1100 X 650 HR 20 4 05 PDF

1100 x 650
44” x 26”
HYDRAULIC RELEASE
JAW CRUSHER
Advanced Crushing Technology

Flywheel
Cheek Cross
plates beam
Mainframe
Hydraulic
cylinder
Jaw
bolts
Shims
Fixed
Jaw stock
jaw
Swing
jaw
Toggle
Spring plate
Shims Cylinders
Cross
beam
Cheese
Toggle
seat
Toggle Mainframe
plate
JAW MOTION

PREMIERTRAK PRODUCT CURVES + TONNAGES
•50mm (2”) minimum closed side setting in demolition 85mm (3 3/8” ) open side.
•75mm (3”)minimum closed side setting in rock 110mm (4 3/8” ) open side
setting.
•Capacities and product curves are only guide lines only and vary
depending on the material.

C9 ENGINE
The newer machines are now being fitted with the new C9 electrical engine.

C9 START PANEL
There are various lights, buttons and switches on the Caterpillar start up panel.
The maintenance due light will illuminate every 250 hours and will stay on until
the reset button is pressed.
The diagnostic light will flash indicating fault codes.
Count the number of times it flashes and the Cat book can be cross referenced
to give possible causes.
Fuses

C9 FLASH CODES
Flash Code Description of Code Flash Code Description of Code

13 Fuel temperature sender 51 System voltage intermittent
15 Injector actuation pressure sensor 52 Personality module fault
17 High injector actuation pressure 53 Electrical control module error
18 Injector actuation control valve open/short 56 Check programmable parameters
21 Digital sensor supply 58 J1939 Data link communications
24 Engine oil pressure 59 Incorrect engine software
25 Turbo outlet pressure 61 Event of high coolant temperature
26 Atmospheric pressure 62 Event of Low coolant level
27 Engine Coolant temperature 63 Low fuel pressure event
28 Throttle position calibration required 64 Event for high inlet manifold air temperature
32 Throttle position signal abnormal 65 Event for high fuel temperature
34 Speed/timing sensor 72 Injector Cylinder # 1 Fault
37 Engine oil temperature Injector Cylinder # 2 Fault
38 Intake manifold air temperature 73 Injector Cylinder # 3 Fault
39 Injector actuation pressure sensor Injector Cylinder # 4 Fault
42 Engine timing calibration 74 Injector Cylinder # 5 Fault
46 Low oil Pressure Injector Cylinder # 6 Fault

C9 DISPLAY SCREEN
There are also a series of warning lights on the Cat PLC screen.

C9 DISPLAY SCREEN
The ‘EMS SCROLL’ changes the parameters that are shown on the screen.
Some of the parameters can be viewed in metric or US.
The engine speed is on a rocker switch to set the 2 position engine speed.

DIESEL FILLER CAP
The filler cap is accessible without opening the engine canopy.
Always fill the tank through the strainer.

ENGINE CANOPY
There are two clasps on either side of the engine that need to be undone.
The release lever needs to be pulled down and the canopy can be raised.
The dip stick is situated at the rear of the engine nearest the hydraulic tank.
The oil should be checked on a daily basis.
Clasps Release lever Dip stick

CANOPY SAFETY STAY
Once the canopy has been raised the safety stay needs to be raised into
position.
To close the canopy, replace the safety stay and push in the gas strut outer
cover then pull down the canopy.
Push in
to close

AIR FILTER
An indicator is attached on the outlet pipe to show the condition of the filter.
The filter cleaning / changing intervals are all down to the operating
conditions.
The outer air filter is the only one that should be blown out with an airline,
not the inner.

COOLANT LEVEL
The coolant level needs to be checked on a daily basis.
It is important that the coolant level is within 30mm(1 3/16”) of the top of the
radiator because there is a low level sensor that will stop the engine and flash
the warning light.
Warning light Level sensor

THERMAL OVERLOADS
There is a panel of thermal overloads in the engine

compartment.
If one of them trips out it needs to be pressed back
in to reset it
50 amp customer supply for the Pegson

electrical panel.
15 amp electronic control module
supply.
SMMS is a relay inside the
panel that the 3rd stage of
the ignition switch energised
to start the engine.
80 amp alternator supply.

BATTERY ISOLATION
The battery isolator key is now wired through the positive side of the
battery.
Always switch the key off when carrying out maintenance, especially if
welding.

ECM PLUGS
The ECM is the electronic control module for the engine.
Whenever any welding is done on the machine the battery isolator key must
be turned off, negative battery lead removed and the ECM plugs must
disconnected.
The plugs are held in by a bolt and require a 4mm allen key to remove them.
ECM Plugs
4mm Allen key

FUEL FILTERS
There are 2 fuel filters filters fitted to the engine.
The 1st one is a primary filter with a water separator.
The second one is a 2 micron filter.
They both have 250 service intervals.

REMOTE FUNCTIONS
LED
Red/Green
Remote On
Track Siren
Remote Feeder
Start/Stop
Remote Off

START UP
Turn the ignition onto the first stage and wait for the 10 second start delay.
With the C9 engine if something is incorrect in the start up system the engine
will not crank over.
If the ignition key is turned before the siren has timed out, the engine will not
crank and the start up procedure needs to be carried out again.

TRACKING
If the machine needs to be tracked first turn on the ignition.
2nd Turn on the transmitter (hand set).
3rd Select remote on.
4th Start up the engine.
5th Select track mode.
6th Press the siren button on the hand set, wait 10 seconds then track the
machine with the directional buttons.
Remote on Track mode
LED
Siren

REMOTE CONTROL
Battery Isolator position
LED
On Off
Charging Point
12 v dc Cigarette
Lighter Charger
Battery Isolator
Emergency Stop

CHARGER
The new remote control chargers can now be plugged in 12v or 24v systems

REMOTE CONTROL
Battery Pack
LED
• The LED indicates the battery condition
• Green indicates batteries are good
• Red indicates batteries are going flat and

will shut the machine down in 1 hour
• The siren will sound when the LED turns red
• 12 hours run down time from fully charged
• Charge time approx 1.5 hour from flat

REMOTE CONTROL
When the remote control is in use the hard wired cable coming out from the
electrical panel will be plugged in.
16 pin plug and socket

UMBILICAL REMOTE
The umbilical remote can also be used to track the plant.
The hard wired plug can be removed and the umbilical plugged in instead.
Fit the plastic cover into the end of the hard wired plug to prevent dirt
ingress.
Plastic cover

REMOTE CONTROL TUNING (frequency)
The frequency of the machines is set at random to eliminate interference if
there are 2 machines working together.
The frequency is set by dip switches at the back of the frequency modules.
Open up the transmitter and remove the tele radio frequency module
by removing the two screws.

The four dip switches on the radio module in the receiver box are on
the underside, so the cable tie needs cutting to gain access.
The only time these dip switches need to be changed is if interference
is effecting the remote control .
To change the frequency, move the position of the switches ensuring
that both frequency modules are in the same position.

Switch positions for operating frequency’s-

REMOTE CONTROL TUNING. ID CODE
For a transmitter to operate with a receiver unit there is also an ‘ID code that
have to match between the 2 units.
The frequency module needs to be removed in the transmitter to gain access.
There are 2 rows of 8 switches in the receiver and transmitter.
The 2 switches on their own in the receiver should be in the off position.
If any of them are on, it will switch of the transmitter if none of the buttons
are pressed within a certain time period.

860 REMOTE CONTROL
The new 860 remote control has a white face and red buttons.
The isolator key on the rear has now been removed.
The transmitter can accept 12 to 35 volts DC.
The function buttons operate the same as the 840 unit(including the
umbilical).
LED’s
1
2
3
Button numbers

860 REMOTE CONTROL TUNING (frequency)
The frequency modules in the transmitter and receiver are not removable so
there is no need to open anything to change the frequency.
1. Press the 9 and 0 buttons for at least 1 second, release 9 but keep 0
depressed.
2. Release 0 and press 8 within 0.3 seconds. The yellow LED(2) lights
continuously and the green LED(3) flashes.
3. Enter the pin number 1 2 3 4 then the yellow LED(2) goes out and the green
LED(3) flashes. This indicates the pin number has been entered correctly.
4. Enter 1 of the 16 channel numbers to set the frequency. Note. For single
digit numbers 0 must be pressed first.
5. The yellow LED flashes 3 times and then the transmitter switches off.
The frequency change has now been accepted.
Note. Each time a button is pressed the yellow LED(1) lights also.
860 REMOTE CONTROL TUNING (frequency)
CHANNEL NUMBER FREQUENCY MHz

01 434.650
02 434.600
03 434.550
04 434.500
05 434.450
06 434.400
07 434.350
08 434.300
09 434.250
10 434.200
11 434.150
12 434.100
13 434.050
14 434.000
15 433.950
16 433.900

860 RECEIVER UNIT
Transmitter signal strength Power LED’s E Stop relays
Fault LED’s
4 5 6 8 9 10 3
1
Function 2
selector
No. of transmitters programmed Reset button Power supply

STATUS LED’s IN RECEIVER
Green LED 1- This indicates the strength of signal that the receiver is getting
from the transmitter.
Reset button(2)- This puts the receiver into ‘the learning mode’ where it will
tune itself into the transmitter.
Yellow LED(3)- When this LED is illuminated it means that the receiver is
powered up.
Yellow LED(4+8)- This flashes when a transmitter is programmed to the
receiver.
Red LED(5+9)- This indicates faults on the receiver.
Green LED(6+10)- This lights up when the receiver locks onto a transmitter
signal.
Selector switch 2

PROGRAMMING A TRANSMITTER I D CODE TO A
RECEIVER
1. In the receiver unit turn the function selector switch 2 to the ON position.
2. Press the red reset button. Both sets of green red and yellow LED’s should
illuminate.
3. Release the reset button. The green and red LED’s should go out. The
yellow ones should remain illuminated.
4. Press buttons 9 + 0 simultaneously to power up the transmitter.
5. Press buttons 9 + 0 simultaneously again until the yellow LED’s start to
flash. This indicates the receiver has found the transmitter.
6. On the receiver unit turn the function selector 2 switch to the off position.
7. The receiver is now programmed to the transmitter.

ERASING A PROGRAMMED TRANSMITTER
FROM A RECEIVER
1. Turn the function selector switch 2 to the ON position.

2. Press the reset button. The green red and yellow LED’s should light
continuously.
3. Release the reset button. The green and red LED’s should go out. The
yellow ones should remain illuminated.
4. Turn selector switch 2 to the off position.
5. Turn switch 2 to the on position within 2 seconds. The yellow LED’s should
flash. This indicates the receiver has been erased.
6. Turn the function selector switch 2 to the off position.

PROGRAMMING AN 860 TRANSMITTER INTO AN 840
The 840 transmitter is no longer available so all new transmitters are 860’s.
The 860 transmitter can be configured to operate as an 840.
If an 840 receiver fails the receiver and transmitter will have to be replaced
because an 840 transmitter will not operate with an 860 receiver.
1. Switch on the transmitter by pressing buttons 9 + 0 for at least 1 second.

2. Release button 9 but continue to hold button 10.
3. Release button 10 and press button 6 within 0.3 seconds. The Yellow LED
should illuminate and the green LED should flash.
4. Enter the safety code 4,9,2,7,6,5. Each button has to be pressed within 5
seconds of each other. The green LED flashes and the yellow one goes out.
5. Enter 0 for 860 mode or 1 for 840 mode. The yellow LED flashes 3 times
and then the transmitter switches itself off.

TUNING THE TRANSMITTER INTO AN 840 RECEIVER
1. Switch on the transmitter by pressing buttons 9 + 0 for at least 1 second.
2. Release button 9 but continue to hold button 10.
3. Release button 10 and press button 5 within 0.3 seconds. The green LED
should flash.
4. Enter the receiver ID code(5 numbers).Example:ID-code 2594 will be 02594
5. Once the code has been entered the yellow LED flashes 3 times and the
transmitter switches off.
Note. If at any time the ID on the receiver was changed the programming will
not work because the ID code will be incorrect for the dip switch position.

TUNING THE TRANSMITTER INTO AN 840 RECEIVER
Remove the frequency module to see the position of the dip switch’s.
Compare the position of the switch’s to the frequency chart to establish the
frequency and the channel number.
Carry out the frequency change procedure and the 2 units will now function.
CHANNEL NUMBER FREQUENCY MHz

01 434.650
02 434.600
03 434.550
04 434.500

PLANT SET UP
PROCEDURE

START UP
Once the engine has started the mode of operation needs to be selected on the
PLC screen.

TAIL LIFT
With the engine running select set up mode.
The tail lift can then be raised or lowered with the buttons on the PLC
Screen as can the dirt conveyor.

PREMIERTRAK TAIL LIFT UP POSITION FOR
TRACKING
The tail lift is hydraulically operated up and down from the start up console.
The under carriage provides protection for the tail drum when tracking over
rough ground in either direction.
Under
Carriage

PREMIERTRAK TAIL LIFT DOWN POSITION FOR
CRUSHING
The tail drum is exposed below the under carriage in the down position.
Lowering the tail drum gives more clearance between the belt and the jaw.
Under
Carriage
Tail
drum

PLANT LOADING/OFF LOADING
Load / unload the machine on level ground.
Long shallow ramps enable easier loading.
Load / unload the machine on engine idle using the both tracks forwards/back
The machine will pull one way if the hydraulic oil is less than 5ºc (>41ºF) with
high rpm.
Ramp
PLANT SET UP
PROCEDURE

HYDRAULICALLY FOLDING HOPPER
Check the position of the cross brace and

head guard before folding the up the hopper
Hopper Folding
Levers
Position Bolts
From This
Direction
Only
HYDRAULICALLY FOLDING HOPPER
Cross Brace
Bolt
Locking
Bracket Wedge
Wedge
The locking bracket could be welded to

the wedge if the machine is stopping on
site for a long period
Advanced Crushing Technology 31

NEW TYPE HOPPER WEDGES
Drive the wedges in the same as before.

Fit the bracket to the end of the wedge with the long bolt and tighten.

SET UP
Handrail Sockets
• Front Access Ladder
• Fold Out Dirt Conveyor
• Fit Head Guard
• Always fit Rubber Skirts
• Fit Handrails
Rubber Skirts Head Guard

DIRT CONVEYOR TWO WAY CHUTE
• Move two way chute daily • Two way chute has no

interlocks with the dirt conveyor
Dirt Conveyor Chute OPC Dirt Chute Two Way Door
Lever Dirt Conveyor OPC Position

Position
MAGNET DISCHARGE
The belt speed of the magnet can be adjusted by undoing the locking ring and
tuning the centre section of the speed control valve
Set the belt speed fast enough so that any steel gets picked up and gently
thrown clear. Setting the belt speed too fast will result in a ripped belt.
Locking ring Speed control Shedder plate (handed)

valve

MAGNET DISCHARGE
The magnet can be reversed to discharge the steel on the other side, but a R/H
shedder plate and plough are required.
The barge board is not handed and can be swapped side to side
The quick release couplings can be swapped to reverse the belt
Barge Board
Quick Release Couplings Rubber plough Shedder plate L/H

CONTROLS
Other than the the start up

functions that are hard wired
on the rear control box,
everything else is operated
from the PLC screen.

PLANT START UP
1. Track the machine into position on reasonably level ground and slew it
from side to side to ensure it is sat evenly on the tracks.
2. Select the plant mode. Leave the remote on if the feeder needs to be
operated by the remote control. If the remote control is not required for the
feeder, switch off from the remote mode on the PLC screen and then turn off
the transmitter.
3. Press the jaw on button and the cylinders will start to pressurise. The
screen will display ‘cylinder pre load pressure low’

PLANT START UP
4. Start the product conveyor.
5. Ensure the engine is on low idle (1200 rpm). When the pressure reaches
250 bar the crusher can be started.
6. Rev the engine up to 1600 rpm. The pressure in the cylinders will continue
to rise until 420 bar is achieved.
7. Start the dirt conveyor (if required).
8. Press start on the feeder. If the remote is switched on the feeder will not
start until the start button is pressed on the transmitter.
The feeder will only start once the pressure is above 380 bar.

OPERATION TIPS
• Always watch excavator tip • Watch for magnet discharging steel
• Don’t heap up the hopper. • Check regularly for trapped steal
• Always watch belts to ensure • Always chain out pieces that are too
they are running big
• Use feeder speed control

CHOKE FEEDING
• Ensures maximum capacities
• Maximum reduction
• Maximum jaw life
Advanced Crushing Technology 41

SHUT DOWN
•Stop the Feeder
•Stop the Dirt Conveyor
•Slow Down the Engine rpm to idle
•Stop the Crusher
•Stop the Product Conveyor
•Idle the Engine For 1 Minute
•Stop the Engine

DE-RIG
•Remove Dirt Conveyor Head Guard •Fold Up Dirt Conveyor
•Remove Rubbers Skirts •Remove Hopper Wedges
•Remove Hand Rails •Fold Down Hopper
•Remove Cross Brace Sides +Back
•Remove Hopper Bolts •Fold Up Front
Access Ladder
Hopper Up Hopper Down

4116 mm 3800 mm
13’6” 12’6”

JAW ADJUSTMENT

JAW ADJUSTMENT
Remove the 2 covers from either side of the chassis to reveal the shims.
Remove both retaining pins from out of the shims.
The retaining pins prevent the shims from riding out whilst the machine is
crushing.
Cover Retaining pin Shims

JAW ADJUSTMENT
Press set up mode from the 1st screen to get into the adjustment screen.
Press the jaw out button to retract the hydraulic cylinders to release the
shims.
When the jaw / out button is pressed a there will be a siren and a 3 second
time delay before anything will move.
There is also a flashing beacon that will illuminate on the blind side of the
machine for extra safety when the cylinders are adjusted.

JAW ADJUSTMENT
With the cylinders fully retracted remove all of the shims from both sides of
the crusher.
With the cylinders fully retracted the gap within the shimming area is 133mm
(5.1/4 inch).

SHIMS
Clean all of the shims and dress up any burrs.
Shimming the crusher is opposite to the old machines. You remove shims to
tighten the jaw setting.
The shims are in 3 different sizes. 20mm 10mm and 4mm(3/4, 3/8, 3/16)
The ratio between the shim and the jaw setting is approximately 1:2.
Fitting a 20mm(3/4) shim will open the jaw setting by approximately 40 mm
(1 1/2).
Approximate settings with new
jaws fitted
Shims Shims fitted C.S.S.

Retaining 20mm 56mm
pin 30mm 73mm
40mm 90mm
50mm 110mm
54mm 120mm
SHIMS
Fit an equal amount and thickness of shims to each side of the machine.
Always fit the thick shims first, then the medium and then the thinnest.
Fitting unequal sized shims to either size of the machine could result in serious
damage to the crusher.

JAW ADJUSTMENT
Press ESC on the PLC screen to escape back to the original select mode
screen.
Press plant mode then jaw on and the cylinders will automatically pressurise
and clamp the shims.
Press plant mode then jaw on and the cylinders will automatically pressurise
and clamp the shims.
With the jaw static the maximum the cylinders will pressurise to is 250 bar.
The shims can also be manually clamped by pressing jaw in (250 bar max).

TOGGLE SPRING
It is not necessary to touch the spring when changing the jaw setting.
The pin centres on the spring remain constant at 460mm (18 1/16”) regardless
whether the jaw is fully open or closed.
Old type tension spring.
460mm (18 1/16”)

SPRING ADJUSTMENT
The spring is under tension not compression.
To tension the spring undo the locking nut and turn the adjusting nut until
the pin centres measure 460mm (18 1/16”).
The adjusting nut is difficult to turn to achieve the 460mm (18 1/16”) .

NEW TYPE SPRING
The compressed spring length should be 220mm(8 5/8”).
This spring compression is difficult to achieve.
The spring does not have to be touched when the setting is changed.

JAW SETTINGS
The movement at the bottom of the Jaw normally stops on the open side.
jaw is 35mm(1 5/16” ) from open to Check position of flywheel end cap
closed
Jaw Setting Measuring Point

(Tip to Root)
JAW ADJUSTMENT
Always refit the covers on the chassis before commencing crushing.

Ensure that the toggle beam is hard on the shims at all times.
Breathing within the cylinders will reduce the seal life and also cause twisting
on the jaw-stock.

ALARMS
Whilst the cylinders are charging up to the static pressure setting the PLC will
display ‘ cylinder pre-load pressure low’.
The PLC will not allow the crusher to be started until the pressure reaches
250 bar.

RUNNING PRESSURES
Once the crusher has been started the cylinder pressure will then rise to 420
bar.
The pressure will decay 10 bar before the PLC will re-charge the cylinder
pressure.
The feeder cannot be started until the cylinder pressure exceeds 380 bar.

PRESSURE OVER LOAD
When the pressure in the hydraulic cylinders exceeds 492 bar the crusher will
go into a pressure overload which allows the oil in the back of the cylinders to
go to tank.
Whatever is in the crushing chamber will force the jaw open allowing the
tramp material to pass through the crusher. The feeder will automatically
stop but the jaw will continue to run to empty the crushing chamber.

PRESSURE OVER LOAD
When an overload has occurred the ‘ACKN ALARM’ button needs to be

pressed.

PRESSURE OVER LOAD
Once the ‘ACKN ALARM’ has been pressed, the press the ‘JAW ON’ button
and the cylinders will re-charge back up to 420 bar.
Check for and remove any tramp material from the stock pile then re-start
the feeder.

HYDRAULIC CYLINDERS
The hydraulic cylinders are pressurised which push the crossbeam forwards
until it is hard up against the shims.
If any tramp material enters the crushing chamber the oil port on the full
bore side of the cylinders (rear) is opened up to tank. The jaw immediately
opens from the pressure in the crushing chamber and allows the tramp
material to pass through.

TYPICAL CRUSHING PRESSURE VARIATIONS
The reason the cylinders are fully pressurised onto the shims is so that
cylinders don’t feel the crushing pressure variations.

PRESSURE TRACE DURING OVERLOAD
Cylinder pressure

HOW IT WORKS
THREE BANK VALVE
The jaw gets its hydraulic supply from the three bank valve in the engine
compartment.
The two relief valves are set at 75 bar, 1088 psi(105 bar1533 psi from the test
point).
The lever moves down when the cylinders are being pressurised.
Jaw in
Jaw out

HYDRAULIC LAYOUT
Dump
valve
assembly
Dump
hose
Cylinders

VALVE BLOCK
Solenoid Cylinders
valve (full bore)
Pressure
switch
Pressure
intensifier
Relief
valves
PRESSURE FILTER
The oil from the bank valve passes through an inline pressure filter before
going into the main valve block.
To the
valve
block Feed from
bank valve

PRESSURE INTENSIFIER
The pressure intensifier is used to increase the oil pressure from the bank
valve into the adjustment circuit.
The intensifier increases the pressure 6.6 fold.
75 bar x 6.6 = 495 bar.
Extend
cylinders
Retract
cylinders

PRESSURE SWITCH
The pressure switch monitors the pressure within the full bore side of the
cylinders.
If the pressure is below 250 bar it will not allow the crusher to start.
At 250 bar the crusher can start, then feeder when 380 bar is achieved.
If the pressure exceeds 492 bar the jaw will dump and open up.
The pressure switch also sends a 0 to 10 volt signal into the PLC which gets
converted into a pressure reading on the PLC screen.
Digital pressure
read out

PRESSURE SWITCH
The PLC controls the pressure in the cylinders by operating the bank valve
splice on and off to keep the pressure between 410 to 420 bar when the
crusher is operating.
The bottom LED indicates a power supply to the switch.
The top LED lights up when the pressure switch changes over at 492 bar.

RELIEF VALVES
The relief valves are set at 500 bar to prevent the system over pressurising
when the jaw needs to dump should the logic valves not respond quick
enough.
The check valve prevents any pressure spikes going back to the intensifier.
Check
valve
Relief
valves

OLD TYPE VALVE BLOCKS
The older machines operated at lower pressures.
Static pressure 250 bar, operating pressure 340 bar, overload 414 bar,
relief valves 420 bar.
Static pressure 3625psi, operating pressure 4930psi, overload 6003psi,
relief valves 6090psi.
The pressure reducing valve was screwed all of the way in to act as a one way
check valve.
Pressure
reducer
Relief
valves

SOLENOID AND LOGIC VALVES
When the pressure switch registers 492 bar and changes over to open circuit it
drops the power supply going to the solenoid valve.
The solenoid valve moves which allows the logic valves to open which creates
a direct return to tank for the full bore side of the cylinders.
Solenoid valve Logic valves Full bore side

SYSTEM PRESSURE
The system pressure can be measured from the test points on either of the
hydraulic cylinders.
Test
points

CROSS BEAM
When the jaw dumps and opens up the shims remain where they are and the
cross beam is pushed back increasing the jaw discharge.
The jaw opens up to 280 (11”)open side setting with brand new jaws.
The cross beam is fitted with thrust blocks to prevent any movement within
the cross beam when it is not under compression.
Shims Cross beam Thrust blocks

GUIDE BEAM
A guide beam is fitted to prevent any movement within the crossbeam as well
as the thrust blocks.

GENERAL
MAINTENANCE

MANUAL CLUTCH
High temperature grease
Grease Nipples 1 Shot

Every 10 Hours
DO NOT OVER-GREASE
Grease Nipple on other side.

2 Shots Every 100 Hours(EP2)
The nut on the end of the clutch is

to measure the engagement force
when adjusting the clutch
(218 to 289 lbs feet)
(295 to 392 N/M)

MANUAL CLUTCH
Adjusting Ring
(Clockwise) Locking Pin pulls out
Clutch Inspection Cover

All Greasing and Adjustment Instructions on Plate

HFO CLUTCH
Grease Nipple 1
Shot every 10 Hours Hydraulic Feed
(high temp grease) into Clutch
DO NOT OVER-GREASE

GREASING POINTS L/H SIDE
Two Shots A Week (EP2)
Dirt Con Head Drum Two Way Chute
OPC Tail Drum Bearing Magnet

GREASING POINTS L/H SIDE
OPC Head Drum Grease Pipes

Remote greasing points fitted since July 2001 (approx)
GREASING POINTS R/H SIDE
Two Way Chute Dirt Conveyor+Tail Lift
Magnet
JAW GREASING POINTS
Grease Nipples (85 Grams, 3 ounces per week of E.P 2)

MAGNET MAINTENANCE
The magnet belt is designed to run with the belt sagging. Over tensioning the
belt will enable steel to puncture through it causing rips and the belt to fail.
The belt tracking / tensioning is done on adjusters on the L/H drum rollers
Adjuster x 2 Belt sag

RUBBER PLOUGH
It is essential that the rubber plough is in good condition and replaced if it
gets ripped. The plough stops any material going up the inside of the barge
board, causing the wing rollers or transom brackets getting damaged.
Problem
Rubber plough Barge board
area

SKIRT RUBBERS
Check the condition of the skirt rubbers on a daily basis especially in
recycling. Any ripped skirt rubbers must replaced. Ripped skirt rubbers
result in material spillage, belt stoppages, punctured and ripped belts, so it is
false economy not to replace them as soon as they are damaged
Always make the skirt rubbers as long as possible to reduce the amount of
joins to prevent spillage

BELT SCRAPERS
Check the belt scrapers on a weekly basis to ensure that they are tensioned
correctly and in contact with the belt all the way across.
If the belt scrapers are not maintained correctly dirt will build up on the
return rollers causing the belt to run out of track.

FEEDER MAINTENANCE
Ensure the machine is sat on level ground before checking the oil level
Oil level should be in the middle of the sight glass
Over filling will cause the feeder to leak
Oil Level
Sight Glass

FEEDER MAINTENANCE
EP220 Gear Oil, 200 hour oil change

3.5 litres 0.9 USG capacity (approx) each
side
Filler Plug
Oil Level
Sight Glass
Side Case
Drain Plug
FEEDER MAINTENANCE
Check bolts regularly to ensure nothing is loose.
Cracked paint often indicates something is moving.
If any bottom cover bolts come loose re-fit them using stud lock.
Unit Housing and Feeder

Motor Retaining Bolts Cover Bolts (24 off) Breather

FEEDER MAINTENANCE
Regularly check that the retaining bolts ate tight. Once they have been
loose and elongated the holes, they will never stop tight
Grizzly section and Discharge Lip Retaining Bolts

FEEDER LINER PLATES
All liner plates are handed
Always tighten the nuts on the liner plate retaining bolts
Pan Liners
L/H/S Side
R/H/S Side Liners
Liners
Shear Blocks
Discharge
Grizzly
Lip
Section

JAW BOLTS
Always keep jaw the bolts tight. Failure to do so will damage the bolts
The fiber washers help maintain bolt tension
Fixed
Jaw
Bolts
Nut
Fibre (55mm A/F)
Washer
Washers

JAW LOCATION
Main Frame Clearance
May Burr Over

Nut
Washer
Jaw Wedge
Fibre Washer
Washer
Jaw
Jaw Bolt
JAW REMOVAL
Turn or change the jaws when the ribs of the jaw first become flat.
Continued use will pocket the jaws causing packing and excessive power draw.
Wearing too much off the fixed jaw allows the material to wear away the jaw
support teeth causing them to fail.
The fixed jaw

wears quicker than
the swing jaw.
6 Jaw teeth

JAW REMOVAL
Remove jaw bolt nuts
Knock the jaw bolts out to remove the wedges
It may be necessary to grind around the wedges to ease removal
In extreme cases one wedge may need to be burnt out
Fixed Jaw Jaw Bolts

Wedges
Side Clearance Upper

Cheek Plates
Fixed Jaw Lower

Cheek Plates
Jaw location
Teeth
JAW REMOVAL
With the jaw wedges removed, pry the jaw forward or drive
wedges between the mainframe back wall and jaw
It may be necessary to clean down the sides of the jaw if it won’t move
Pry the jaw forward and drop a hammer down the back of the jaw to hold it
forward
Recess

JAW REMOVAL
Lifting holes cast into the rear of the jaw
Grind any burrs off the jaw wedges if they are being re-used
The swing jaw and fixed jaw are both reversible
Lifting Holes
Grind tapers flat
when turning jaw

CHEEK PLATE REMOVAL
Try to time the cheek plate changes to fit in with the fixed jaw change as the
fixed jaw needs to be removed.
Weld a suitable lifting lug to the cheek plate and take the weight before
removing the retaining bolts.
Ensure the mainframe is clean before bolting on the new cheek plate.
The lower cheek plates will wear two to three times quicker than the uppers.
Ensure the cheek plates are replaced before they wear through to the mainframe

RE-FITTING JAWS
Grind the underside of the top plate to remove any burrs
Remove any dirt or stones off the jaw teeth
Fit the jaw and centralise. Fit jaw wedges, bolts and tight
Hit the wedges with a sledge hammer and tighten again. Repeat a few times
Check bolt tension regularly for the next few days until the wedges seat in
Top plate
Fixed Jaw
Wedges Centralise Jaw
Jaw Teeth

SWING JAW
The swing jaw removal / turning is the same process as the fixed jaw
The jaw guard is a replaceable wear part to protect the Swing jaw.
Jaw Guard
Swing Jaw

SWING JAW LOCATION
The swing jaw locates on a key welded into the jaw-stock.
Its purpose is to stop the jaw moving across into the cheek plates
Swing Jaw Jaw Key Jawstock

JAW RECONITION
The swing jaw has a cut out for the jaw-stock key and is slightly longer than
the fixed jaw
Swing Jaw Fixed Jaw

TRACK GEARBOX
Sit the machine on level ground
Initial Oil Change at Six Weeks
Change Oil Once A Year
SAE 80w/90 Gear Oil
Filler Plug Level Plug Drain Plug

TRACK TENSION
The track tension is applied by pumping grease into the track grease nipple
Cover Grease Nipple

TRACK TENSION
Span the tracks with a straight edge between the longest section of
tracks that’s unsupported. The tracks should have 15mm (5/8”) of sag.

TRACK TENSION
If there is less then 5mm (3/16”) of sag in the tracks, it will be necessary to let
off some tension. To do this slowly unscrew the grease nipple until it releases
grease .
The grease nipple is under extreme pressure so never remove it until the
grease has stopped coming out.
Recess for grease extraction
Grease Nipple

OPC BELT ADJUSTMENT
The belt tension is all done on the head drum
Loosen the top two locking bolts and the adjuster lock-nuts (52mm) (2 1/16”)
Keep the head drum square and do any tracking on the return rollers
Locking
Bolts
Measuring Adjuster
Point
Adjusting
Nut
Lock Nut

BELT TRACKING
To move the belt to the left hand side of the head drum the return rollers
need to be knocked up towards the head drum on the left hand side.
L/H Return Roller R/H
D.O.R

BELT TRACKING
The belt can also be tracked from the top transom sets
Knocking the rollers up on the left hand side towards the head drum will
move the belt to the right
Knocking the rollers up on the right hand side towards the head drum will
move the belt to the left
Belt Direction
L/H R/S
D.O.R

DRIVE GAURDS
The belt tension can be checked by removing the small inspection guard
Both inspection guards need to be removed to change the belts
Inspection Guards

CRUSHER DRIVE BELT ADJUSTMENT
Loosen the four retaining bolts on the drive guard around the clutch
Adjustable guards to allow for engine movement
Retaining
Bolts

CRUSHER BELT ADJUSTMENT
Loosen the four retaining bolts on each corner of the engine
The front drive side bolt is easier to get to if the access plate is removed
Engine retaining bolts Access plate

Wire brush the threads clean and lubricate them to ease adjustment.
Loosen the inside nuts (1) and run them down the threads 30mm(1 3/16”).
Tighten the outside nuts (2) to pull the whole of the engine back to tension the
belts. Pull the engine back evenly to prevent the engine twisting and the
retaining bolts fouling on the slots in the chassis.
Adjuster Nut 1 Nut 2

SPC Belt section 11.7 kg (26 lb/feet)of force 32 mm(1 1/4”) belt deflection
Basically tension the belts so that when one belt is pressed with your finger it
deflects 20mm (3/4”)
Belt deflection

Note - As the adjusters are only small (M20) it would be difficult to over
tension the belts.
Measure the distance between the engine and the chassis so that it is level,
which ensures the drive belts are running true.
Tighten the inside nuts (1) to secure.
Measuring Point Adjuster Nut 1 Nut 2

Tighten the four engine retaining bolts
Replace and tighten all guards
NOTE. If new drive belts are being fitted, tension them start the crusher to
settle them and re-tension them again.
The belt tension should be checked weekly and adjusted as necessary.

HYDRAULIC PUMP BELTS
Check the belt tension weekly and adjust as necessary.
The belt deflection should be kept to approximately 5mm (3/16”) at all times.
Always look down the belts and square up the pump. The back-nuts enable
you to push the rear end for alignment.
Adjusting Bolts Drive Belts Pump Locking Bolts Back nuts

(4 off)

HYDRAULICS
The suction and return filters both have indicators fitted to establish the
condition of the filters
Unscrewing the shut off valve locks the oil in the hydraulic tank to prevent oil
loss whilst carrying out maintenance.
Pressure indicator Suction Filter Pressure
Shut Off Valve
Return Filter indicator

HYDRAULICS
Don’t fill the hydraulic tank above the sight glass because it will throw oil out
through the breather when the it is tracked about with hot oil
There are two inline pressure filters fitted either side of the engine canopy
Both are fitted with red /green indicators. Red = Blocked. Green = Good.
They will indicate red in cold temperatures when the hydraulic oil is thick
Sight Glass Indicator Inline Pressure Filter

HYDRAULIC TANK
Change the filters every 1000 and the oil every 2000 hours
Use 46 grade hydraulic oil if the ambient temperature is below 86º F (30º C)
Use 68 grade hydraulic oil if the ambient temperature is above 86º F (30º C)
Inspection covers are fitted to the side of the tank to clean it out when the oil
is changed
Jaw dump
Breather line
Level Float
Inspection
(low oil level cut off )
Covers

AIR BLAST COOLER
The air blast cooler works directly from the ignition. The older machines were
fitted with a thermostat.
The cooler needs cleaning out on a regular basis, either with an air line or a
pressure washer.
Clean out from the front

Air Blast Cooler

THRUST BLOCKS
Check the thrust blocks on the cross beam and replace them as they wear.
Maximum clearance is 4mm to 5mm(3/16”) between the pad and the
mainframe.

FLYWHEEL ALIGNMENT
The flywheels are fixed to the shaft with a ring fedder clamp. This means the
flywheel can spin on the shaft if the crusher stalls through tramp material
that opens the crusher to the maximum. If this happens, the two arrows will
be miss-aligned and the machine will bounce around because it will be out of
balance.
To re-align the flywheel, first remove the end cap.
Flywheel
Dowel
End cap Hole
Alignment
Arrows

LOOSENING SEQUENCE
Start with the 3 silver screws and slacken off in sequence so that the ring
fedder will turn.
If the ring fedder will not turn it will be necessary to strip it down and
remove it piece by piece
9 10
8 1
7 2
6 3
Dowel 5 4
5
4
3
6 Ring fedder
7
2
8
1
12mm allen 9 Brass bush
10
keys 10
9
1
8
2
7
6 3
5 4

FLYWHEEL ALIGNMENT
Drop a piece of wood in the jaws to stop it from turning
Turn the flywheel so the arrow is in-line with the center line on the shaft.
Ensure the dowel hole is opposite to the arrow
Alternately the end cap can be fitted to align the arrows, but the dowel
sometimes shears so make sure the dowel lines up with the hole in the shaft
otherwise it could be 180º out
Dowel Hole
Ring fedder
Brass
Bush
Straight
Edge
Arrow

CLAMPING THE FLYWHEEL
When the flywheel is turn to re-align it, its possible that it can move off the
shaft slightly. It is therefore necessary to pull the flywheel back onto the shaft
with a clamping plate. Tighten the accessible cap screws and remove the clamp.
Clamping plate
Tighten
Accessible
Capscrews

TIGHTENING SEQUENCE
Tighten the ringfedder in sequence up to 195 N.m(144 lb/f) It will be necessary
to tighten around the the clamp several times before it is clamped correctly
Failure to tighten sufficiently will result in the flywheel slipping unnecessarily.
9 10
8 1
7 2
6 3
4
5
5
195 N.m
4
3
6 144 lb/feet
7
2
8
1
9
10
10
9
1
8
2
7
6 3
5 4

END CAP
Re-fit the end cap, tighten the retaining bolts and bend over the locking tabs

BASIC HYDRAULIC
SYSTEM

HYDRAULIC PUMP TANK SIDE
Two identical pumps are mounted either side of the engine, belt driven from
the engine crankshaft
This pump supplies oil to the two bank valve
The oil is drawn through a suction filter into the pump, through an inline
pressure filter and into the two bank valve
Drive belts
To the 3
bank valve
Pump
Suction
Pressure
Filter

THREE BANK VALVE
The three bank valve is mounted in the engine compartment to the rear of the
pump.
The end section is the feed and return to the valve.
The 1st splice goes to the tracks.
The 2nd splice goes to the product conveyor + magnet. If a hydraulically
operated clutch is fitted, it tee’s in on the feed line for the conveyor.
The 3rd is for the crusher adjustment.
H.F.O Clutch
Restrictor
valve
Feed
Product
conveyor
Return
Crusher
adjustment
TRACK DRIVE
The feed comes in to the cross line check valve block and automatically
releases the brake.
The two track motors tee the case drains together before going to tank
The purpose of the cross line check valve is to prevent the machine from
running away on a steep slope or if a pipe bursts
Track feeds Track Motor Brake Release Motor Case Drain
Cross line
check
valve
block

HYDRAULICALY OPERATED CLUTCH
The feed to the clutch comes through the restrictor valve, then the solenoid
valve and then a relief valve before going to the clutch.
Pressure
Solenoid valve Relief valve Feed to clutch
switch
Restrictor valve

PRODUCT CONVEYOR MOTOR
The feed comes in through a 4.5 bar (66psi)check valve and into port B in the
motor.
The check valve is fitted to prevent the belt running back if it stops loaded.
The case drain is necessary because the magnet is driven from the conveyor
return, so it prevents back pressure going to the motor.
Feed Line Check Valve
(B Port)
Return Line
(A Port)
Case Drain

MAGNET SPEED CONTROL
The return oil from the product conveyor tee’s into the magnet speed control
valve. Its bleeds off some oil before the magnet motor to control its speed
If you don’t want the magnet belt to run, stop the belt on the magnet speed
control not by disconnecting the quick release couplings.
Product conveyor
return line Locking Ring Magnet Return
Magnet Magnet Speed

Feed Control Valve Tank
MAGNET
If you don’t want the magnet belt to run, stop the belt on the magnet speed
control not by disconnecting the quick release couplings.
Quick Release Couplings

CRUSHER ADJUSTMENT
Feed
Return

HYDRAULIC PUMP CRUSHER SIDE
The pump nearest the crusher supplies oil to the five or seven bank valve at
the rear of the machine.

7 BANK VALVE
Splice 1 goes to the tracks
Splice 5 goes to the dirt conveyor fold
Splice 2 goes to the feeder
Splice 6 goes to the folding hopper sides
Splice 3 goes to the dirt conveyor
Splice 7 goes to the folding hopper back
Splice 4 goes to the tail lift
1 2 3 4 5 6 7
Tank
Feed
In

R/H TRACK
Track Motor
Track Feed & Return Lines

FEEDER MOTOR
The feeder will work the same regardless of which direction the motor is
turning but it should be turning clockwise as you look at it. The reason for this
is so the gears pick up the oil and carry it through the middle where they
contact.
Return Line Feed Line

DIRT CONVEYOR MOTOR
Feed Line
(port B)
Return Line
(port A)

HYDRAULIC CYLINDERS
Both cylinders on each circuit tee together so they operate evenly
Tail Lift Dirt Conveyor Fold

DIRT CONVEYOR AND TAIL LIFT CHECK VALVE
Both cylinder circuits go through a check valve to hold the conveyors up
without them creeping back down
To Bank Valve + Cylinder Down To Cylinder up To the Bank

Valve
1
2
3

HOPPER FOLD
The cylinders on the hopper fold have the check valves built into the bottom
of the cylinder with steel pipe work. It is done this way as a safety aspect so if
a flexible hose fails the hopper side / back cannot fall under its own weight
Check Valve

HYDRAULIC SYSTEM

HYDRAULIC PUMP
The hydraulic pump only only delivers oil flow on demand, unlike fixed gear
pumps. The standby pressure is set at 30 bar(435psi) and the pump will
deliver a small amount of oil to maintain that pressure. When a function is
operated, the pump detects a pressure drop on the 30 bar(435psi) and the
swash plate is moved to pump more oil. This happens in a split second. The
system always maintains 30 bar(435psi) more in the pressure line than the
load sensing line.
Case Drain
Load Sensing
Line
Standby Pump Relief Valve

Pressure Relief (320 bar)
(30 Bar)
(4641 psi)
(435psi)

HYDRAULIC PUMP
When all functions are switched off the pump will de-swash and return to a
low flow maintaining the 30 bar (435psi)stand by pressure.
The pump has its own relief valve set at 320 bar(4641psi). If the pressure
exceeds 320 bar(4641psi), the pump will de-swash, drop to a low flow but
maintain 320 bar(4641psi).
Case Drain
Load Sensing
Line
Standby Pump Relief Valve

Pressure Relief (320 bar)
(30 Bar)
(4641psi)
(435psi)
SECTION VEIW - 57 CC/REV. FULL STROKE
Servo Piston Rotating Kit
Swash plate
Tapered
Tapered Roller
Roller Bearing
Bearing
Shaft Seal
Valve Plate
Bias Piston
Piston
SWASH PLATE OPERATION
Servo Piston Swash plate
• Two piston design.
• Bias piston uses system pressure

to hold pump at full stroke.
• Servo piston
– Three times bias piston
area.
– The servo piston is the
control piston.
Bias Piston

LOAD SENSE OPERATION THEORY
Load Pressure
Control Handle
Valve /Orifice
Flow to
Servo Piston
System Pressure
Pump

LOAD SENSING CIRCUIT
Engine running. No function selected.
M Port blocked.
0 bar.
CONTROL
Bank valve
VALVE
X PORT
B Port
30 bar (435psi).
BIAS
Remote Port
Stroked to
give 2cc / rev Bleed Orifice (LB
Control)Plug (LS Control)
.
M4 Port
L1,L2 Ports S port

Gain Orifice (Optional)
Engine running. Product conveyor selected.
Bank valve M 70 litres min (18.4 USG)@ 60 bar (870 psi)

60 bar(870 psi)
CONTROL
VALVE
X PORT
B Port
90 bar (1305 psi)

BIAS
Remote Port
Stroked to
give 39 / rev Bleed Orifice (LB
.
M4 Port
L1,L2 Ports S port

Engine running. Tracks selected.
M 90 litres min (23.7 USG)@ 180 bar (2610 psi)

180 bar (2610 psi)
CONTROL
Bank valve
VALVE
X PORT
B Port
210 bar (3045 psi)

BIAS
Remote Port
Stroked to give
50cc / rev Bleed Orifice (LB
M4 Port
L1,L2 Ports S port

Engine running. Tracks selected + stalled
M LS WITH LOAD
3 litres minAT@PC290
SETPOINT
bar (1 USG @ 4205psi)
290 bar(4205psi)
CONTROL
Bank valve
VALVE
X PORT
B Port
320 bar (4640psi). BIAS
Stroked to give
2cc / rev Bleed Orifice (LB
. Control)Plug (LS Control)
M4 Port
L1,L2 Ports S port

Ga in Orifice (Optional)

THREE BANK VALVE
The three bank valve has a main relief valve set at 350 bar(5075psi). This is a
last line relief to protect the pump should the pump relief not respond quick
enough. The product conveyor relief is set at 180 bar(2610psi)
The hydraulic pressure in the system can be taken from a test point on the
bank valve. On the 5/7 bank valve when there are two circuits are working at
once, the pressure gauge will only read the highest of the two, not the
combination of the two.
Jaw
adjustment System Test
(75 bar) Point
(1087psi)
Product
conveyor relief
Main (180 bar)
pressure (2610psi)
relief
Load sensing
( 350 bar)
Line
(5075psi)
H.F.O CLUTCH CIRCUIT
The hydraulic operated clutch needs to maintain 33 bar(479psi) operating
pressure, but not exceed it. This is achieved by passing oil through a relief
valve set at that. A pressure switch is fitted in the circuit to stop the feeder if
the pressure drops below 23 bar(333psi).
Restrictor Orifice Divertor Test Point Pressure Switch

Valve Tank line Valve (23 Bar)
(333psi)
Clutch
Feed
A C
B
Relief Valve
(33 Bar)
(479psi)
De energised
With the divertor valve in the off position, the oil comes through the restrictor
valve and dead heads against the divertor valve. The purpose of the orifice
and restrictor valve is to limit the amount of oil flow going through the clutch
circuit.
23 (333 psi)
5 L/M( 1..3 gal)
orifice Divertor
Set at 33 bar(479 psi)

Energised
When the divertor valve is energised the spool moves to allow oil to pass
through and go to the clutch. The pressure switch changes over to indicate
good oil pressure and allows the feeder to be started.
The relief valve ensures that 33 bar(479psi) is maintained in the system.
23 (333 psi)
5 L/M( 1..3 gal)
orifice Divertor

De energised
When the H F O clutch is switched off the spool on the divertor valve moves
into the neutral position allowing all oil in the clutch circuit to return to tank.
23 (333 psi)
5 L/M( 1..3 gal)
orifice Divertor

5 BANK VALVE RELIEFS
The premier trak can be fitted with a 5 or 7 bank valve.
The track splice doesn’t have a relief valve built into it. The pump will de-
swash or it will relieve through the main bank valve if the pressure gets too
high.
The feeder and dirt conveyor are set at 180 bar (2610psi) on the relief valves.
All folding circuits are set at 100 bar(1450psi) on the relief valves.
Relief Valves
(180 Bar) Dirt con
Track Dirt con
fold
2610psi Feeder Tail lift
Main Bank DC
Valve Relief
Relief Valves
(350 Bar)
(100 Bar)
5075psi
1450psi

3 BANK VALVE RELIEFS
Crusher
adjustment
Valve Relief
Product Crusher
Track conveyor adjust (75 Bar)
1087psi
Main Bank
Valve Relief Product
(350 Bar) conveyor
5075psi Valve Relief
(210 Bar)
3045psi
APPROXIMATE BANK VALVE VOLTAGES
Tracks Feeder Conveyors + Folding Cylinders
Reverse Low Speed 16v 16-20v 24v

Reverse High Speed 19v
Forwards Low Speed 8v
Forwards High Speed 5v
Track Feeder Dirt con Tail lift Dirt con

fold

ACTUATOR PINS
PIN 1 is the supply voltage into the actuator.
PIN2 is the variable voltage into the actuator which controls the spool
direction and spool travel for variable oil flow.
None of the pins receive any voltage until a track button is pressed.
Earth.
Pin 1. Pin 2.

ACTUATOR PINS
There are only 2 wires used on the on / off type actuator.
Pin 1 receives 24 volts which moves the lever up which pressurises out of the
bottom port. (as the valve is shown)
Earth.
Pin 1
24 volt

SPOOL TRAVEL
Lever travels down to

Max spool pressurise out of the
Max flow 19 volts
travel bottom port. (as the
valve is mounted)
No spool travel no flow 12 volts
Lever travels up to
Max spool pressurise out of the
Max flow 5 volts
travel top port. (as the
valve is mounted)

FULL SPEED VOLTAGES
•Feeder + Actuators Require 75% Of Battery Voltage To Obtain

Full Speed
•Example
24 Volts x 75 % =18 Volts
•Track Actuators Require 25 % Or 75 % Of Battery Voltage Depending On

Spool Direction
•In the event of a feeder speed control switch failure, a link wire between
the supply voltage and the variable voltage on the hersman plug will give
full speed.
ACTUATOR IDENTIFICATION
Three types of actuator are fitted to the bank valves. The track and feeder
actuator look the same but are different. The feeder actuator is more sensitive
and can move the spool more gradually for a wider range of oil flows. The
feeder actuator can also be identified by an LED. The track and feeder work
on a variable voltage where as the others are either on or off.
LED Feeder Tail lift

Track Dirt con Dirt con
fold
PVEM PVEH
Track Number
Conveyors Or Hydraulic Cylinders Feeder Number 157B4128
157B4088
157B4228
ACTUATOR IDENTIFICATION
On the new machines all of the actuators look the same although the feeder
actuator can still be identified by the LED on the front.
LED

PVEM/PVEH/PVES
+8
+6
+4
+2
0
20% 4% 0,2%
-2
P tank: 8 bar
-4 U DC : 24 V
Freq: 0,02 Hz
-6
-8

ACTUATOR OPERATION
Closed loop control of the main spool
Pilot-oil
Electronics
Valves Electronic sender Locator pin

unit
ACTUATOR OPERATION
O rings Locator pin

BODY IDENTIFICATION
All of the splices in the bank can be identified by the numbers on the bottom
Inlet body number 5111 Track body number 6000

All other body numbers 6203
All of the end caps are the same
The only difference between the track body and the other bodies is the relief
valves
Engraved
numbers End cap
Inlet

5 BANK SPOOL SIZES
The oil flow through each splice depends on the size of the spool fitted.
The spools should move smoothly in the body.
The spool can be removed by unscrewing the four allen bolts from the
aluminium cover and removing. The spool can then be pulled out. Oil loss can
be reduced by blanking off the feed and return pipes to the bank valve.
Folding Circuits
25 L/M
6.8 USG
Tracks
100 L/M
26.3 USG Feeder
65 L/M
17.1 USG
•Spool
Removal Dirt Conveyor
25 L/M
6.8 USG
3 BANK SPOOL SIZES
Product Crusher
Track conveyor adjust Crusher
adjustment
10 L/M
2.63 USG
Tracks
100 L/M
26.3 USG
Product
conveyor
100 L/M
26.3 USG

SPOOL SIZES
The size of the oil groove in the spool determines the oil flow.
The bigger the groove the greater the flow.
The spool size can be identified by the Danfoss number etched into the end of
it.

PVG32 BANK VALVE CROSS SECTION
The pressure compensator ensures the the valve delivers a constant oil flow
regardless of the working pressure.
Spool
Pressure
compensator

SPOOL DIRECTION
The direction of the spool determines which port is pressure and which is the
return.
Tank Pressure
Load
sensing

SPOOL LIMIT SCREWS
The limit screws are used to restrict the spool movement to control the
amount of oil flow to set up the correct speeds
If the limit screw is less than 8mm(5 /16”) from the tip to the body, it means
that the spool is being restricted
The arrows below show the top screw restricts the travel to the right and the
bottom screw restricts it to the left
8mm (5/16”)

PREMIERTRAK HYDRAULIC CIRCUIT
R/H

CROSS LINE CHECK VALVE

Cylinders
Pressure switch
N.C
Test point 492 bar
Relief valve 500 bar
Logic elements
Solenoid valve
1” check valve 500 bar
Check valve
Manifold block
Pressure
intensifier x 7 10 litre spool
@ 75 bar relief
Bank valve Advanced Crushing Technology
Reading Tolerance Limits Actual
Item Measured Position / Time
Required Upper Lower Reading
Front 29 30 28
Stand By Pressure
- Bar
Rear 29 30 28
Front 320 330 310

Pump Stall Pressure
- Bar
Rear 320 330 310
Start N/A N/A N/A

Right Hand Track Fast
Running – Bar
Running <150 150 N/A
Start N/A N/A N/A

Left Hand Track Fast
Running - Bar
Start 238 238 60

Product Conveyor
Pressure - Bar
Product Conveyor Belt Speed – m/min >105 N/A 105
Start <100 100 40

Dirt Conveyor
Pressure – Bar
Running <60 60 N/A
Dirt Conveyor Belt Speed – m/min 75-80 80 75
Start <180 180 N/A

Feeder Pressures - Bar
Feeder Speed Without Dirt Conveyor – rpm >900 915 900
Feeder Speed With Dirt Conveyor – rpm <900 910 885
Feeder Throw 11 11 10
Clutch Control Bar 30.5 30 31
Minimum Feeder Speed <750 750 N/A

PLC SCREEN OPTIONS
By pressing the adjust button on the start up screen 3 other screens can be
accessed.

LANGUAGE
If the language button is pressed there are 3 languages to choose from by

pressing the button underneath the arrows.

LEVEL CONTROL
The level control screen is used if a level sensor is fitted to the end of the
product conveyor.
The enable light should only be on if a sensor is fitted.
If the level of material gets within 35cm(14”) of the sensor head it will go blind
and the feeder will not stop.

ALARM COUNTS
This screen displays various faults and how many times they have occurred.

PLC ACCESS
One of the options on the PLC screen is ‘CONFG MODE’.

Enter into this screen and it will ask for a password.

PIN CODE
The pin code number can be found on the side of the PLC within the electrical
panel.
The pin code for this PLC is ‘0613’.
This also can be seen on the PLC screen as soon as the ignition is turned on.

PLC ACCESS
Enter the relevant pin code and press enter.

All of the jaws start with 06**.
There are various screens and settings that can be accessed.

I / O SCREENS

RESET ALARM COUNTS
The fault counter can be reset from within the configuration mode.

SCREEN SET UP
The brightness and contrast is adjustable.

ENGINE LOAD
Press the engine load button and it will display all load set points and delay
times

HIGH SET POINTS
The high set point is adjustable and it will stop the feeder if the engine load
reaches the set point for the pre entered time delay.
The feeder will automatically re-start when the engine load drops below the
re-set set point.

RESET SET POINTS
The re-set point at which the feeder will automatically start up again is also
adjustable along with the time delay.
The feeder will not start up until the engine load has dropped below the ‘reset
set point’ for the time delay entered.

FEED LIMIT SET POINTS
The feed limit set points only start to control the speed of the feeder when the
engine load goes above the high set point.
If the engine load is below the high set point, the feeder speed is set by the
speed control potentiometer.

FEED LIMIT SET POINTS
When the engine load goes above the high set point it will reduce the feeder
speed by 25% every four seconds until the engine load drops down to the
re-set point.
The feeder will then speed up by 25% every 2 seconds until it gets back to the
original potentiometer speed.

OVERSHOOT SET POINTS
The is used each time the feeder slows down a step.
A 15% reduction in one go will barely reduce the feed into the crusher so the
overshoot will reduce the feeder speed by 50% for 2 seconds to act a brake to
the feeder speed.
After then it will speed up to the original 25% reduction speed.

INDEX STEPS
If the engine is under high load the feeder speed will keep stepping down to a
maximum of 4 steps.
The screen will display the amount of steps and its current position.
The PWM indicates the current feeder speed.
The engine average load can also be viewed.

CUT OUT SET POINTS
When the engine load reaches the cut out set point of 100 % for 3 seconds it
will automatically stop the feeder.
The feeder will not restart until the ‘Feeder start’ button is pressed on the
operators control station.
This function is to reduce the chance of stalling the engine.

SELECT MODE
The ‘SELECT MODE’ screen gives you the option to enable or disable the
feed limit mode or the cut-out mode.
If a mode is enabled the red LED will illuminate underneath it.
If nothing is enabled, there will be no lights.

FEEDER SET UP
The values that are entered below set the minimum and maximum feeder
speeds.
These should never be adjusted without B L Pegsons approval.

JAW SET UP
The PLC is used on the Hydraulic adjust (HA) and the Hydraulic
release (HR) crushers.
Ensure that the mode selected matches the type of crusher fitted.
The STATIC OPERATING and ALARM applies to both types of machines
but the values are different.
The 2ND DUMP is not used.

STATIC SET POINTS
The static set point of 250 bar is the pressure that needs to be developed in the
adjustment cylinders before the crusher can be started.
When the pressure naturally leaks below 240 bar in the cylinders they
pressurise back up to 250 bar.

OPERATING SET POINTS
Once the crusher has been started the pressure is then increased in the
cylinders to the working pressure of 420 bar and then stops charging.
When the pressure decays to 410 bar the cylinders will be re-pressurised back
up to 420 bar.

ALARM SET POINTS
When the crusher is being started the feeder cannot be started until the
pressure in the cylinders is above 380 bar.
Whilst crushing if the pressure drops below 380 bar it will automatically stop
the feeder and display a pressure fault warning on the PLC screen.

OUT OF SEQUENCE
The ‘OUT OF SEQ’ button can be selected and it will allow functions to be
started out of order.
For example, the feeder can be started before the product conveyor.
This is for test purposes only.

PLC FAULT NUMBERS AND MESSAGES
PLC FAULT NUMBER DESCRIPTION

1 Emergency stop fault
2 Radio stop fault
3 Oil level low (hydraulic)
5 Crusher HFO pressure low
6 Cylinder pre-load pressure low
7 Cylinder pressure overload
8 Engine overload feed inhibit
10 Engine overload feed cut out
11 Can block error
12 Can bus error
PLC MESSAGE
Out of sequence - warranty invalid
Tracking mode – ensure radio on
Cylinder pre-load pressure low
Feed stopped material too close to belt

How to check the jaws hydraulic circuit,
For this you will require a pressure test gauge, for this contact
Terex Pegson (Part No:Kobold MAN-SD with a 1/2″ female
connection). There are four test points from were to do these
checks from, these being the Danfoss valve bank, the jaw valve
block and the two hydraulic cylinders. In the table below are
the pressures that the crusher should be at.
TEST POINTS what the pressure should be
Danfoss valve bank Jaw valve block Cylinders
Engine runing 25-27 bar 0-1 bar 0-1 bar
Pressuring up 250 bar 80-100 bar increasing 0-250 bar increasing 0-250 bar
Pressurised to 250 bar 25-27 bar 250 bar 250 bar
Pressurised upto 370 bar 104-110 bar 360-380 bar 360-380 bar

This is part of the electrical
Electrical circuit diagram, circuit diagram of the can
bus system which enables
the hydraulic jaw to
pressurise.
To Main control panel
Drawing No: HYD JAW 06-

CAN-V04.VSD
To NODE 4
Within the can bus system there is a series of NODES, these
nodes have a series of LED’s that show the status of the node
which are listed below.
Diagram of NODE
LEDS located
on the NODE

Fault finding on the hydraulic jaw,
Reported Fault Diagnosis Effect & Solution
Pressure Fluctuating Faulty pressure reducer/relief Replace valve or adjust alarm points to
valve (old style control). compensate (temporary fix)
Low Pressure Alarm Activating Pressure reducer set too Adjust pressure reducer or pressure switch
close to the alarm trigger (old style machine)
point.
Operating pressure on PLC Adjust PLC settings (general rule is 30 bar
set to close to low pressure difference - ensure LP alarm is above static
alarm. pressure).
Internal leak in system. Test system by measuring decay rate
(disconnect hirshman plug on valve bank slice
whilst at pressure and measure at 20s periods
for 5 mins. Decay should be steady). Report to
engineering.
Check valve settings - pressure reducer and
main relief valves.
Remove Solenoid dump valve and clean using
air line. Lubricate and refit. (Check for
contaminatio).
Check for leakage across the cylinders - Close
the machine so that the toggle beam sits
against the shims. Disconnect the annulus side
hoses and put open end into a bucket.
Pressurise the system and see if any oil flow is
present.

System pressure does not Check the slice pressure (standby ~30bar,
fully charge total ~ 95 bar depending on the type of
intensifier).
Check that the intensifier is operating (the unit
will 'click' when charging)
Is the unit correctly piped (are the hoses going
to the correct sides of the intensifier). The unit
should charge when 'Jaw In' or 'Jaw On' are
activated.
Check that the pressure reducer/relief valve is
correctly set (on PLC version machines it
should be fully wound out).
Is the solenoid dump valve operating correctly.
During normal operation the valve should be
constantly energised (24V). Check the
solenoid and wiring to the relay. Check for
contamination (filters now being fitted).,
Press the manual overide (spool) on the top of
the dump valve and make sure it moves freely.
If stiff, remove the valve and clean with an air
line. If this still does not work replace the valve.
Overload Alarm Activating Application Check the CSS for the material, the material
properties (take a sample) and the amount of
fines. The machine will not cope with material
above the stated max of 390kN (10% Fines).
Check for asphalt in the feed and packing in
the jaw.
Steel. Steel (larger than the CSS) will result in
Overloads.

Settings. Check that the operating pressure is not too
close to the overload alarm point (414bar).
Max operating pressure should be 370bar
(was 380bar). In hard applications this can be
dropped to create a bigger window between
the operating pressure and the overload
settings.
Electrics. Check all the connections to ensure there are
no breaks.
Check the alarm on the PLC display. If this
shows that an 'Overload' has taken place
check the pressure switch is reading correctly
and that the connections between it and the
node (relay) are sound. Check the wire from
the PLC to the node.
If a low pressure alarm is displayed on the
PLC: Check the node (relay) cable to the
solenoid dump valve for integrity. Check the
solenoid dump valve as per the low pressure
check discussed previously. Ensure that there
is plenty of slack at the ends of the cable, if not
cut the tiewraps holding the wires to the 2"
return hose and re-route (when this hose
'KICKS' it can pull the connections). Check the
relay- earlier verisions weren't 100% reliable
and have since been changed. To test tap the
relay during operation to see if latch can drop.

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4mm Allen key

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CHANNEL NUMBER FREQUENCY MHz

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