicy
Engine Timing MS from crank sensor
637 Sensor 9 abnormal update rate (SC+,SC-,OC)
J1939 Network
#1, Primary
Vehicle Network
( previously SAE SC+, SC– or OC on either
639 J1939 Data Link) 2 signal erratic line.
Engine Variable
Geometry
Turbocharger Over range (Desired
641 Actuator #1 0 shutdown position)
Engine Variable
Geometry
Turbocharger
641 Actuator #1 2 signal erratic OCM, SC+M, SC-M
Engine Variable
Geometry
Turbocharger
641 Actuator #1 3 voltage high Motor SCH
Engine Variable
Geometry
Turbocharger
641 Actuator #1 5 current low Motor OC, SCL
Engine Variable
Geometry
Turbocharger
641 Actuator #1 6 current high Motor over current
Engine Variable
Geometry
Turbocharger Missing signal from VSRA
641 Actuator #1 9 abnormal update rate on Engine Subnet

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 Appendix B

Engine Variable
Geometry
Turbocharger Missing signal from VSRA
641 Actuator #1 9 abnormal update rate on Engine Subnet
Engine Variable
Geometry
Turbocharger Missing signal from VSRA
641 Actuator #1 9 abnormal update rate on Engine Subnet
Engine Variable
Geometry
Turbocharger
641 Actuator #1 11 derate Motor OC
Engine Variable
Geometry
Turbocharger
641 Actuator #1 17 warning High temperature
Engine Fan Clutch
Output Device
647 Driver 3 voltage high SC+
Engine Fan Clutch
Output Device
647 Driver 4 voltage low SC-
Engine Fan Clutch
Output Device
647 Driver 5 current low OC
SC+, Low Side (SV/NCV
Engine Injector on EUI and Shorted load
651 Cylinder #01 3 voltage high on CR)
Engine Injector
651 Cylinder #01 4 voltage low SC-, High Side
SC+, SC-, OC, High Side
SV/NCV, SC-, Low Side
SV/NCV on EUI.
Engine Injector SC+ HS, OC HS, OC LS,
651 Cylinder #01 5 current low SC- LS on CR.
SC+, Low Side (SV/NCV
Engine Injector on EUI and Shorted load
652 Cylinder #02 3 voltage high on CR)
Engine Injector
652 Cylinder #02 4 voltage low SC-, High Side
SC+, SC-, OC, High Side
SV/NCV, SC-, Low Side
SV/NCV on EUI.
Engine Injector SC+ HS, OC HS, OC LS,
652 Cylinder #02 5 current low SC- LS on CR.
SC+, Low Side (SV/NCV
Engine Injector on EUI and Shorted load
653 Cylinder #03 3 voltage high on CR)

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Appendix B

Engine Injector
653 Cylinder #03 4 voltage low SC-, High Side
SC+, SC-, OC, High Side
SV/NCV, SC-, Low Side
SV/NCV on EUI.
Engine Injector SC+ HS, OC HS, OC LS,
653 Cylinder #03 5 current low SC- LS on CR.
SC+, Low Side (SV/NCV
Engine Injector on EUI and Shorted load
654 Cylinder #04 3 voltage high on CR)
Engine Injector
654 Cylinder #04 4 voltage low SC-, High Side
SC+, SC-, OC, High Side
SV/NCV, SC-, Low Side
SV/NCV on EUI.
Engine Injector SC+ HS, OC HS, OC LS,
654 Cylinder #04 5 current low SC- LS on CR.
SC+, Low Side (SV/NCV
Engine Injector on EUI and Shorted load
655 Cylinder #05 3 voltage high on CR)
Engine Injector
655 Cylinder #05 4 voltage low SC-, High Side
SC+, SC-, OC, High Side
SV/NCV, SC-, Low Side
SV/NCV on EUI.
Engine Injector SC+ HS, OC HS, OC LS,
655 Cylinder #05 5 current low SC- LS on CR.
Engine Injector
656 Cylinder #06 3 voltage high SC+, Low Side SV/NCV
Engine Injector
656 Cylinder #06 4 voltage low SC-, High Side
SC+, SC-, OC, High Side
SV/NCV, SC-, Low Side
SV/NCV on EUI.
Engine Injector SC+ HS, OC HS, OC LS,
656 Cylinder #06 5 current low SC- LS on CR.
Engine Starter
677 Motor Relay 3 voltage high SC+
Engine Starter
677 Motor Relay 4 voltage low SC-
Engine Starter
677 Motor Relay 5 current low OC
Engine Injection
Control Pressure
679 Regulator 3 voltage high SCH
Engine Injection
Control Pressure
679 Regulator 4 voltage low SC- HS

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Engine Injection
Control Pressure
679 Regulator 5 current low OC, SC+ HS
Engine Injection
Control Pressure Not Responding
679 Regulator 7 Properly Mprop stuck open
Engine Inlet Air
729 Heater Driver #1 4 voltage low SC-
Engine Inlet Air
729 Heater Driver #1 5 current low OC
Engine Inlet Air
729 Heater Driver #1 6 current high SC+
Engine Inlet Air Not Responding
729 Heater Driver #1 7 Properly SC-
Engine Inlet Air Only J2012-WWH:
729 Heater Driver #1 12 Failure Incorrect sensor mounted
Engine Auxiliary
970 Shutdown Switch 3 voltage high SC+
Engine Auxiliary
970 Shutdown Switch 4 voltage low SC-
Engine Auxiliary
970 Shutdown Switch 5 current low OC
Engine Auxiliary
970 Shutdown Switch 11 system fault Root cause not known
Engine Auxiliary Only J2012-WWH:
970 Shutdown Switch 12 failure Incorrect sensor mounted
Engine
(Compression)
1072 Brake Output #1 3 voltage high SC+
Engine
(Compression)
1072 Brake Output #1 4 voltage low SC-
Engine
(Compression)
1072 Brake Output #1 5 current low OC
Engine (Exhaust)
1074 Brake Output 3 voltage high SC+
Engine (Exhaust)
1074 Brake Output 4 voltage low SC-
Engine (Exhaust)
1074 Brake Output 5 below normal OC
Engine
Turbocharger 1
1188 Wastegate Drive 3 voltage high SC+
Engine
Turbocharger 1
1188 Wastegate Drive 4 voltage low SC-

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Engine
Turbocharger 1
1188 Wastegate Drive 5 current low OC
SC+, SC– or OC on either
1231 J1939 Network #2 2 signal erratic line.
Engine Fuel
1239 Leakage 1 14 Special Instruction Minor leakage
Engine Fuel Pump
Pressurizing Not Responding
1347 Assembly #1 7 Properly Mechanical problem
1485 ECM Main Relay 3 voltage high SCH
1485 ECM Main Relay 4 voltage low SCL
1485 ECM Main Relay 5 current low OC
MS, SC+M, SC-M, OCM,
1639 Fan Speed 3 voltage high OCG
SC+, SC– or OC on either
1668 J1939 Network #4 2 signal erratic line.
Aftertreatment 1
SCR Catalyst Tank
1761 Level 12 Failure Electrical, Rationality
Aftertreatment 1
SCR Catalyst Tank
1761 Level 12 Failure Electrical, Rationality
Aftertreatment 1
SCR Catalyst Tank Level low, warning to
1761 Level 17 warning driver
Aftertreatment 1
SCR Catalyst Tank
1761 Level 18 moderate low range Level low, stop dosing
Source Address
2017 17 9 abnormal update rate Missing VP70 from DCU
Source Address
2036 36 9 abnormal update rate Missing VP70 from DCU
Engine Exhaust
Gas Recirculation
(EGR) Mass Flow
2659 Rate 18 moderate low range Below Range
Engine Exhaust
Gas Recirculation
(EGR) Valve
2791 Control 2 signal erratic Dynamic Rangefault
Engine Exhaust
Gas Recirculation
(EGR) Valve
2791 Control 3 voltage high SCH

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Engine Exhaust
Gas Recirculation
(EGR) Valve
2791 Control 3 voltage high Stuck valve, H-bridge SC-
Engine Exhaust
Gas Recirculation
(EGR) Valve
2791 Control 4 voltage low SCL
Engine Exhaust
Gas Recirculation
(EGR) Valve
2791 Control 5 current low Motor Terminal Open
Engine Exhaust
Gas Recirculation
(EGR) Valve
2791 Control 5 current low OC
Engine Exhaust
Gas Recirculation
(EGR) Valve
2791 Control 6 current high Over Current
Engine Exhaust
Gas Recirculation
(EGR) Valve Not Responding
2791 Control 7 Properly Valve Stuck
Engine Exhaust
Gas Recirculation
(EGR) Valve
2791 Control 9 abnormal update rate Missing signal
Engine Exhaust
Gas Recirculation
(EGR) Valve
2791 Control 11 system fault Feedback Fault
Engine Exhaust
Gas Recirculation
(EGR) Valve
2791 Control 12 Failure Sensor Error
Engine Exhaust
Gas Recirculation
(EGR) Valve
2791 Control 17 warning High Temp Termistor
Aftertreatment 1
Diesel Exhaust
Fluid Tank
3031 Temperature 12 Failure Electrical, Rationality
Aftertreatment 1
Selective Catalytic
Reduction Intake
3216 Nox 2 signal erratic Plausibility
Aftertreatment 1
3216 Intake NOx 3 voltage high SC NOx signal (WP23)

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Aftertreatment 1
3216 Intake NOx 5 current low OC NOx signal (WP23)
Abnormal update,
Aftertreatment 1 Missing signal from NOX1
3216 Intake NOx 9 abnormal update rate on Engine Subnet (WP23)
Aftertreatment 1
3216 Intake NOx 11 system fault Removed
Aftertreatment 1
3216 Intake NOx 12 failure Incorrect value
Aftertreatment 1
3216 Intake NOx 13 calibration required Incorrect value
Aftertreatment 1 MS from sensor due to
3216 Intake NOx 14 Special Instruction Vbatt (WP23)
Aftertreatment 1
3226 Outlet NOx 2 signal erratic Plausibility / Stuck Low
Aftertreatment 1
3226 Outlet NOx 3 voltage high SC NOx signal (WP23)
Aftertreatment 1
3226 Outlet NOx 5 current low OC NOx signal (WP23)
Aftertreatment 1 Not Responding
3226 Outlet NOx 7 Properly Removed
Abnormal update,
Aftertreatment 1 Missing signal from NOX2
3226 Outlet NOx 9 abnormal update rate on Engine Subnet (WP23)
Aftertreatment 1
3226 Outlet NOx 12 failure Incorrect value
Aftertreatment 1
3226 Outlet NOx 13 calibration required Incorrect value
Aftertreatment 1 MS from sensor due to
3226 Outlet NOx 14 Special Instruction Vbatt (WP23)
Aftertreatment
1 Exhaust Gas
3241 Temperature 1 19 network data error Electrical, Rationality
Aftertreatment 1
Diesel Exhaust
3361 Fluid Dosing Unit 12 Failure Stop dosing
Aftertreatment 1
Diesel Exhaust
3361 Fluid Dosing Unit 12 Failure Electrical, Rationality
Aftertreatment 1
SCR Catalyst Tank
3364 Reagent Quality 2 signal erratic Plausibility
Aftertreatment 1
SCR Catalyst Tank
3364 Reagent Quality 12 Failure Electrical, Rationality
Aftertreatment 1
Diesel Exhaust
3364 Fluid Tank Quality 17 warning Too Low

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 Appendix B

Engine Throttle
Actuator 1 Control
3464 Command 3 voltage high SC+
Engine Throttle
Actuator 1 Control
3464 Command 4 voltage low SC-
Engine Throttle
Actuator 1 Control
3464 Command 5 current low OC
Engine Throttle
Actuator 1 Control Not Responding
3464 Command 7 Properly Stuck Low
Engine Throttle
Actuator 1 Control abnormal rate of
3464 Command 10 chnage Slow response
Engine Throttle
Actuator 1 Control
3464 Command 12 failure Stuck high
Engine Fuel
3468 Temperature 2 2 signal erratic Plausability
Engine Fuel
3468 Temperature 2 4 voltage low SCL
Engine Fuel
3468 Temperature 2 5 current low OC
Engine Fuel Hp fuel pump temperature
3468 Temperature 2 16 moderate high range too high
Sensor supply
3509 voltage 1 3 voltage high Above range
Sensor supply
3509 voltage 1 4 voltage low below range
Sensor supply
3510 voltage 2 3 voltage high Above range (SCH)
Sensor supply
3510 voltage 2 4 voltage low below range (SCL)
Sensor supply
3511 voltage 3 3 voltage high Above range (SCH)
Sensor supply
3511 voltage 3 4 voltage low below range (SCL)
Engine Exhaust
Gas Recirculation
(EGR) Cooler Not Responding
4752 Efficiency 7 Properly Low efficiency
Aftertreatment 1
Diesel Exhaust
5394 Fluid Dosing Valve 12 Failure Electrical, Rationality

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Engine Exhaust
Gas Recirculation
1 Actuator 1 abnormal rate of
5765 Temperature 10 chnage Temp stuck
Fuel Pressure
520244 Relief Valve 3 voltage high SC+, Low Side EPRV
Fuel Pressure
520244 Relief Valve 4 voltage low SC- HS
OC, SC+ HS
or
SC+, SC-, OC, High Side
Fuel Pressure EPRV, SC-, Low Side SV/
520244 Relief Valve 5 current low NCV
Fuel Pressure Not Responding
520244 Relief Valve 7 Properly ePRV stuck closed
Fuel Pressure PRV has been activated
520244 Relief Valve 12 Failure too many times
Fuel Pressure Rail pressure positive
Regulator Closed deviation in closed loop
520245 Loop Operation 0 severe high range control mode
Fuel Pressure Rail pressure negative
Regulator Closed deviation in closed loop
520245 Loop Operation 1 severe low range control mode
Rail pressure controller
Fuel Pressure integral part too big
Regulator Closed (possible high pres circ
520245 Loop Operation 16 moderate high range leakage)
Fuel Pressure
Regulator Closed Rail pressure controller
520245 Loop Operation 18 moderate low range integral part too low
Engine Control
Module Internal
Battery Potential
520335 Sensor 5 current low Too high
Starter Relay
520395 Circuit High Side 3 voltage high SC+ HS
Starter Relay
520395 Circuit High Side 4 voltage low SC- HS
Starter Relay
520395 Circuit High Side 5 current low OC HS
Lost
Communication
with Reductant
Control Module on Missing signal from ACM
520416 Engine Subnet 9 abnormal update rate on Engine Subnet
Gate Interlock
520552 Valve 3 voltage high SC High
Gate Interlock
520552 Valve 4 voltage low SC Low

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 Appendix B

Gate Interlock
520552 Valve 5 current low open circuit

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Appendix B

(2) Cat Engine Fault Codes

Error Code Failure Mode Index Description
1074 short to +batt Retarder Solenoid Current
1074 calibration required Retarder Solenoid Current
626 short to +batt Ether Injection Control Solenoid
626 calibration required Ether Injection Control Solenoid
678 short to ground 8 Volt DC Supply
678 abnormal rate of change 8 Volt DC Supply
620 short to ground 5 Volt Sensor DC Supply
1079 short to ground 5 Volt Sensor DC Supply
620 abnormal rate of change 5 Volt Sensor DC Supply
1079 abnormal rate of change 5 Volt Sensor DC Supply
100 short to ground Engine Oil Pressure
100 abnormal rate of change Engine Oil Pressure
100 signal erratic Engine Oil Pressure
102 short to ground Boost Pressure Sensor
102 abnormal rate of change Boost Pressure Sensor
102 signal erratic Boost Pressure Sensor
108 short to ground Atmospheric Pressure
108 abnormal rate of change Atmospheric Pressure
110 short to ground Engine Coolant Temperature
110 abnormal rate of change Engine Coolant Temperature
91 system fault Throttle Position
91 warning Throttle Position
190 warning Engine Speed
grounded/current above
723 Secondary Engine Speed
normal
190 below normal Engine Overspeed
190 short to ground Engine Overspeed
94 abnormal rate of change Fuel Pressure
94 short to ground Fuel Pressure
105 voltage high Intake Manifold Air Temp
105 system fault Intake Manifold Air Temp
164 Injector short Injector Actuation Pressure
164 derate Injector Actuation Pressure
164 above normal Injector Actuation Pressure
164 short to +batt Injector Actuation Pressure
637 calibration required Engine Timing
100 calibration required Low Engine Oil Pressure
100 above normal Low Engine Oil Pressure
100 open/short to +batt Low Engine Oil Pressure
729 open/short to +batt Air Inlet Heater Relay
729 shutdown Air Inlet Heater Relay

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grounded/current above
168 System
normal
168 Injector open circuit System
168 below normal System
630 Injector short Check Programmable Parameters
639 derate J1939 Data Link Communications
110 above normal High Engine Coolant Temperature
grounded/current above
110 High Engine Coolant Temperature
normal
110 Injector short High Engine Coolant Temperature
111 derate Low Engine Coolant Level
grounded/current above
111 Low Engine Coolant Level
normal
111 below normal Low Engine Coolant Level
grounded/current above
94 High Fuel Pressure
normal
94 Injector open circuit High Fuel Pressure
94 below normal High Fuel Pressure
1636 short to ground Low Fuel Pressure
1636 abnormal rate of change Low Fuel Pressure
grounded/current above
174 High Inlet Air Temperature
normal
174 Injector open circuit High Inlet Air Temperature
174 below normal High Inlet Air Temperature
grounded/current above
441 High Fuel Temperature
normal
441 Injector open circuit High Fuel Temperature
441 below normal High Fuel Temperature
1836 short to ground High Auxiliary Temperature
1836 abnormal rate of change High Auxiliary Temperature
grounded/current above
1837 Auxiliary Temperature Sensor
normal
1837 Injector open circuit Auxiliary Temperature Sensor
1837 below normal Auxiliary Temperature Sensor
1835 short to ground High Auxiliary Pressure
1835 abnormal rate of change High Auxiliary Pressure
651 short to +batt Cylinder #1
651 calibration required Cylinder #1
652 short to +batt Cylinder #2
652 calibration required Cylinder #2
653 short to +batt Cylinder #3
653 calibration required Cylinder #3
654 short to +batt Cylinder #4
654 calibration required Cylinder #4

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655 short to +batt Cylinder #5

655 calibration required Cylinder #5
656 short to +batt Cylinder #6
656 calibration required Cylinder #6

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 Appendix B

(3) Machine Fault Codes

E r r o r
Title Description
Code

Loss of communications with Master

I/O Module (unit in left hand side of
0 Master I/O Module CAN fault panel.) Check Fuse F2. Check CAN
L / CAN H wiring from display to I/O
Module

Loss of J1939 communications with

engine. Check engine is getting
power (Fuse F44 in relay box), Check
1 Engine CAN fault +24V on pins 48,52,53 and 70 on
CAT ECU connector C10. Check
J1939 wiring from panel to CAT ECU
(pins 34 and 50).
Fault logging that crusher was
2 Key-off while crusher active switched off without correct ramping
down procedure
Fault logging that crusher was
3 E-Stop pressed while crusher active estopped without correct ramping
down procedure
Fault logging fact operator has
4 Sensor Error - Conveyor Pressure Bypass manually bypassed pressure sensor.
Feeder speed will be reduced to 50%
Fault logging fact operator has
manually bypassed temperature
5 Sensor Error - Temperature Bypass
sensor. Feeder speed will be
reduced to 50%
Log to indicate engine service interval
6 Maintenance Reset
has been reset
Fault logging fact operator has
6 Sensor Error - Jaw Pressure Bypass manually pressure sensor. Feeder
speed will be reduced to 50%
Fault logging fact operator has
7 Sensor Error - Hyd Oil Level Bypass manually bypassed Oil Level sensor.
Feeder speed will be reduced to 50%
Fault logging Emergency Stop is
active. Check all estop switches.
If none pressed, check fuse F6 in
101 Emergency Stop activated panel. If no estop present, check
+24V on Estop return terminal 9
in panel and Pin 70 of CAT ECU
connector C10.
Fault logging stop button on doglead
102 Doglead Handset Stop Request
handset has been pressed.
Fault logging stop button on radio
103 Track Radio Handset Stop Request
handset had been pressed

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Appendix B

Fault logging stop button on small

104 Small Radio Handset Stop Request
radio handset had been pressed
Fault logging hydraulic oil
temperature has reached warning
105 Hydraulic Oil Temperature Warning
point, feeder speed will be reduced to
50%
Fault logging hydraulic oil
temperature has reached error point,
106 Hydraulic Oil Temperature Error
crusher will be halted, engine will
carry on running
Fault logging hydraulic oil level has is
below minimum switch point, crusher
107 Hydraulic Oil Level Error will be halted, engine will carry on
running, can be bypassed in service
mode.
Fault logging disconnected ultrasonic
sensor used to monitor crusher
108 Sensor Error - Chamber Level
chamber level, can be bypassed by
using manual feeder speed.
Fault logging disconnected pressure
transducer used to monitor conveyor
109 Sensor Error - Conveyor Pressure
pressure, can be bypassed in service
mode.
Fault logging disconnected pressure
transducer used to monitor crushing
110 Sensor Error - Crushing Pressure
pressure. Can be bypassed in
service mode.
Fault logging incorrect current drawn
by proportional valve operating pump.
113 Valve Error - Pump current feedback
If valve is not connected, fault is in
Master I/O Module hardware or wiring
Fault logging incorrect current drawn
by proportional valve operating pump.
114 Valve Error - Pump current feedback
If valve is not connected, fault is in
Master I/O Module hardware or wiring
Fault logging incorrect current drawn
by proportional valve operating pump.
115 Valve Error - feeder current feedback
If valve is not connected, fault is in
Slave I/O Module hardware or wiring
Loss of communications with Slave
I/O Module (unit in right hand side of
116 Slave I/O Module CAN fault panel.) Check Fuse F3. Check CAN
L / CAN H wiring from display to I/O
Module
Loss of communications from display
117 Display CAN fault unit. Note this fault is only visible with
service laptop.
Hydraulic Oil Temperature sensor
118 Sensor Error - Hydraulic Temperature
disconnected

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Crusher Drive pressure transducer

125 Crusher Error – Over Pressure seeing > 320Bar for 60seconds,
shutdown machine
Sensor Error - Hydraulic Temperature Hydraulic Oil Temperature sensor
126
shorted to GND shorted to GND
Problem with oil cooler drive, check
151 Oil Cooler Fault
for stalls / blocked fan.
Fault with doglead or loom from
152 Doglead Button Fault doglead to panel, check for water in
doglead plug.
CAT Engine is running but alternator
is not producing high enough charge
154 Charge Warning
voltage. Check alternator fuse and
drive belt for slippage.
Master module is not sure of machine
155 Unknown Machine Type type, select machine type via panel.

Crusher speed sensor is detecting

less crusher rpm than required to
156 Crusher Stall
run machine. Check speed sensor,
check belts.

Crusher is stopping due to a problem

161 Crusher Stopping due to Engine Fault
with engine. See engine error

162 Low Fuel Warning Warning machine running low on fuel

(4) Schematics

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