Cobra 290 & 290R Operations Manual Revision 2.3 (En)

Cobra 290 &
290R
MOBILE CRUSHER
Issue Date: 16/05/2019

Operations Manual Language: English (en)
Revision No.: 2.3
Original Instructions
Parts Manual On USB Inside Front Cover

EvoQuip
200 Coalisland Road
Dungannon, Co. Tyrone
BT71 4DR
Telephone: +44 (0) 28 8774 0701
Serial Number
Year of Construction
Date of Delivery
Dealer Stamp
Notice
Record of Revisions
Record of Revisions
Revision Reason for Change Date
Number
Introduction of the Cobra 290. 06 September
1.0
2018
Service Maintenance Schedule Updated. 07 November
1.1
2018
290R has been added into manual 06 December
2.0
2018
Storage chapter updated 11 January
2019
2.1 Afterscreen tie-down image updated
Engine Coolant procedure updated
Exclusion Zone Added 07 February
2019
Noise Test Added
2.2 Placing Lighting Mast procedure added.
Note added about light condition, additional
lighting to be used
2.3 Stage V option added 16 May 2019
Operations Manual Revision 2.3 16-05-2019

Cobra 290 and 290R Page 3
Record of Revisions
Intentionally Left Blank
16-05-2019 Revision 2.3 Operations Manual

Page 4 Cobra 290 and 290R
Table of Content
Table of Content
Table of Content...................................................................................................... 1
1 Introduction.................................................................................................1-1
1.1 Notes to the Operations Manual .................................................................... 1-2
(1) Units .......................................................................................................... 1-2
(2) Optional Equipment ................................................................................... 1-2
1.2 Safety Information .......................................................................................... 1-3
(1) Safety Alert Symbol ................................................................................... 1-3
(2) ANSI Hazard Classification System .......................................................... 1-3
(3) California Proposition 65 Warnings ........................................................... 1-3
1.3 Intended Use.................................................................................................. 1-4
1.4 Prohibited Use................................................................................................ 1-4
1.5 Declaration of Conformity............................................................................... 1-4
1.6 Copyright........................................................................................................ 1-4
1.7 Bulletin Distribution and Compliance ............................................................. 1-5
1.8 Contacting the Manufacturer.......................................................................... 1-5
1.9 Transfer of Machine Ownership ..................................................................... 1-5
1.10 Machine Identification Plate ........................................................................... 1-6
2 Safety ...........................................................................................................2-1
2.1 General Safety ............................................................................................... 2-2
(3) Property Damage Messages ..................................................................... 2-3
(4) Description of Safety Symbols................................................................... 2-3
2.2 Machine Safety Signs .................................................................................... 2-9
(1) Machine Safety Sign Locations ............................................................... 2-20
2.3 Personal Safety............................................................................................ 2-25
(1) Personal Protective Equipment (PPE)..................................................... 2-25
2.4 Work Area Safety ......................................................................................... 2-26
(1) General Work Area Guidelines ................................................................ 2-26
(2) Safety Warnings and Labels.................................................................... 2-26
(a) Modifications ....................................................................................... 2-26
(3) Transportation Safety .............................................................................. 2-27
(4) Operation Safety...................................................................................... 2-28
(5) Hydraulic and Pneumatic Safety ............................................................. 2-30
(6) Electrical Safety....................................................................................... 2-31
(a) Electrical and/or Lightning Storm ........................................................ 2-32
(7) Maintenance Safety................................................................................. 2-33
(8) Gas, Dust, Steam, Smoke ....................................................................... 2-35
(9) Hazardous Substances ........................................................................... 2-35
(10) Noise Levels ............................................................................................ 2-35
(11) Fire Hazards ............................................................................................ 2-36
(a) Recommended Fire Extinguisher Locations ....................................... 2-36
(12) Exclusion Zones ...................................................................................... 2-37
(a) Magnet Exclusion Zone ...................................................................... 2-37
(b) Impactor Exclusion Zone .................................................................... 2-38
(c) Conveyor Exclusion Zone ................................................................... 2-39
3 Technical Data.............................................................................................3-1

Table of Content
3.1 General Information ....................................................................................... 3-2

3.2 Dimensions .................................................................................................... 3-3
(1) Working Position With Side Conveyor (Standard) ..................................... 3-3
(2) Working Position With No Side Conveyor (Standard) ............................... 3-4
(3) Transport Position (Standard) ................................................................... 3-5
(4) Working Range Dimensions (R Model) ..................................................... 3-7
(5) Transport Range Dimensions (R Model) ................................................... 3-9
3.3 Noise Emissions........................................................................................... 3-10
(1) 290 Noise Emissions .............................................................................. 3-10
(2) Cobra 290................................................................................................ 3-10
3.4 Machine Weights.......................................................................................... 3-11
3.5 Machine Components .................................................................................. 3-11
(1) Machine Components.............................................................................. 3-11
(a) Machine Component Specifications.................................................... 3-13
3.6 Impactor Capacity ........................................................................................ 3-16
3.7 Impactor Settings ......................................................................................... 3-17
(1) Product Gradings..................................................................................... 3-18
(2) Apron Gap Settings ................................................................................. 3-19
(3) Rotor Speed ............................................................................................ 3-19
3.8 Blow Bar Specifications................................................................................ 3-20
(1) Overview.................................................................................................. 3-20
(a) Martensitic Steel Blow Bars ................................................................ 3-20
(b) Ceramic/Martensitic Blow Bars ........................................................... 3-20
(c) High/Medium Chromium Steel Blow Bars........................................... 3-20
(d) Manganese Steel Blow Bars............................................................... 3-21
(e) Using 2 Long and 2 Short Blow Bars .................................................. 3-21
(f) Using 4 Long Blow Bars...................................................................... 3-21
4 Machine Description...................................................................................4-1
4.2 Systems ......................................................................................................... 4-3
(1) Electrical System ....................................................................................... 4-3
(a) Telematics ............................................................................................. 4-3
(2) Drive System ............................................................................................. 4-3
(a) Power Unit ............................................................................................ 4-3
(3) Crushing System ....................................................................................... 4-3
(a) Impactor Crusher .................................................................................. 4-3
(b) Chutes................................................................................................... 4-3
(c) Dust Suppression Sprays ..................................................................... 4-3
(4) Conveying System..................................................................................... 4-4
(a) Discharge Conveyor ............................................................................. 4-4
(b) Bypass Conveyor (Optional) ................................................................. 4-4
(c) Vibrating Feeder ................................................................................... 4-4
4.3 Maintenance Walkways.................................................................................. 4-4
4.4 Chassis .......................................................................................................... 4-4
4.5 Guards ........................................................................................................... 4-4
4.6 Control and Display Elements ........................................................................ 4-5
(1) Radio Remote Control Tracking Button Sequences .................................. 4-5
(2) Umbilical Control Handset ......................................................................... 4-6
(3) Machine Information Decals ...................................................................... 4-7

Table of Content
(4) Options .................................................................................................... 4-13

5 Transportation.............................................................................................5-1
5.1 Transport Safety............................................................................................. 5-2
5.2 Preparation Prior to Transportation ................................................................ 5-3
(1) Activating the Control Banks ..................................................................... 5-4
(2) Placing the Discharge Conveyor into the Transport Position .................... 5-6
(3) Placing Bypass Conveyor Into Transport Position..................................... 5-8
(a) Placing Bypass Conveyor into Transport Position ................................ 5-8
(4) Placing Recirculating Conveyor Into Transport Position (R MODEL
ONLY)...................................................................................................... 5-10
(5) Placing Lighting Mast Into Transport Position ........................................ 5-16
5.3 Locking screenbox for transport................................................................... 5-17
5.4 Loading the Machine for Transport .............................................................. 5-18
5.5 Transport Tie-Down Points........................................................................... 5-19
(1) Transport Tie Down Point Locations........................................................ 5-20
5.6 Unloading the Machine From Transport....................................................... 5-23
6 Initial Setup and Adjustments ...................................................................6-1
6.1 Assembly and Installation .............................................................................. 6-2
6.2 Initial Inspection Check .................................................................................. 6-3
6.3 Location Considerations................................................................................. 6-4
6.4 Measures Before Setup ................................................................................. 6-5
6.5 Measures after Long-Term Standstill ............................................................. 6-5
6.6 Setting Up The Machine................................................................................. 6-6
(1) Placing the Discharge Conveyor into the Working Position ...................... 6-7
(2) Placing Bypass Conveyor Into Working Position....................................... 6-9
(3) Placing recirculating conveyor into working position (R MODEL
ONLY)...................................................................................................... 6-10
(4) Placing Lighting Mast into Working Position............................................ 6-14
6.7 Setting Up And Using The Water Pump (Option)......................................... 6-16
6.8 Initial Startup And Running In ...................................................................... 6-17
7 Standard Operating Procedures ...............................................................7-1
7.1 Pre-Operating Checks.................................................................................... 7-2
7.2 Starting The Engine ....................................................................................... 7-3
7.3 Manoeuvring .................................................................................................. 7-5
(1) Umbilical Tracking ..................................................................................... 7-7
(2) Remote Tracking (Optional)..................................................................... 7-10
7.4 Standard Operation...................................................................................... 7-13
(1) Putting the Machine into Operation (Standard Models)........................... 7-13
(a) Auto Mode........................................................................................... 7-14
7.5 Setting The Vibrating Feeder Speed ............................................................ 7-15
(1) Enabling Manual Or Auto Feeder Mode .................................................. 7-15
(a) Adjusting Feeder Speed In Manual Mode........................................... 7-17
(b) Adjusting Feeder Speed In Auto Mode ............................................... 7-18
7.6 Radio Remote Control Crushing Operation ................................................. 7-19
(1) Enabling Track Whilst Crushing............................................................... 7-21
(2) Obtaining Four Digit Security Pin ............................................................ 7-23
(3) Track Whist Crushing Function................................................................ 7-24
7.7 Introducing Material to the Machine ............................................................. 7-25
7.8 Shutdown ..................................................................................................... 7-25

Table of Content
(1) Shutting Down The Machine Via The Control Panel ............................... 7-26
7.9 Blocked Crusher........................................................................................... 7-27
(1) Temporary Opening of Upper Apron System........................................... 7-28
(2) Open Upper Apron using Radio Remote Control [if fitted]....................... 7-29
(3) Manually Clearing The Blockage............................................................. 7-30
7.10 Impactor Access........................................................................................... 7-31
(1) Testing Chamber Safety Switches........................................................... 7-31
(2) Activating Battery Operated Hydraulic System........................................ 7-34
(3) Accessing Inspection Door ...................................................................... 7-37
(4) Opening Impactor Body........................................................................... 7-39
(5) Closing Impactor Body ............................................................................ 7-44
7.11 Crusher Apron Adjustment........................................................................... 7-47
(1) Upper Apron Adjustment ......................................................................... 7-48
(2) Lower Apron Adjustment ......................................................................... 7-52
7.12 Detaching and Attaching the R section ........................................................ 7-56
(1) Detaching the ‘R’ Section ........................................................................ 7-56
(2) Attaching the ‘R’ Section ......................................................................... 7-60
8 Emergency Operating Procedures............................................................8-1
8.1 Lockout and Tagout........................................................................................ 8-2
(1) Before Carrying Out Any Work On The Machine ...................................... 8-2
(2) After Carrying Out Work on the Machine................................................... 8-5
(3) Emergency Stop ........................................................................................ 8-6
(4) Restarting After an Emergency Stop ......................................................... 8-7
(5) Testing Emergency Stop............................................................................ 8-8
9 Maintenance ................................................................................................9-1
9.1 Safety Before and During Maintenance ......................................................... 9-4
(1) Main Discharge Conveyor ......................................................................... 9-6
(2) Diesel Engine ............................................................................................ 9-6
(3) Crusher...................................................................................................... 9-7
(4) Feeder ....................................................................................................... 9-7
(5) Bypass Conveyor ...................................................................................... 9-7
(6) Recirculating Conveyor (R Model) ............................................................ 9-8
(7) Transfer Conveyor (R MODEL) ................................................................. 9-8
(8) Fines Conveyor ( R Model) ....................................................................... 9-8
(9) Screen Box (R Model) .............................................................................. 9-8
9.3 Maintenance Schedules................................................................................. 9-9
(1) User Maintenance Schedule ..................................................................... 9-9
(2) Service Maintenance Schedule ............................................................... 9-13
(3) Extended Service Schedule .................................................................... 9-16
9.4 Greasing Schedule....................................................................................... 9-17
9.5 Lubricants, Oils, and Fluids.......................................................................... 9-20
(1) Lubrication, Quantities and Levels .......................................................... 9-20
(2) Machine Grease Lubrication.................................................................... 9-22
(a) Standard Viscosity Option................................................................... 9-22
9.6 Hydraulic Maintenance................................................................................. 9-23
(1) Hydraulic System Overview..................................................................... 9-23
(a) Hydraulic Fluids .................................................................................. 9-24
(b) Oil Tank, Pipes & Fittings .................................................................... 9-24

Table of Content
(2) Hydraulic Filtration................................................................................... 9-25

(a)
Hydraulic Tank .................................................................................... 9-25
(b)
Suction Line Filters ............................................................................. 9-26
(c)
Return Line Filter ................................................................................ 9-26
(d)
Pressure Filter..................................................................................... 9-27
(e)
Hydraulic Oil Tank Breather ................................................................ 9-27
(3) Changing Hydraulic Filters and Oil .......................................................... 9-28
(a) Changing Return Filter........................................................................ 9-28
(b) Changing ‘R’ System suction filter ...................................................... 9-30
(c) Changing Suction Filter....................................................................... 9-32
(d) Changing Pressure Filter .................................................................... 9-34
(e) Changing Hydraulic Oil ....................................................................... 9-36
(f) Changing Condensation Control Breather .......................................... 9-38
9.7 Conveyor Maintenance ................................................................................ 9-39
(1) Conveyor Checks .................................................................................... 9-39
(2) Conveyor Belt Adjustment and Tensioning.............................................. 9-41
(3) Belt tracking on Transfer Conveyor (R Model Only) ............................... 9-42
(a) Belt Tensioning on the Recirculating Conveyor ................................. 9-43
(4) Belt tracking on Fines Conveyor ............................................................. 9-44
(a) Belt Tensioning on the Fines Conveyor ............................................. 9-45
(5) Belt Tracking on Discharge Conveyor ..................................................... 9-46
(a) Belt Tensioning On Discharge Conveyor ............................................ 9-47
(6) Belt Tracking On Bypass Conveyor......................................................... 9-48
(a) Belt Tensioning on Bypass Conveyor ................................................. 9-49
(7) Cleaning Conveyor Belts ......................................................................... 9-50
(8) Checking the Skirting Rubber and Skirting Clamps for Wear .................. 9-51
9.8 Vibrating Feeder Maintenance ..................................................................... 9-52
(1) Checking Feeder Oil Level And Refilling ................................................. 9-52
(2) Changing Feeder Oil ............................................................................... 9-52
9.9 Vibrating screen box maintenance (R Model) .............................................. 9-53
(1) Changing Screen Box Mesh ................................................................... 9-53
9.10 Volvo Engine Overview ................................................................................ 9-54
(1) Changing Engine Filters and Oil.............................................................. 9-55
(a) Checking the Engine Oil ..................................................................... 9-55
(b) Changing the Engine Oil ..................................................................... 9-56
(c) Volvo Crankcase Breather Filter Change............................................ 9-57
(d) Changing the Air Cleaner Elements.................................................... 9-59
(2) Cooling System Maintenance.................................................................. 9-60
(a) Checking Engine Coolant Level.......................................................... 9-60
(b) Checking Antifreeze and Corrosion Inhibitor ...................................... 9-62
(c) Draining Coolant ................................................................................. 9-63
(d) Filling the Engine Coolant ................................................................... 9-64
(3) Fuel System............................................................................................. 9-65
(a) Bleeding the Fuel System ................................................................... 9-65
(b) Changing the Fuel Pre-filter ................................................................ 9-67
(c) Changing the Fuel Cleaner ................................................................. 9-68
(d) Changing the Final Fuel Filter............................................................. 9-69
(e) Draining the Water Trap...................................................................... 9-72
(4) Servicing the DEF (Diesel Exhaust Fluid) System (Tier 4 Machines
Only) ........................................................................................................ 9-73

Table of Content
(a) DEF Tank Location.............................................................................. 9-73

(b) Changing the DEF Pump Filter ........................................................... 9-74
(c) DEF Tank Flush .................................................................................. 9-75
(d) Refilling the DEF (Diesel exhaust fluid) System ................................. 9-77
9.11 Clutch Maintenance ..................................................................................... 9-79
9.12 Refuelling ..................................................................................................... 9-80
(1) Refuelling the Machine ............................................................................ 9-81
9.13 Track Maintenance....................................................................................... 9-83
(1) Changing Track Gear Box Oil.................................................................. 9-84
(2) Track Adjustments ................................................................................... 9-85
(a) To Release Track Tension................................................................... 9-86
(b) To Increase Track Tension .................................................................. 9-87
9.14 Impactor Maintenance.................................................................................. 9-88
(1) Checking Components For Wear ............................................................ 9-88
(a) Daily Component Checks ................................................................... 9-88
(2) Impactor Checks...................................................................................... 9-89
(3) Blow Bar Wear Profiles............................................................................ 9-90
(4) Hard Facing Rotors ................................................................................. 9-93
(5) Replacing Impactor Blow Bars ................................................................ 9-94
(a) Removing Impactor Blow Bars............................................................ 9-95
(b) Turning Blow Bars............................................................................... 9-97
(c) Fitting the Impactor Blow Bars ............................................................ 9-98
(d) Replacing the Impactor Wear Plates ................................................ 9-102
(e) Replacing Inlet Chains and Curtains................................................. 9-105
9.15 Crusher Drive Belt Maintenance ................................................................ 9-106
(1) Aligning The Belt ................................................................................... 9-108
(2) Belt Tensioning Measurements ............................................................. 9-110
(3) Belt Tensioning Adjustment ................................................................... 9-112
(4) Replacement Of Vee Belts .................................................................... 9-113
9.16 Electrical Maintenance ............................................................................... 9-115
(1) Prior To Welding .................................................................................... 9-115
(2) Battery Removal And Installation .......................................................... 9-117
9.17 Dust Suppression Maintenance ................................................................. 9-119
9.18 Hydraulic Cylinder Maintenance ................................................................ 9-119
9.19 Washing The Machine................................................................................ 9-119
10 Troubleshooting........................................................................................10-1
10.1 Crusher Troubleshooting Guide ................................................................... 10-2
(1) General Troubleshooting ......................................................................... 10-2
(2) VGF Troubleshooting............................................................................... 10-3
(3) Conveyor Troubleshooting....................................................................... 10-4
(4) Component Troubleshooting ................................................................... 10-5
(5) Hydraulic Troubleshooting ....................................................................... 10-6
(6) Tracks Troubleshooting ........................................................................... 10-9
(7) Electrical Troubleshooting ..................................................................... 10-11
(8) Impactor Chamber Troubleshooting ...................................................... 10-12
10.2 Diagnostic Information ............................................................................... 10-13
10.3 Engine Troubleshooting ............................................................................. 10-14
(1) Viewing The Engine Information Screen ............................................... 10-14
(2) Viewing SPN And FMI Codes................................................................ 10-16

Table of Content
(3) Accessing Stage V Information ............................................................. 10-18

10.4 Stage V Engine Fault Code........................................................................ 10-20
(1) SPN and FMI Fault Codes..................................................................... 10-20
10.5 Constant Speed Engine Fault Codes......................................................... 10-37
(1) SPN and FMI Fault Codes For Constant Speed ................................... 10-37
10.6 Machine Troubleshooting ........................................................................... 10-41
(1) Accessing Active Alarms And Alarm History ......................................... 10-41
(2) Machine Diagnostic Fault List................................................................ 10-43
10.7 Clutch Diagnostic Data............................................................................... 10-47
(1) Accessing The PT Tech Status Screen ................................................. 10-47
(2) PT Tech Clutch Symbols Explained....................................................... 10-49
(3) PT Tech SPN and FMI Fault Codes ...................................................... 10-52
10.8 Vee Belt Troubleshooting ........................................................................... 10-56
11 Storage ...................................................................................................... 11-1
11.1 Storage......................................................................................................... 11-2
12 Glossary Of Terms....................................................................................12-1
12.1 Glossary Of Terms ....................................................................................... 12-2
Appendix A Declaration Of Conformity............................................................ A-1
A.1 Declaration Of Conformity ..............................................................................A-1
Declaration of Conformity Example................................................................A-2
Appendix B Warranty ......................................................................................... B-1
B.1 Non-USA Sales Warranty...............................................................................B-1
B.2 USA Sales Warranty ......................................................................................B-4
B.3 Machine Warranty Registration ......................................................................B-7
B.4 Engine Warranty Registration ........................................................................B-7
Appendix C Schematics..................................................................................... C-1
Appendix D Oil Specifications .......................................................................... D-1
D.1 Oil Specification .............................................................................................D-1
D.1.1 Engine Oil 5W-30 ......................................................................................D-1
D.1.2 Engine Oil 15W-40 ....................................................................................D-2
D.1.3 Gear Oil Grade 68/220 Synthetic Blend ....................................................D-3
D.1.4 Gear Oil 80W/90........................................................................................D-3
D.1.5 Gear Oil Grade 150 Synthetic ...................................................................D-4
D.1.6 Gear Oil Grade 220 ...................................................................................D-4
D.1.7 Gear Oil Grade 320 ...................................................................................D-5
D.1.8 Hydraulic Oil Grade 32 (cold climate)........................................................D-6
D.1.9 Hydraulic Oil Grade 68 (hot climate) .........................................................D-6
D.1.10Hydraulic Oil Grade 46 (standard climate) ...............................................D-7

Table of Content

Introduction 1
Table of Content
1 Introduction.................................................................................................1-1
1.1 Notes to the Operations Manual .................................................................... 1-2
(1) Units .......................................................................................................... 1-2
(2) Optional Equipment ................................................................................... 1-2
1.2 Safety Information .......................................................................................... 1-3
(3) California Proposition 65 Warnings ........................................................... 1-3
1.3 Intended Use.................................................................................................. 1-4
1.4 Prohibited Use................................................................................................ 1-4
1.5 Declaration of Conformity............................................................................... 1-4
1.6 Copyright........................................................................................................ 1-4
1.7 Bulletin Distribution and Compliance ............................................................. 1-5
1.8 Contacting the Manufacturer.......................................................................... 1-5
1.9 Transfer of Machine Ownership ..................................................................... 1-5
1.10 Machine Identification Plate ........................................................................... 1-6

Cobra 290 and 290R Page 1-1
1 Introduction
1 Introduction
1.1 Notes to the Operations Manual
This Operations Manual contains important information on how to operate the machine safely
and correctly. The machine must only be operated by trained and competent users. Read
this Manual carefully to learn how to operate your machine. Compliance may prevent injury
to persons or damage to property. Consider this Manual a permanent part of your machine.
Always keep it with the machine in the storage location provided. Included with this Manual is a
USB which contains the original language version of this Manual which is English.
There is a separate manual from the engine manufacturer which must also be read and
understood before any operation or maintenance of the machine. Keep this manual with the
machine at all times.
The following procedure bar indicates the start of a procedure. Any safety warnings related to
the procedure are highlighted before the procedure.
PROCEDURE
Any results from a step in the procedure are indicated in italic below that step. The end of a
procedure is indicated with a line under the last step or the last image in a procedure.
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 always.
Compliance may prevent possible danger to persons or property from accidents or harmful
exposure.
Where supplied as a basic machine only (with or without optional extras) the machine
is intended for incorporation into a complete processing machine NOT designed and/or
constructed by Terex. In these circumstances, or where supplied as a replacement machine,
Terex is NOT responsible for addressing environmental issues and/or health and safety
protection measures for the machine installation as a whole. Terex bears NO responsibility for
ensuring compliance with any regulations and/or statutory requirements that apply unless
included in the Contract of Sale.
Any information within this manual is subject to change without prior notice. The images used in
this manual are for illustrative purposes only and may not represent your machine.
(1) Units
All units of measurement contained within this manual are metric measurements. After each
metric measurement is a bracket containing the approximate imperial conversion.
(2) Optional Equipment

Terex machines can include optional equipment and/or special features which are extra to
the standard specification. These options can alter the information given in this operations
manual. Refer to Chapter 4 of the operations manual for extra equipment or variations that
can be applicable to the standard specification. Take note of any variations to the standard
procedures and/or component specifications.

Page 1-2 Cobra 290 and 290R
Introduction 1
1.2 Safety Information

(1) Safety Alert Symbol
The safety alert symbol is used on safety signs and throughout this manual to alert you to
potential personal injury hazards. Obey all messages that follow this symbol to avoid injury
or death.
Conduct thorough risk assessments and mitigate identified risks in accordance to the
assessment.
For more information related to machine safety, refer to the safety section of the manual
(Chapter 2).
(2) ANSI Hazard Classification System

A multi-tier hazard classification system is used to alert you to potential personal injury hazards.
Signal words used with the safety alert symbol indicate a specific level of severity of the
potential hazard. Signal words used without the safety alert symbol relate to property damage
and protection only. All are used as attention-getting devices throughout this manual as well as
on ANSI type decals and labels fixed to the machine.
� DANGER
DANGER Indicates a hazardous situation that, if not avoided, will result in death or serious
injury. (Contains white letters on red background).
� WARNING
WARNING This indicates a hazardous situation that, if not avoided, could result in death or
serious injury. (Contains black letters on orange background).
� CAUTION
CAUTION This indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury. (Contains black letters on yellow background).
The hazards associated with each procedure are highlighted before each procedure, as
described.
(3) California Proposition 65 Warnings
� WARNING
Operating, servicing and maintaining this equipment can expose you to chemicals including
engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of
California to cause cancer and birth defects or other reproductive harm. These chemicals can
be emitted from or contained in other various parts and systems, fluids and some component
wear by-products. To minimize exposure, avoid breathing exhaust, do not idle the engine
except as necessary, service your equipment and vehicle in a well-ventilated area and wear
gloves or wash your hands frequently when servicing your equipment or vehicle and after
operation. For more information go to www.P65Warnings.ca.gov/passenger-vehicle.

1 Introduction
1.3 Intended Use

This product and its approved attachments are designed to be used in Materials Processing
crushing, screening, and washing applications. Compliance with the operating instructions,
the performance of maintenance work as specified and adherence to maintenance intervals
are all aspects of proper use. Use of this product in any other way is prohibited and contrary
to its intended use.
1.4 Prohibited Use

Operating the machine outside of its recommended range of applications results in a loss of
any guarantee. The manufacturer or supplier cannot be held liable for any damage or injury
resulting from such misuse.
Use of this product in any way other than its intended use is prohibited. The manufacturer
accepts no liability for any damage resulting from such use.
1.5 Declaration of Conformity

This machine is in conformity with the provisions of the EC Machinery Directive 2006/42/EC
together with appropriate EN Harmonized Standards and National BS Standards and
Specifications.
A Declaration of Conformity certificate is applicable to each machine. Refer to Appendix A for
an example of a Declaration of Conformity certificate. The original copy of the certificate is
sent out with the machine.
1.6 Copyright
The copyright of this operations manual is reserved by Evoquip.
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 2018.
Evoquip
200 Coalisland Road
Dungannon, Co. Tyrone
BT71 4DR
Telephone: +44 (0) 28 8774 0701
Email: EvoQuip@terex.com
To order additional copies contact your local Evoquip dealer.

Introduction 1
1.7 Bulletin Distribution and Compliance

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

At times, it may be necessary to contact the manufacturer of this machine.
When you do, be ready to supply the model number and PIN number of your machine, along
with your name and contact information. At minimum, the manufacturer can be contacted for
any of the following reasons:
• Accident Reporting.
• Questions regarding product applications and safety.
• Standards and regulations compliance information.
• Questions regarding product modifications.
• Current owner updates, such as changes in the machine ownership or changes in your
contact information. (See transfer of machine ownership).
Contact:
Evoquip
200 Coalisland Road
Dungannon, Co.Tyrone
BT714DR
Telephone: +44 (0) 28 8774 0701
1.9 Transfer of Machine Ownership

If you are not the original owner of this machine, provide the model number and PIN number of
your machine. Also include your name and the date of the transfer of ownership. It ensures
that you are the owner on record for this machine, allowing you to receive any applicable
notices and advisories in a timely manner.

1 Introduction
1.10 Machine Identification Plate

The machine identification plate gives important information about the machine, (Reference;
Figure 1.1)
Figure 1.1 - Identification Plate

1 Machine Model
2 Year Manufactured
3 Machine Mass
4 Serial Number
The machine identification plate is located in the catwalk steps (Item 1, Reference; Figure
1.2) on the left hand side of the machine.
Figure 1.2 - Location of Machine Identification Plate

Safety 2
Table of Content
2 Safety ...........................................................................................................2-1
2.1 General Safety ............................................................................................... 2-2
(3) Property Damage Messages ..................................................................... 2-3
(4) Description of Safety Symbols................................................................... 2-3
2.2 Machine Safety Signs .................................................................................... 2-9
(1) Machine Safety Sign Locations ............................................................... 2-20
2.3 Personal Safety............................................................................................ 2-25
(1) Personal Protective Equipment (PPE)..................................................... 2-25
2.4 Work Area Safety ......................................................................................... 2-26
(1) General Work Area Guidelines ................................................................ 2-26
(2) Safety Warnings and Labels.................................................................... 2-26
(a) Modifications ....................................................................................... 2-26
(3) Transportation Safety .............................................................................. 2-27
(4) Operation Safety...................................................................................... 2-28
(5) Hydraulic and Pneumatic Safety ............................................................. 2-30
(6) Electrical Safety....................................................................................... 2-31
(a) Electrical and/or Lightning Storm ........................................................ 2-32
(7) Maintenance Safety................................................................................. 2-33
(8) Gas, Dust, Steam, Smoke ....................................................................... 2-35
(9) Hazardous Substances ........................................................................... 2-35
(10) Noise Levels ............................................................................................ 2-35
(11) Fire Hazards ............................................................................................ 2-36
(a) Recommended Fire Extinguisher Locations ....................................... 2-36
(12) Exclusion Zones ...................................................................................... 2-37
(a) Magnet Exclusion Zone ...................................................................... 2-37
(b) Impactor Exclusion Zone .................................................................... 2-38
(c) Conveyor Exclusion Zone ................................................................... 2-39

2 Safety
2 Safety
2.1 General Safety
This safety section covers a wide variety of hazardous situations (but not necessarily limited to
all that is described). These hazards can apply to a specific machine installation but can also
be generalized. They are given for general guidance only to assist the operator in setting up
and maintaining an appropriate regime to help ensure health and safety. Where the machine
is supplied for incorporation into equipment designed, supplied and located by others, Terex
cannot be aware of particular hazards. These hazards can be present or can occur and
therefore Terex accepts no liability for addressing or resolving these issues.
The operator should conduct a risk assessment and mitigate identified risks in accordance
with this assessment.
The following signs and designations are used in the manual to designate instructions of
particular importance.
(1) Safety Alert Symbol
Figure 2.1 - Safety Alert 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.
Conduct thorough risk assessments and mitigate identified risks in accordance to the
assessment.
(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
DANGER Indicates a hazardous situation that, if not avoided, will result in death or serious
injury. (Contains white letters on red background).
� WARNING
WARNING This indicates a hazardous situation that, if not avoided, could result in death or
serious injury. (Contains black letters on orange background).
� CAUTION
CAUTION This indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury. (Contains black letters on yellow background).
The hazards associated with each procedure are highlighted before each procedure, as
described.

Safety 2
(3) Property Damage Messages

The signal word NOTICE, shown without the safety alert symbol, is used throughout this
manual and on machine labels to address specific practices, or draw attention to supplemental
information that is not related to personal injury.
NOTICE
NOTICE indicates information considered important, but not hazard related (e.g., messages
related to property damage). Contains white italic letters on blue background.
(4) Description of Safety Symbols

Table 2.1 - Description of Safety Symbols
Symbol Description
Electrocution hazard
Electrical shock/ electrocution from conveyor to power line contact.
Stay sufficient distances from electrical power lines.
Entanglement hazard
Entanglement in belt drive or conveyor.
Entanglement hazard
Arm entanglement in belt drive.
Stay clear of conveyor.
Install covers and guards before operation.
Turn off machine and remove the key.
Lockout machine.
Read and understand operations manual before using equipment.

2 Safety
Symbol Description
Injection hazard
Skin injection from high-pressure fluid.
When checking for leaks use cardboard or wood.
Crush hazard
Crushed foot from support leg.
Stay clear of support legs and jacks.
Falling material hazard

Struck from falling or flying material.
Stay clear of hopper during operation.
Fall Hazard
Falling from a height.
Do not climb onto the machine.
Use personnel lift to reach high places.
Check tire pressures before transportation.
Check wheel nut torque. Recheck wheel nut torque every 150 miles (200
km).

Safety 2
Symbol Description
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.
Hearing hazard
Loss or degradation of hearing.
Wear hearing personal protective equipment.
Explosion hazard
Explosion during an operation or service procedure.
Burn hazard
Burns from corrosive material.
Keep open flame away.
Emergency Stop
Press to engage, twist to reset.

2 Safety
Symbol Description
Flying Material Hazard
Face struck by flying objects
Wear eye personal protective equipment
Crush Hazard
Crush from overhead impact.
Stay clear of moving conveyors.
Unauthorized persons prohibited.

Struck by flying material.
Do not stand on platform while machine is in operation
Do not stand on machine while in operation.
Inhalation Hazard
Inhalation of poisonous/ toxic fumes or dust.
Use dust suppression (water spray) during operation of this equipment.
Use dust collection (filter) during operation of this equipment.
Wear respiratory personal protective equipment.

Safety 2
Symbol Description
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
Stay clear of hot surface or liquid.
Impact Hazard
Impact from spring loaded door.
Stay clear of spring loaded door while opening.

2 Safety
Symbol Description
Magnetic Hazard
Magnetic fields can disturb pacemaker operation within 3 meters of the
magnet and result in serious injury or death to pacemaker wearer.
Maintenance Hazard
Switch off and lockout all energy sources prior to performing maintenance
or adjustments.

Safety 2
2.2 Machine Safety Signs

NOTICE
Safety Signs are designed and fitted to the machine to warn of possible dangers, and MUST be
replaced immediately when they become unreadable or lost.
If parts have been replaced on safety signs that were fixed, be sure that new safety signs are
fitted before the machine is put into service.
Use mild soap and water to clean safety signs — DO NOT use solvent based cleaners, as they
will damage the safety sign material.
List the safety signs that are on this machine. The item number in the table indicates the
position of the safety signs on the machine. Refer to the machine safety sign locations.
Item ISO ANSI
1

2 Safety

Safety 2

2 Safety
10
11

Safety 2
12
13
14

2 Safety
15
16
17

Safety 2
18
19
20

2 Safety
21
22
23

Safety 2
24
25
26

2 Safety
27
28
29

Safety 2
30
31

2 Safety
(1) Machine Safety Sign Locations

The illustrations show the locations of the safety signs fitted to the machine. Use the information
provided to identify each safety decal location.
Figure 2.2 - Left Hand Side Safety Signs

Safety 2
Figure 2.3 - Right Hand Side Safety Signs

2 Safety
Figure 2.4 - Machine Rear Safety Signs
Figure 2.5 - Front of Machine Safety Signs

Safety 2
Figure 2.6 - R Model Additional Safety Signs

2 Safety
Figure 2.7 - ‘R’ Decals

Safety 2
2.3 Personal Safety

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

Where possible when working close to engines or machinery, only do so when they are stopped.
If it is not practical, remember to keep tools, test equipment, and all other parts of your body
away from the moving parts. Loose or baggy clothing can get caught in running machinery.
For safety reasons, long hair must be tied back or otherwise secured, garments must be close
fitting and no jewelry such as rings can be worn. Injury can result from being caught up in the
machinery or from rings catching on moving parts.
Always wear correctly fitting (EN/ANSI approved) protective clothing.
For transport, setup, operation, and maintenance or when in the vicinity of the machine PPE
must be worn. PPE includes but is not limited to: Hard Hat, Safety Glasses, Ear Protection,
Dust Mask, Close fitting Overalls, Steel Toed Boots and a High Visibility Vest. Additional PPE
could be required as needed.

2 Safety
2.4 Work Area Safety

(1) General Work Area Guidelines
Operators must have received specific training in all operating and service tasks as required for
the safe operation and service of the machine. Operators must know the location and correct
operation of all controls and safety features such as remote stop buttons and isolator switches.
Operators must be aware of all moving parts on the machine.
Keep the work area as neat and as clean as practical. Keep your equipment clean and free
of dirt and grease so it can be checked for loose, cracked or broken parts. Replace defective
parts as soon as they are discovered.
The guards provided are designed and manufactured to ensure so far as reasonably practicable
that the machinery and plant on which they are fitted can be operated safely and without risk to
health when properly used. However, it cannot be guaranteed that the guards provided will
meet the requirements laid down by individual Inspectors and any additional guard and/or
modification to guarding supplied, which may be required for any reason whatsoever, will be
charged as an addition to the Contract Price.
Maintenance platforms 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 maintenance platforms 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 that replacement parts include warning or instruction labels where necessary.
(a) Modifications
Never modify, or make any additions or conversions to the machine which affects safety without
the written approval from the manufacturer.
If there are safety relevant modifications or changes in the behavior of the machinery during
operation, stop the machine and lock out and tagout immediately. Report the malfunction to
the responsible authority/ person.

Safety 2
(3) Transportation Safety
NOTICE
Always check the machine for loose or damaged components before transportation. Ensure all
loose items which are transported with the machine are transported on the machine.
Check that the transport dimensions and weight of the machine are within the regulation limits.
Failure to comply can result in damaging the machine.
Before transporting the machine, observe the prescribed transport position, admissible speed,
and itinerary. Make sure that any mains power connections are disconnected and isolated
before transport. Only use appropriate means of transport and lifting gear of adequate capacity.
Know the overall height to avoid contacting overhead obstructions such as bridges and power
lines.
The preparations to move equipment by an articulated lorry requires supervision by a minimum
of two persons. Ensure persons transporting the machine adhere to all safety signs and
procedures.
Before transportation on public roads, ensure that 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. Avoid soft or uneven ground.
On sloping terrain, always adapt your traveling 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 controlled remotely and could start without notice to bystanders and workers.
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 setup procedure must be strictly in
accordance with the operating instructions. Before traveling with the machine, check that the
braking and any signaling and lighting systems are fully functional. Before setting the machine
in motion, check that the accessories have been safely stowed away.

2 Safety
(4) Operation Safety

Before attempting to operate the machine, DO read, fully understand, and observe the contents
of this manual. Also read any other relevant manuals for other equipment incorporated in the
machine, for example, Engine manual. Read and understand all safety signs on your machine.
Conduct the pre-operating checks specified in Chapter 7 of the operations manual before
starting the machinery.
Ensure the engine compartment is inaccessible at all times by securing the locking handles with
suitable padlocks. The padlocks must only be removed to perform maintenance tasks.
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 its 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.
There is a risk of flying or ejected materials when the crusher is being operated or serviced.
On the jaw crusher keep the feed inlet guard, in the working position during operation.
Removal of material from stalled crusher is extremely dangerous. Follow the instructions in the
maintenance section of the manual
Before starting the engine, ensure that it is safe to do so. Never leave the machine unattended
while it is in operation.
Before starting, walk completely around the machine. Make sure no one is under it, in 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. Ensure
that the warning siren and beacon and the remote control 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. If there is material
blockage, any malfunction or operational difficulty, stop the machine immediately and lockout
and tag out. 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 lock out and tag out 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 maintenance platforms 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 in
emergency situations or during safety drills.
Never check the tension of drive belts, drive chains, and conveyors when machine is running.

Safety 2
Check frequently the stability of the machine. The chassis SHOULD NOT have undue vibration
during operation.
After each day of operation, always run the machine dry; never leave material in the belt feeder
on conveyor belts or screen box. Starting a machine with a full load causes strain problems in
your machine.
Diesel engine exhaust emissions contain products of combustion which could be harmful to
your health. Always operate the machine in a 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.
Ultra Low Sulfur Diesel (ULSD) poses a greater static ignition hazard than earlier diesel
formulations with higher Sulfur content. Avoid death or serious injury from fire or explosion;
Consult with your fuel or fuel system supplier to ensure the delivery system is in compliance
with fueling standards for proper grounding and bonding practices.
When operating the machine in poor visibility conditions, it is important to use additional
lighting to carry out work.

2 Safety
(5) Hydraulic and Pneumatic Safety

Only persons having special knowledge and experience in hydraulic and pneumatic systems
must carry out work on hydraulic and pneumatic equipment. Never disable or alter any hydraulic
circuit or component without consulting with Terex.
Relieve all pressure in the hydraulic system by returning all controls to the neutral position. Turn
off the machine and isolate power supply before any pipes, filter caps, filters, or hydraulic fittings
are disconnected or removed. Depressurize all system sections and pressure pipes (hydraulic
system, compressed air system) to be removed in accordance with the specific instructions
for the unit concerned before carrying out any repair work.
Hydraulic oil and equipment can become hot when working. There is a high risk of a burn
hazard. A minimum cooling down time of 30 minutes must be allowed before any maintenance
activities are carried out on the hydraulic system. A minimum cooling down time of 90 minutes
must be allowed before any maintenance activities are carried out on the engine and powerunit.
The cool down times reduce the risk of a burn hazard. Wear gloves when working with hydraulic
and pneumatic equipment.
Check for leaks in tanks or tubing with flashlights or other proper equipment. Never check
for leaks using an open flame. Check for leaks by using a piece of cardboard. Do not use
your hand. Hydraulic fluid under pressure can penetrate the skin causing serious injury. Fluid
injected under the skin must be surgically removed or gangrene could result. Get medical help
immediately. Wear personal protective equipment including goggles and gloves.
Check all lines, hoses, and screwed connections regularly for leaks and obvious damage.
Splashed oil can 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 when servicing hydraulic components. Do not exceed safe
limits. Never set a pressure relief valve to a pressure higher than the factory setting.
For questions concerning accumulators, which are pressure-containment vessels, contact your
Terex distributor. Malfunctioning valves or poor maintenance practices can result in build-up of
high hydraulic and/or pneumatic pressures inside the accumulator.

Safety 2
(6) Electrical Safety

Work on the electrical system or equipment can only be carried out by a skilled and qualified
electrician or by specially instructed personnel under the control and supervision of such an
electrician. Work on the electrical system must be 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 before activating the main isolator switch. If machine is electric-hydraulic or
direct electric drive, the ‘mains’ electrical supply to the machine must always be isolated by
unplugging/uncoupling the ‘mains’ power socket. It is recommended that an earth leakage
safety switch is fitted in the supply line to the power point on site. Special care must 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 carried out close to overhead lines, the working equipment must be kept away from them.
See the Technical Data section for machine dimensions.
If your machine comes into contact with a live wire:
• Warn others against approaching and touching the machine.
• Have the live wire de-energized.
If provided for in the regulations, the power supply to machines and parts of machines, on which
inspection, maintenance, and repair work is carried out, must be isolated. Before starting any
work, check the de-energized 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 must 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.
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 it can cause a
fire and could also damage the electrical system. Make sure that the power pack is isolated if
welding is carried out on the machine.
The battery contains sulfuric acid, an electrolyte which can cause severe burns and produce
explosive gases. Wear suitable personal protective equipment such as eye and face protection,
gloves, and protective clothing. Avoid contact with the skin, eyes, and 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 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 Safety
(a) Electrical and/or Lightning Storm

In the event of an electrical and / or lightning storm, all machine operatives must vacate the
machine immediately.
Seek safe shelter until the storm has passed.
Being near any large steel structure during an electrical/lightning storm is not recommended in
any case.

Safety 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.
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.
The operator should not walk on the GRP guards at any time as there is a risk of slipping
or falling.
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 maintenance platforms. Always use any maintenance platforms
provided or a safe and secure platform approved by the regional safety enforcing authority.
When working at height make sure you take all necessary precautions in line with local
regulations and use approved PPE, safety harnesses and maintenance platforms. If you are not
aware of working at height requirements speak to your manager before starting any work. Keep
all handles, steps, handrails, platforms, landing and ladders free from dirt, oil, snow and ice
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 6 mm. The gap between
the idler roller and the guard must be renewed. Contact your local Terex dealer to obtain
an approved replacement.
Maintenance and Repairs During Operation; Disposal of Parts and Consumables
Observe the adjusting, maintenance, and intervals set out in these operating instructions,
except where:
• Warning, horn/light/gauge, or indicator calls for immediate action.
• Adverse conditions necessitate more frequent servicing.
Observe information on the replacement of parts and equipment. Skilled personnel only must
carry out such tasks.
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 and tag out procedure.

2 Safety
• Attaching a warning signs 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. Never allow 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 must be carefully attached to lifting tackle and secured. Use only suitable
and technically adequate lifting gear. Never permit working or standing 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 machines can cause injury or even death. Do not climb on the machine
while 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.
The fastening of loads and instructing of crane operators must be entrusted to experienced
persons only. The Marshall giving the instructions must be within sight or sound of the operator.
After cleaning, examine all fuel, electrical wiring, lubricant, and hydraulic fluid lines for leaks,
loose connections, chafe marks and damage. Any defects found must be rectified without delay.
Any safety devices removed for setup, maintenance or repair purposes must be refitted and
checked immediately upon completion of the maintenance and repair work to ensure full
working order.
Improperly disposing of waste can threaten the environment and ecology. Potentially harmful
waste used with Terex equipment includes such items as oil, fuel, coolant, filters, and batteries,
etc. Use leakproof containers when draining fluids. Do not use food or beverage containers that
could mislead someone into drinking from them. Do not pour waste onto the ground, down a
drain or into any water source. Ensure that all consumable’s and replaced parts are disposed of
safely and properly 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 while 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 that the machine is functioning properly. After testing, shut down, check the work you
performed. Recheck all fluid levels before releasing machine for operation.

Safety 2
(8) Gas, Dust, Steam, Smoke

Death, serious injury, or delayed lung disease can 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.
Use extraction, not blowing, to remove dust found on the machine or produced during work
on the machine. Dust waste must be dampened, placed in a sealed container and marked, to
ensure safe disposal.
When the operation of this equipment generates dusts, 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 it has been expressly
authorized, as there is 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. Make sure that the premises are
adequately ventilated as there is a risk of explosion.
Ensure operators wear a suitable respiratory device where exposed to possible harmful effects
of air pollution of any kind.
(9) Hazardous Substances

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

HEARING HAZARD EXCEEDS 90 dB (A)
This hazard can cause loss or degradation of hearing over a time.
Always ensure that operators are provided with ear protection of approved pattern and that they
are always worn when the machine is operating.

2 Safety
(11) Fire Hazards
� WARNING
This machine has two allocated positions for a fire extinguisher to be mounted. The fire
extinguisher is provided by the end user and not by Terex. The following illustrations show the
recommended location of where the extinguisher can be fitted.
Holes are required to be drilled for the fire extinguisher mounting brackets and caution must
be taken. There are hydraulic hoses and pipes on the opposite side of the recommended
mounting area. When the holes are drilled, they are to be threaded to allow the fire extinguisher
bracket to be securely mounted.
It is the owners responsibility to ensure that the fire extinguishers fitted are adequate for the
following types of combustible materials on the machine:
• Ordinary combustibles
• Flammable liquid and gas
• Electrical
(a) Recommended Fire Extinguisher Locations
Figure 2.8 - Recommended Fire Extinguisher Locations

Safety 2
(12) Exclusion Zones

(a) Magnet Exclusion Zone
� DANGER
Strong Magnetic Field Hazard.
Strong magnetic field can disrupt pacemaker operation and result in serious injury or death to a
pacemaker wearer.
STAY CLEAR FROM MAGNET.
The operator must stand out of the exclusion zones while the machine is operating. The
magnetic field can disturb pacemaker operation if within 3 meters.
� WARNING
Materials discharged from the magnet can result in serious injury or death.
NOTICE
The operator must stay clear of the magnet while in operation. If inspection of magnet is
required lockout and tagout the machine.
Figure 2.9 - Magnet Exclusion Zone

2 Safety
(b) Impactor Exclusion Zone
� WARNING
Operator Crush Hazard
When the machine is operating, the operator must stay clear of the Impact crushing chamber
to prevent serious injuries or death. Do not enter the exclusion zones while the machine is
operating. The machine must be locked out and tagged out when using the door for inspection
purposes.
Figure 2.10 - Impactor Exclusion Zone

Safety 2
(c) Conveyor Exclusion Zone
� WARNING
Material discharged from the conveyor can result in serious injury or death
STAY CLEAR FROM CONVEYOR
The operator must stand out of the exclusion zones while the machine is operating
Figure 2.11 - Conveyor Exclusion Zone

2 Safety

Technical Data 3
Table of Content
3 Technical Data.............................................................................................3-1
3.2 Dimensions .................................................................................................... 3-3
(1) Working Position With Side Conveyor (Standard) ..................................... 3-3
(2) Working Position With No Side Conveyor (Standard) ............................... 3-4
(3) Transport Position (Standard) ................................................................... 3-5
(4) Working Range Dimensions (R Model) ..................................................... 3-7
(5) Transport Range Dimensions (R Model) ................................................... 3-9
3.3 Noise Emissions........................................................................................... 3-10
(1) 290 Noise Emissions .............................................................................. 3-10
(2) Cobra 290................................................................................................ 3-10
3.4 Machine Weights.......................................................................................... 3-11
3.5 Machine Components .................................................................................. 3-11
(1) Machine Components.............................................................................. 3-11
(a) Machine Component Specifications.................................................... 3-13
3.6 Impactor Capacity ........................................................................................ 3-16
3.7 Impactor Settings ......................................................................................... 3-17
(1) Product Gradings..................................................................................... 3-18
(2) Apron Gap Settings ................................................................................. 3-19
(3) Rotor Speed ............................................................................................ 3-19
3.8 Blow Bar Specifications................................................................................ 3-20
(1) Overview.................................................................................................. 3-20
(a) Martensitic Steel Blow Bars ................................................................ 3-20
(b) Ceramic/Martensitic Blow Bars ........................................................... 3-20
(c) High/Medium Chromium Steel Blow Bars........................................... 3-20
(d) Manganese Steel Blow Bars............................................................... 3-21
(e) Using 2 Long and 2 Short Blow Bars .................................................. 3-21
(f) Using 4 Long Blow Bars...................................................................... 3-21

3 Technical Data
3 Technical Data
3.1 General Information
Every endeavor is made to supply equipment as specified. We reserve the right, where
necessary, to amend specifications without prior notice as we operate a policy of continual
product development.
It cannot be guaranteed that the machine meets any specific requirements in respect of noise
or vibration levels, dust emissions, or any other factors relevant to health and safety measures
or environmental protection needs.
The technical data given in this chapter are given as approximations for reference only.

Technical Data 3
3.2 Dimensions
(1) Working Position With Side Conveyor (Standard)
Figure 3.1 - Working Position With Side Conveyor

3 Technical Data
(2) Working Position With No Side Conveyor (Standard)
Figure 3.2 - Working Position With No Side Conveyor

Technical Data 3
(3) Transport Position (Standard)
Figure 3.3 - Transport Position (Side Conveyor Option)

3 Technical Data
Figure 3.4 - Transport Position (No Side Conveyor Option)

Technical Data 3
(4) Working Range Dimensions (R Model)
Figure 3.5 - Working Dimensions (R Model)

3 Technical Data
Figure 3.6 - Stockpile Dimensions (R Model)

Technical Data 3
(5) Transport Range Dimensions (R Model)
Figure 3.7 - Transport Range Dimensions (R Model)

3 Technical Data
3.3 Noise Emissions

� WARNING
Danger of hearing damage
When working directly beside the crusher or on its platforms, the permissible daily noise
exposure level (LEX,8h) of 80 dB is exceeded.
NOTICE
Noise emission levels are recorded when the machine is running empty. Due to the wide
variations in materials processed through the machine, machine it is not possible to provide
emission levels for all applications. Figures can differ when a machine is processing material.
Constant high noise levels ear protection must be worn.
Noise levels measured in dB(A).
(1) 290 Noise Emissions

COBRA 290R Crushing mode- 1800rpm
In accordance with machinary directive 2006/42/EC
A-Weighted sound power level, LWAd (ref. 1 93Db
pW), in decibels
A-Weighted emission sound pressure level, 69Db
LpAd (ref. 20 µPA) at the operator’s position,
in decibels
Values determined according to basic standard ISO 3746, ISO 11203 Note – Declared
single-number noise emission values are the sum of measured values and the associated
uncertainty, and they represent upper boundaries of the range of values which is likely to
occur in measurements.
(2) Cobra 290

Cobra 290
In accordance with the Machinery Directive 2006/42/EC
A-Weighted sound power level, LWAd (ref. 1 118 db
pW), in decibels
A-Weighted emission sound pressure level, 92. db
LpAd (ref. 20 µPA) at the operator’s position,
in decibels
Values determined according to the
Machinery Directive 2006/42/EC. Note –
Declared single-number noise emission
values are the sum of measured values and
the associated uncertainty, and they represent
upper boundaries of the range of values
which is likely to occur in measurements.

Technical Data 3
3.4 Machine Weights

NOTICE
The weights shown are an approximate only. For further information on specific machine
weight configurations, consult your local dealer.
Item Weight (Approximately)

Cobra 290 29,100kg
Item Weight (Approximately)

Cobra 290R 31,750kg
3.5 Machine Components

(1) Machine Components
Figure 3.8 - Machine Components

Item Description
1 Discharge Conveyor
2 Magnetic Conveyor
3 Chassis
4 Impactor Rotor Drive Pulley
5 Tracks
6 Control Screen
7 Catwalk / Maintenance Platform

3 Technical Data
8 Power Unit
9 Feeder Hopper
10 Vibrating Feeder
11 Impactor Chamber
12 Bypass Conveyor
13 Screenbox
14 Fines Conveyor
15 Recirc Conveyor

Technical Data 3
(a) Machine Component Specifications

Feeder / Hopper:
Feed in width: 2050mm inside to inside at the top
Feed in height: 3130mm
Feed in length: 3750mm
Hopper Capacity: 3.3 m³
Discharge Conveyor
Belt Width: 1000mm (40”)
Belt Spec: Straight Warp (SW630/2) with 9mm + 3mm Covers (UBELT)
Belt Spec: (EP500/3) 8mm + 2mm Covers (UPAN)
Discharge Height: 3400mm
Belt Speed: 80mpm — 95mpm
Distance from Tip 400mm
of Blowbar (new
(285mm to Underpan)
bar) to belt:
Ground 295mm to Underpan Belt
Clearance:
(225 to Underpan Conveyor)
Feedboot: Fabricated Steel with Wear Resistant Steel Liners
Impact Area: Low Friction Impact Bars
Engine Compartment: Tier 3

Engine: Volvo TAD853VE
Power: 235kW
Speed Range: 1500–1800rpm
Engine Compartment: Tier 4

Power: 235kW
Speed Range: 1500–1800rpm
Engine Compartment: Stage V

Power: 235kW
Speed Range: 2200RPM
Tracks
Sprocket Centres: 3300mm

3 Technical Data
Track Shoe Width: 400mm

Dual Speed as standard

Technical Data 3
Magnetic Conveyor
Belt Width: 750mm
Belt Speed: 100–125mpm depending on Engine Speed
Single Pole
Can discharge from either side of
machine
Bypass Conveyor (Option)

Belt Width: 500mm
Belt Spec: 4mm Top 2mm Bottom (EP400/3)
Discharge Height: 2480mm
Belt Speed 65–80mpm
Recirc Conveyor
Belt Type EP315/3 +1.5 with 15mm cleats
Belt width 500mm (20”) wide belt
Discharge height 3.8m (10’ 4”)
Lubrication Grease (Shaft Bearings)
Drive Conveyor can hydraulically slew to enable customer to
stockpile oversize material.
Fines Conveyor
Belt type EP500/3,5 +1.5
Belt width 1200mm
Discharge height 3m (9’ 10’)
Lubrication Grease (Shaft Bearing)
Hydraulic
Transfer Conveyor
Belt Type EPS500/3,5 +1.5
Belt width 500mm (20”) wide belt
Drive Hydraulic
Lubrication Grease Shaft Bearings

3 Technical Data
3.6 Impactor Capacity

In order to obtain the optimum output from the impactor, it’s feed should be continuous and
regulated. Additionally, all feed should be of a size that will readily enter the chamber and under
size material should be removed from the feed prior to entry to the impactor.
Product curves shown are typical only, based on average limestone, and indicate the product
gradings from the impactor only. Any natural fines in the feed material which bypass the
impactor are not taken into account.
Curves will vary dependant on nature, type and grading of the material being processed.
Capacity shown is based on feed material weighing loose, approximately 1.6t/m³ (100lbs/ft³)
and indicates the throughput of the machine.
Do not exceed the maximum material feed size. Material size can alternatively be quoted as
a diagonal corner to corner dimension Z of a cube or cube side dimensions of Y. Reference
Figure 3.9
Figure 3.9 - Feed Cube Dimensions

For suitability of particular applications, please consult your local Terex® dealer or Terex®
Technical Support.
The very variable nature of feed material and crushing applications may require consideration
of alternative configurations in order to achieve optimum performance.

Technical Data 3
3.7 Impactor Settings

Lower apron gap A is set first at 0 to 5mm (0 to 0.2in) smaller than the desired maximum
product size. Upper apron gap B is then set.
Make sure the apron gap settings A and B remain within the minimum and maximum
dimensions shown while still conforming with the settings ratio.
All settings are subject to the suitability of the feed material.
Product gradings are typical only and will vary depending on material characteristics.
Adjustment of Impact Aprons
Keep ratio of A to B between 2.5:1 and 2:1
A-Lower:
Minimum 18mm (0.71in)
Maximum 75mm (3in)
B-Upper:
Minimum 50mm (1.97in)
Maximum 150mm(5.90in)
Figure 3.10 - Apron Gap A & B Product Gradings

3 Technical Data
(1) Product Gradings

803 [Type 1] Sub Base Limestone - Feed 75 to 200mm (3 to 8in)
P-
e-
r-
c-
e-
n-
t-
a-
g-
e
P-
a-
s-
s-
i-
n-
g
(
%
)
SIEVE SIZE
Sieve Size
A 75μm (0.003in)
B 600μm (0.025in)
C 5mm (0.2in)
D 10mm (0.4in)
E 38mm (1.5in)
F 75mm (3in)
Graph
X Upper Limit
Y Lower Limit
Z at 1750rpm with aprons set to: 25mm (1in) Lower, 70mm (2.8in) Upper

Technical Data 3
804 [Type 2] Sub Base

P-
e-
r-
c-
e-
n-
t-
a-
g-
e
P-
a-
s-
s-
i-
n-
g
(
%
)
SIEVE SIZE
(2) Apron Gap Settings

The upper apron has a great effect on the product output as a small gap setting holds the
material in the first chamber for longer, which allows the rotor to make more impacts and break
down the material further, although the output rate is reduced.
The lower apron gap setting reduces the over sized product effectively, without greatly affecting
the output rate.
(3) Rotor Speed

Increasing the rotor speed will create more fine material and reduce the output rate, therefore
should not be used to reduce the over sized material.
By increasing the rotor speed a smaller product can be obtained but has the disadvantage of
increased fine material and wear on components as well as a reduced output rate.

3 Technical Data
3.8 Blow Bar Specifications

NOTICE
If you have any doubts about any aspect of the machine’s capability, please consult your local
Terex® dealer or Terex® Technical support.
(1) Overview
This machine is designed for both demolition and quarrying applications. When fitted with
martensitic steel blow bars the crusher will tolerate small quantities of steel reinforcing bar in the
feed. However, the machine is not designed to accept large pieces of steel or other uncrushable
objects and the feed material should be assessed and inspected for suitability prior to use.
It is vitally important that large pieces of steel or similar uncrushable objects are not allowed to
enter the crushing chamber as severe damage and injury may occur.
When high/medium chromium steel bars are fitted, NO steel should be allowed to enter the
crushing chamber and the machine should only be used on quarry applications or clean
uncontaminated materials. Feed size needs to be monitored closely when using chrome bars.
(a) Martensitic Steel Blow Bars

Martensitic steel blow bars have a grain structure like needles which provides good wear
against fine and high silica feed materials.
This type of blow bar also has the ability to accept a small amount of steel in the feed recycling
material.
(b) Ceramic/Martensitic Blow Bars

These blow bars are extremely hard as supplied and have properties between high chrome
and martensitic steel.
Abrasion resistance is better than martensitic steel.
These can be used for recycling or in quarry applications where material is abrasive or tough.
(c) High/Medium Chromium Steel Blow Bars

These blow bars are extremely hard as supplied and provide good resistance to wear.
They are suitable for use in applications having fine or high silica content feed material.
Medium chrome bars are less brittle than high chrome blow bars but are higher wearing than
martensitic.
This type of blow bar is not ductile and can be damaged or fail by large or heavy material
striking it, as the bar cannot absorb and dissipate the energy.
If the rotor speed is too high, the energy imparted to this type of blow bar by material cannot be
dissipated and may cause catastrophic failure. No steel should be in the feed and feed size
needs to be monitored closely when using chrome bars.

Technical Data 3
(d) Manganese Steel Blow Bars

These austenitic steel blow bars are supplied in soft condition which hardens when deformation
occurs as large material impacts the bar.
The blow bar then resists wear by having this hard surface but remains tough underneath.
This type of blow bar therefore can tolerate hard, dense stone and some steel in the material
feed.
Should the material feed be fine abrasive or unable to impact the blow bar it will not achieve the
hardening of the surface. This may cause the blow bar to wear quickly and unevenly.
(e) Using 2 Long and 2 Short Blow Bars

This arrangement is suitable for primary applications and soft secondary applications. This
arrangement is not suitable for producing fine products in one pass.
Feed rates shown are for maximum feed sizes.
Smaller feed sizes can achieve higher feed rates.
Smaller feed sizes may require the use of 4 full blow bars.
(f) Using 4 Long Blow Bars

This arrangement is suitable for secondary applications with a cube feed size of 200mm (8in) or
less.
This arrangement is not suitable for primary feed cube size in excess of 200mm (8in).
Larger feed sizes may require the use of 2 short + 2 full blow bars.

3 Technical Data

Machine Description 4
Table of Content
4 Machine Description...................................................................................4-1
4.2 Systems ......................................................................................................... 4-3
(1) Electrical System ....................................................................................... 4-3
(a) Telematics ............................................................................................. 4-3
(2) Drive System ............................................................................................. 4-3
(a) Power Unit ............................................................................................ 4-3
(3) Crushing System ....................................................................................... 4-3
(a) Impactor Crusher .................................................................................. 4-3
(b) Chutes................................................................................................... 4-3
(c) Dust Suppression Sprays ..................................................................... 4-3
(4) Conveying System..................................................................................... 4-4
(a) Discharge Conveyor ............................................................................. 4-4
(b) Bypass Conveyor (Optional) ................................................................. 4-4
(c) Vibrating Feeder ................................................................................... 4-4
4.3 Maintenance Walkways.................................................................................. 4-4
4.4 Chassis .......................................................................................................... 4-4
4.5 Guards ........................................................................................................... 4-4
4.6 Control and Display Elements ........................................................................ 4-5
(1) Radio Remote Control Tracking Button Sequences .................................. 4-5
(2) Umbilical Control Handset ......................................................................... 4-6
(3) Machine Information Decals ...................................................................... 4-7
(4) Options .................................................................................................... 4-13

4 Machine Description
� WARNING
This machine is designed for stone crushing applications. It is vitally important that large pieces
of steel or similar uncrushable objects are not allowed to enter the crushing chamber as severe
injury or damage to machine may occur.

This machine has been designed for stone crushing applications, to maximise throughout and
product shape in a wide range of quarrying applications. It features include:
• Suitable for many sizes of rock or stone materials.
• Unique design giving excellent products shape and high reduction ratios.
• Easily transported on and off site.
• Magnetic Conveyor.
• Dust suppression sprays.
• Choice of impactor blow bars.
• Water cooled diesel engine with hydraulically controlled clutch.

4.2 Systems
(1) Electrical System
(a) Telematics
A telematics system is included on the machine. The telematics system, administered by a
third party collects a range of operational data about the equipment including, but not limited to:
usage, performance, and reliability. The buyer consents to the seller obtaining such data for
warranty, product improvement, and customer support purposes. The buyer understands that
the equipment warranty is conditioned on the proper operation of the telematics system. The
buyer must not disable, tamper, or interfere with the telematics system.
To, access telematics system information contact your local Terex dealer.
(2) Drive System

(a) Power Unit
The power unit is attached to the chassis of the machine under the vibrating feeder. The power
unit is completely enclosed, sound suppressed and lockable.
The power unit contains the Tier 3 and Tier 4/Stage V Volvo TAD873VE.
Hydraulic power is provided from the engine to drive the conveyors, operate the hydraulic
cylinders and give power to the tracks. It also provides power to the control panel.
(3) Crushing System

(a) Impactor Crusher
The crusher is attached to the chassis at the end of the feeder unit. The crusher is designed
to crush the raw material.
A standard machine is fitted with a crusher configuration having two long and two short
martensitic blow bars. Two hydraulically operated adjustable aprons with automatic overload
protection to release and clear blockages
The rotor has four locations to fit reversible long and short blow bars of different materials.
Alternative blow bar configurations and materials are available to suit various applications.
In order to obtain the optimum output from the impactor, it’s feed should be continuous and
regulated. Additionally, all feed should be of a size that will readily enter the chamber and under
size material should be removed from the feed prior to entry to the impactor. The power required
and product gradings will vary with the feed and product size, capacity and rock characteristics.
Usage of wearing parts will depend upon individual crushing conditions and the variable factors
which govern wear.
(b) Chutes
The crusher discharge chute is fabricated in with replaceable abrasion resistant plate and is
designed to direct the crushed material onto the discharge conveyor.
(c) Dust Suppression Sprays

Spray nozzles are mounted at the discharge conveyor discharge point to reduce the amount
of dust produced by the machine. Option of electric pump.

(4) Conveying System

(a) Discharge Conveyor
The discharge conveyor is attached to the front of the chassis to convey crushed material away
from the crusher to the stock pile. Impact bars are provided immediately below the crusher
outlet under the conveyor feed point. Aluminum type dust covers (optional) are used over the
exposed section of the conveyor.
(b) Bypass Conveyor (Optional)
The bypass conveyor has a plain belt and hydraulic folding facility for transportation.
When the optional bypass conveyor is fitted, material passing through the vibrating feeder bars
will by-pass the impactor.
(c) Vibrating Feeder

The feeder is mounted on heavy-duty springs which cushion against shock, provides flexible
support, and prevents vibration being transferred to rest of the machine. The vibrating unit
with its counter-rotating eccentric shafts produces the vibrating action to move material along
the feeder.
4.3 Maintenance Walkways

Provided for inspection and maintenance, allowing access to the crusher. They are made from
steel flooring with steel toe boards, double row handrails and access ladders.
4.4 Chassis
Fabricated steel frame with supports for the feed conveyor, crusher, discharge conveyor, power
unit, track frame, and control systems.
4.5 Guards
Wire mesh/sheet metal guards or GRP are provided for all drives, pulleys, couplings, wedge
belts, and belt conveyors.
The guards provided are designed and manufactured to ensure that the machine on which they
are fitted can be operated safely.
However, it cannot be guaranteed that the guards provided meet the requirements laid down by
individual Inspectors and any additional guard and/or modification to guarding supplied.

4.6 Control and Display Elements

(1) Radio Remote Control Tracking Button Sequences
Figure 4.1 - Machine Tracking Directions

The following list identifies the machines directions. Use the list with the diagram Reference
Figure 4.1
1 Left
2 Right
3 Forward
4 Reverse
5 Right-Hand Side Track
6 Left-Hand Side Track
The crushing control is fully integrated into the machine PLC control system. This enables
crusher setting changes to be made easily.
The control panel is used to operate the following machine functions:
• Engine Speed
• Feeder (Start, Stop and speed)
• Discharge Conveyor (Start, Stop)
• Crusher (Start, Stop)
• Bypass Conveyor
• Crusher Control
• Machine Diagnostics

(2) Umbilical Control Handset

An umbilical control is provided for controlling the tracking function and giving a tracking speed
of approximately 1 km/hour. Reference:
Figure 4.2 - Umbilical Handset

Position 1 Position 2
Button Function Button Function
1 Left Hand Track 1 Open Upper Apron
Forward
2 Right Hand Track 2 Close Upper Apron
Forward
3 Left Hand Track 3 Open Lower Apron
Reverse
4 Right Hand Track 4 Close Lower Apron
Reverse
5 Both Tracks Fast 5 Slew into transport mode
Forward
6 Both Tracks Fast 6 Slew into working mode
Reverse
7 Stop Tracks 7 Stop Tracks
8 Start Tracks 8 Start Tracks

(3) Machine Information Decals

The below table lists the information signs that are on this machine. The item number indicates
the position of the safety sign on the machine. Reference:
Table 4.1 - Machine Information Decals
It- Decal Description
e-
m
1 Switch off machine and disconnect battery
terminals and remote unit before welding.
2 Remove securing pins.
3 Track tie down instructions.

4 Greasing Points
5 Diesel Specification (Tier 4/Stage V)
6 Drain water overnight
7 Batter isolator

8 Hydraulic Oil
9 Diesel Specification (Tier 3)

10 Tie Down Points.
11 Read and fully understand instructions on

refilling urea tank. Refill using correct fluid.
Do NOT use water.

Figure 4.3 - Information Sign Positions Left Hand Side
Figure 4.4 - Information Sign Positions Right Hand Side

Figure 4.5 - Information Sign Positions on Internal Machine and Power Unit

(4) Options
• Underpan Feeder
• Bypass Conveyor
• Twin Pole Magnet
• Dust Suppression
• Hot / Cold Climate Oils
• Radio Remote Control
• Telemetry
• Electric Waste Pump
• Discharge Conveyor Belt Scale
• Discharge Conveyor Dust Covers
• Track Lights
• Workings Lights
• Blowbar Storage Rack
• Feeder Deflector Plates
• Afterscreen Ready


Transportation 5
Table of Content
5 Transportation.............................................................................................5-1
5.1 Transport Safety............................................................................................. 5-2
5.2 Preparation Prior to Transportation ................................................................ 5-3
(1) Activating the Control Banks ..................................................................... 5-4
(2) Placing the Discharge Conveyor into the Transport Position .................... 5-6
(3) Placing Bypass Conveyor Into Transport Position..................................... 5-8
(a) Placing Bypass Conveyor into Transport Position ................................ 5-8
(4) Placing Recirculating Conveyor Into Transport Position (R MODEL
ONLY)...................................................................................................... 5-10
(5) Placing Lighting Mast Into Transport Position ........................................ 5-16
5.3 Locking screenbox for transport................................................................... 5-17
5.4 Loading the Machine for Transport .............................................................. 5-18
5.5 Transport Tie-Down Points........................................................................... 5-19
(1) Transport Tie Down Point Locations........................................................ 5-20
5.6 Unloading the Machine From Transport....................................................... 5-23

5 Transportation
5 Transportation
5.1 Transport Safety

� DANGER
Electrocution Hazard.
Contact with electric power lines result in death or serious injury.
Check and ensure that no power lines are obstructing the machine.
� WARNING
Injection Hazard.
Fluid escaping under pressure can penetrate skin and result in death or serious injury.
Relieve pressure before disconnecting hydraulic lines.
Stay clear of leaks and pin holes. Use a piece of cardboard or wood to search for leaks. Do
not use hand.
Fluid injection into the skin must be surgically removed within a few hours by a doctor familiar
with this type of injury, or gangrene results.
� CAUTION
Ensure that a full and thorough risk assessment has been carried out before disassembling
any of the machine components.
NOTICE
Before transportation, always check the machine for loose and/or damaged components.
Fasten all loose parts, replace missing items, or make repairs as found necessary to ensure
that all components are safely secured during transportation. When transporting the machine, it
is the responsibility of the haulage contractor to ensure that the machine is correctly secured to
the transporter.

Transportation 5
5.2 Preparation Prior to Transportation

� WARNING
Ensure that a full and thorough risk assessment has been carried out prior to carrying out
any transportation of the machine.
Prior to transportation always check the machine for loose and/or damaged components.
Fasten all loose parts, replace missing items or make repairs as found necessary to ensure
that all components are safely secured during transportation.
Nip Point Hazard.

Nip points exist where pins need removed or replaced. Stay clear of moving assemblies.
Crushing Hazard.
When lifting any heavy sub assemblies there is always risk of the object unexpectedly moving.
Ensure adequate distance is kept from the assembly when being raised from the ground.
Failure in doing so may result in serious injuries or death.
Fluid Injection Hazard.

Escaping fluid under pressure can penetrate skin, causing serious injury. Wear personal
protective equipment.
Relieve pressure before disconnecting hydraulic lines. Keep away from leaks and pin holes.
Use a piece of cardboard to search for leaks, DO NOT use hand.
If fluid is injected under skin, get medical help immediately.
Always wear correct personal protective equipment.
NOTICE
Before transportation, always check the machine for loose and/or damaged components.
Fasten all loose parts, replace missing items, or make repairs as found necessary to ensure
that all components are safely secured during transportation. When transporting the machine, it
is the responsibility of the haulage contractor to ensure that the machine is correctly secured to
the transporter.
PROCEDURE
1. Prior to stopping the machine ensure that all material has been processed through the
machine.
2. Ensure that there is no material on the conveyors, feeder or in the crusher.
3. Stop the machine according to the procedure in Section 7.
4. Wash the machine to remove all debris.
5. Prior to transportation always check the machine for loose or damaged components.
6. Ensure that there is no personnel on or around the machine prior to putting the machine
into the transport position and manoeuvring the machine.

5 Transportation
(1) Activating the Control Banks
NOTICE
It is important that you carefully check and understand what each control lever operates. Misuse
of these control levers can result in damaging machine components.
Only one control bank can be used at one time.
When the control banks are activated, the crusher discharge opening settings become activated.
PROCEDURE
1. Observe all safety warnings.
2. Start the engine
» The production screen will appear. (Reference Figure 5.1)
Figure 5.1 - Production Screen

3. On the control panel, turn the setup button (Item 2, Reference Figure 5.2) to the spanners
icon.
Figure 5.2 - Control Panel

» The setup screen will appear. (Reference Figure 5.3)

Transportation 5
4. On the setup screen press the control bank button (Item 3 Reference Figure 5.3) to activate
the control banks.
Figure 5.3 - Setup Screen

» A 5 second timer will begin to countdown, once countdown is complete the control
banks will be activated.

5 Transportation
(2) Placing the Discharge Conveyor into the Transport Position
� WARNING
Crush Hazard.
Contact with folding conveyors can result in death or serious injury.
Keep clear of conveyors when folding for transport or opening to working position.
PROCEDURE
2. Ensure the stays are pinned in place (Reference:Figure 5.4 ). They are on both sides of
the Discharge conveyor.
Figure 5.4 - Discharge Conveyor Stays Pinned in Place

3. Ensure optional aluminium dust covers are removed.
4. Start the engine.
5. Activate the control banks. (Reference: (1) Activating the Control Banks on page 5-4)
6. Proceed to the Discharge conveyor control bank located at the side of the machine.
(Reference: Figure 5.5)
Figure 5.5 - Control Bank Location

Transportation 5
7. Familiarise yourself with the control bank levers before operating. (Reference: Figure 5.6)
Figure 5.6 - Control Bank Lever

8. Operate the control lever by pushing it up (Item 1, Reference: Figure 5.7) to fold the
discharge conveyor into the transport position (Reference: Figure 5.6)
Figure 5.7 - Discharge Conveyor in Transport Position.

9. Ensure the conveyor is secure in the transport position.

5 Transportation
(3) Placing Bypass Conveyor Into Transport Position
� WARNING
Crush Hazard.
NOTICE
Ensure that the Bypass conveyor securing pins have been removed from the conveyor before
folding or unfolding the conveyor. It is important that you carefully check and understand what
each control valve operates. Misuse of these control valves can result in damaging components
and other assemblies.
(a) Placing Bypass Conveyor into Transport Position
PROCEDURE
2. Remove the toggle bolts (Items 1, Reference: Figure 5.8). There is one on each side of
the conveyor.
Figure 5.8 - Bypass Conveyor Toggle Bolts

4. Activate the control banks (Reference:(1) Activating the Control Banks on page 5-4).
5. Proceed to the bypass conveyor control bank (Item 1, Reference: Figure 5.9) at the side
of the machine.

Transportation 5

6. Familiarise yourself with the control bank levers before operating (Reference: Figure 5.10).
Figure 5.10 - Control Bank

7. Operate the control lever (Item 1, Reference: Figure 5.10) and fold the bypass conveyor
into the transport position.
8. Insert the securing pin on the side of the conveyor into the transport hole (Item 1,
Reference: Figure 5.11). Secure the pin with a safety clip.
Figure 5.11 - Bypass Conveyor Transport Pin

9. Ensure the conveyor is secure.

5 Transportation
(4) Placing Recirculating Conveyor Into Transport Position (R MODEL ONLY)
� WARNING
Crush Hazard.
NOTICE
THE MACHINE MUST BE ON LEVEL GROUND BEFORE MOVING THE RECIRCULATING
CONVEYOR. The R section of the machine should be folded using control bank and umbilical
remote.
PROCEDURE
1. STOCKPILE POSITION ONLY
2. Observe all safety warnings
3. Activate the control banks
4. Use hand lever (Item 1, Figure 5.12) to fold the head section of the conveyor
Figure 5.12 - Lever Decal
Figure 5.13 -

Transportation 5
5. Remove the transport pin (Item 1, Figure 5.14) from the hole (Item 2,Figure 5.14 ). Swing
the stay bar (Item 3, Figure 5.14) back into transport position using the bracket (Item
4Figure 5.15, )
Keep the transport pin in a safe place, as this will be needed to lock the recirc conveyor into
transport position.
Figure 5.14 - Stockpile Position
Figure 5.15 - Stay Bar in Transport Position

6. RECIRC POSITION ONLY: Activate the control banks (Ref: (1) Activating the Control
Banks on page 5-4)
7. Use the hand lever (Item 1, Figure 5.16) to fold the head section of the conveyor.

5 Transportation
Figure 5.16 - Lever Decal
Figure 5.17 - Lever to Fold Head Section

8. Remove the pin (Item 1, Figure 5.18) from the rotating point on the recirc conveyor.
Figure 5.18 - Pin in Working Position

9. Proceed to use the umbilical remote located at the rear of the machine (Item 1, Figure 5.19
)

Transportation 5
Figure 5.19 - Remote Location

10. Press button 5 to rotate the recirculating conveyor around into transport position.
Figure 5.20 - Umbilical Control Remote

11. When the recirculating conveyor is in the transport position, re-insert the pin into the rotating
point to lock into place (Item 1, Figure 5.21)
Figure 5.21 - Pin Into Transport Position

12. Lock recirc using transport pin. (Item 1, Figure 5.23)

5 Transportation
Figure 5.22 - Transport Pin
Figure 5.23 - Transport Pin Close-Up

13. Turn and remove pins from telescopic on both sides of the machine (Item 1, Figure 5.24)
Figure 5.24 - Removal of telescopic pins

14. Use the control banks to lower the frame into the transport position.(item 1, Figure 5.25
& Figure 5.26)

Transportation 5
Figure 5.26 - Decal

15. Insert telescopic pins in lowered position
16. Remove the rubber chute from transport, remove the fasteners ( Item 1, Figure 5.27) from
the chute and store in a safe place to prevent loss.
» It is important to remove the rubber chute to ensure the machine is within transport
height and width.
Figure 5.27 - Rubber Chute

5 Transportation
(5) Placing Lighting Mast Into Transport Position
PROCEDURE
2. Gain safe access to the lighting mast.
3. Remove the four bolts (Item 1,Figure 5.28 )
Figure 5.28 - Mast in Working Position

4. Carefully lower the mast down into transport position (Figure 5.29).
Figure 5.29 - Mast In Transport Position

Transportation 5
5.3 Locking screenbox for transport

PROCEDURE
1. When preparing the machine for transport, ensure that the four locking plates (two on each
side of the machine) are added to the screenbox.
Figure 5.30 - Screenbox locking plates

Ensure that the locking plates are removed before running the machine.

5 Transportation
5.4 Loading the Machine for Transport

NOTICE
Before transportation of the machine, check for loose or damaged components. Fasten all
loose parts, replace missing items or make repairs as found necessary to ensure that all
components are safely secured during transportation.
It is mandatory to have a Banksman present when loading the machine for transport.
Securing the machine and any loose items to the low loader trailer is the responsibility of the
haulage contractor.
PROCEDURE
1. Position suitable ramps at the end of the transporter.
2. Ensure that the machine is in the transport position.
3. Ensure that all loose items to be transported with the machine are carefully stowed and
secured.
5. Ensure that the engine speed is at idle.
6. Slowly track the machine onto the transporter.
7. Stop the engine.
8. Remove ramps from the end of the transporter.
9. Secure the machine using the tie down transport brackets and all loose items to the
transporter.

Transportation 5
5.5 Transport Tie-Down Points

NOTICE
When transporting the machine, it is the responsibility of the haulage contractor to secure
it to the transporter.
This machine is fitted with transport tie down brackets. The brackets are indicated on the
machine by a safety symbol (Figure 5.31). The tie down points must never be used to lift
the machinery.
Figure 5.31 - Transport Tie Down Symbol
Figure 5.32 - Transport Tie Down Symbol For Tracks

5 Transportation
(1) Transport Tie Down Point Locations
NOTICE
The following tie down points must never be used to lift the machine.
The machine consists of a total of eight tie down points. The tie down points are on both sides
of the machine (Reference: Figure 5.33 and Figure 5.34) and also the front and rear of the
machine (Reference: Figure 5.35 and Figure 5.36).
The method of tying down the machine is the responsibility of the haulage contractor. The
directional lines shown on the illustrations demonstrate how the tie down chains must be
secured to the transporter.
Figure 5.33 - Left Hand Side Tie Down Points
Figure 5.34 - Right Hand Side Tie Down Points

Transportation 5
Figure 5.35 - Front Tie Down Points
Figure 5.36 - Rear Tie Down Points

Afterscreen can be detached and transported as a lone unit, the afterscreen has 6 tie-down
points (3 on each side) .

5 Transportation
Figure 5.37 - Afterscreen Tie-down points

Transportation 5
5.6 Unloading the Machine From Transport

NOTICE
Removing the fasteners securing the machine and any loose items from the transporter is
the responsibility of the haulage contractor.
Ensure locking plates are removed before running the machine.
PROCEDURE
1. Remove the fastenings securing the machine and any loose items to a transporter.
2. Position suitable ramps at the end of the transporter.
3. Ensure that any loose items transported with the machine wont cause any hazards during
unloading.
5. Ensure that the engine speed is at idle.
6. Slowly track the machine off the transporter.
7. Stop the engine.
8. Remove ramps from the end of the transporter.

5 Transportation

Initial Setup and Adjustments 6
Table of Content
6 Initial Setup and Adjustments ...................................................................6-1
6.1 Assembly and Installation .............................................................................. 6-2
6.2 Initial Inspection Check .................................................................................. 6-3
6.3 Location Considerations................................................................................. 6-4
6.4 Measures Before Setup ................................................................................. 6-5
6.5 Measures after Long-Term Standstill ............................................................. 6-5
6.6 Setting Up The Machine................................................................................. 6-6
(1) Placing the Discharge Conveyor into the Working Position ...................... 6-7
(2) Placing Bypass Conveyor Into Working Position....................................... 6-9
(3) Placing recirculating conveyor into working position (R MODEL
ONLY)...................................................................................................... 6-10
(4) Placing Lighting Mast into Working Position............................................ 6-14
6.7 Setting Up And Using The Water Pump (Option)......................................... 6-16
6.8 Initial Startup And Running In ...................................................................... 6-17

6 Initial Setup and Adjustments

6.1 Assembly and Installation
� WARNING
Lockout and Tag out.
Ensure the lockout and tag out procedure is implemented before performing any assembly and
installation procedures. Failure to comply can result in serious injury.
Observe all safety warnings while carrying out inspections and checks.
Wear personal protective equipment.
� CAUTION
The environment in which the machine operates contains inherent health and safety risks,
which the operator must take steps to avoid.
Dangers from overhead conveyor discharges, over spill material, vehicle movements, and so
on, as well as other site-related hazards must be anticipated.
Avoid all by carrying out risk assessments before the machine is put into operation. Ensure that
appropriate exclusion zone measures are put in place and site personnel safety awareness
training has been undertaken.
Terex recommends that the assembly and installation work of the machine is carried out by
the Terex customer service department. The manufacturer/supplier is not liable for damage
caused by improper assembly or installation.
The environment in which the machine operates contains inherent health and safety risks,
which the operator must take steps to avoid.
Dangers from overhead conveyor discharges, over spill material, vehicle movements, and so
on, as well as other site-related hazards must be anticipated.
Avoid these by carrying out risk assessments before the machine is put into operation. Ensure
that appropriate exclusion zone measures are put in place and site personnel safety awareness
training has been undertaken.
Refer to “Starting the Engine” for initial start-up of the engine.

6.2 Initial Inspection Check

� WARNING
Ensure the lockout and tag out procedure is implemented before performing any assembly and
installation procedures. Failure to comply can result in serious injury.
When the machine is delivered, thoroughly check for any damage that has occurred during
transport. Do not set up the unit until the inspection is complete. Complete any delivery and
start-up forms that were supplied with the equipment. Take note of any damage found, and
photos if possible, and have the driver initial your description of any problems.
Check all loose parts, small-parts boxes, and tools against the packing list to ensure all items
shipped are present. Check in and around the machine for any loose items that may have
been shipped inside the machine.

6.3 Location Considerations

NOTICE
Before setting up the machine, consideration must be given to a suitable layout to prevent
oversize material or metal from entering the machine. In order to prevent bridging of the
crusher, no material above the size recommended must be fed into the machine.
PROCEDURE
2. Position the machine in a safe level operating position. Pay attention to access from the
loading area and to where material is deposited.
3. Make sure that both tracks are in full contact with the ground minimizing movement of the
machine.
4. Ensure the area under the tail drum of the discharge conveyor is clear of large stones and
other hazards which can cause damage to the belt.
5. Regularly check the machine is level and stable.
6. Pay attention to access from the loading area and to where material is deposited.
7. For dusty conditions some account must be taken of the prevailing wind direction to
minimize the possibility of dust entering the air intake.
8. When setting up the machine, ensure that enough space is available around the machine to
enable easy set-up, servicing, and repair work.
9. Machinery arranged before and after this machine has to be placed on the site accordingly.

6.4 Measures Before Setup

Terex recommends that the Terex customer service department carries out the assembly and
installation work of the machine. The manufacturer/supplier are not liable for damage caused
by improper assembly/installation.
PROCEDURE
1. Ensure that all guards are fully secured in correct/closed position.
2. Remove all loose items from the machine.
3. Put control valve levers in neutral (non-operational) position.
4. The machine must be placed on solid ground capable of carrying the weight of the machine.
5. Before removing the machine from the transport vehicle, it is important that the chosen
site is level. Level the work site foundation.
6. Level the machine with a precision spirit level.
7. Do not position the machine above ground level, for example, on blocks.
8. If applicable, refer to the engine manual for the initial startup of the engine.
6.5 Measures after Long-Term Standstill

NOTICE
Before putting the machine into operation, perform the daily (or 10 hour) maintenance schedule.
Check tracks before transporting or moving the machine. Failure to comply can result in
damaging machine components.

6.6 Setting Up The Machine

NOTICE
When the machine arrives it will be in the transport position: Before carrying out any setup
procedures ensure the machine is located in a suitable position and all personnel are clear
of moving parts.
� WARNING
Nip Point Hazard
Nip points exist where pins need removed or replaced. Stay clear of moving assemblies.
Always wear correct personnel protective equipment.
Moving Object Hazard
Ensure an adequate distance is kept from any assemblies that are being operated with. Failure
in doing so may result in serious injuries.
� DANGER
Fluid Injection Hazard
protective equipment. Relieve pressure before disconnecting hydraulic lines. Keep away from
leaks and pin holes. Use a piece of cardboard to search for leaks. Do not use hand. If fluid is
injected under skin, get medical help immediately.
� CAUTION
Ensure that a full and thorough risk assessment has been carried out prior to carrying out any
setup procedures on the machine.

(1) Placing the Discharge Conveyor into the Working Position
� WARNING
Crush Hazard.
PROCEDURE
2. Ensure the stays (Item 1, Reference: Figure 6.1) are pinned in place.
Figure 6.1 - Discharge Conveyor Stays

4. Activate the control banks. (Reference: Figure 6.2).
5. Proceed to the discharge conveyor at the side of the machine.

6. Familiarise yourself with the control bank levers before operating.

Figure 6.3 - Unfold Conveyor Decal

7. Operate the control lever by pushing it down (Item 2, Reference: Figure 6.3) to unfold the
discharge conveyor into the working position (Reference: Figure 6.4).
Figure 6.4 - Discharge Conveyor in Working Position

8. Ensure the discharge conveyor is secure in the working position (Reference: Figure 6.4).

(2) Placing Bypass Conveyor Into Working Position
� WARNING
Crush Hazard.
NOTICE
Ensure that the Bypass conveyor securing pins have been removed from the conveyor before
folding or unfolding the conveyor. It is important that you carefully check and understand what
each control valve operates. Misuse of these control valves can result in damaging components
and other assemblies.

(3) Placing recirculating conveyor into working position (R MODEL ONLY)
� WARNING
Crush Hazard.
NOTICE
THE MACHINE MUST BE ON LEVEL GROUND BEFORE MOVING THE RECIRCULATING
CONVEYOR. The R section of the machine should be folded using control bank and umbilical
remote.
PROCEDURE
2. Attach the recirc rubber chute (Item 1, Figure 6.5) and insert the fasteners to secure in place.
Figure 6.5 - Rubber Chute

3. Turn and remove the telescopic pins
4. Use the control banks to raise the frame up, before putting into working position (Item 1,
Figure 6.6 & Figure 6.7)

Figure 6.7 - Decal

5.
6. Remove the transport pin ( Item 1 , Figure 6.8)
Keep transport pin safe, this will be used to lock the conveyor into stockpile position
Figure 6.8 - Remove Transport Pin

7. Place into Stockpile Position: Remove pin from the rotating point (Item 1, Figure 6.9) to
allow the conveyor to move into working stockpile position.
Figure 6.9 - Pin Location for Stockpile Position

8. Activate the control banks (Ref:(1) Activating the Control Banks on page 5-4 )
9. Proceed to use the umbilical remote located at the rear of the machine, ( Item 1,Figure 6.10 )

Figure 6.10 - Location of Remote

10. Press button 6 to rotate the conveyor to stockpile position (Item 6, Figure 6.11)
Figure 6.11 - Remote

11. Insert pin into the rotating point (Item 1, Figure 6.12) to secure into stockpile position.
Figure 6.12 - Stockpile Position

12. Attach the stay bar (Item 3, Figure 6.13) telescopic to the stockpile conveyor, by placing the
pin (transport pin) through the hole.

Figure 6.13 - Stay Bar

13. Use control banks to unfold the recirculating conveyor head section. (Item 1, Figure 6.14
& Figure 6.15)
Figure 6.14 - Control Bank Lever
Figure 6.15 - Lever

14. INTO RECIRCULATING POSITION: Remove pin (Transport pin)
Figure 6.16 - Transport Pin

15. Use the umbilical remote located at the rear of the machine, ( Item 1,Figure 6.10
16. Press button 6 on the umbilical remote to slew into recirculating position. (Ref 6, Figure 6.11)
17. Insert pin into rotating point (Item 1, Figure 6.17) to secure the recirculating conveyor in
position.
Figure 6.17 - Pin in Working Position

18. Unfold head section, (Ref: (1) Placing the Discharge Conveyor into the Working Position on
page 6-7)
19. Deactivate the control banks
(4) Placing Lighting Mast into Working Position
PROCEDURE
2. Gain safe access to the lighting mast ()

Figure 6.18 - Mast in Transport Position

3. Carefully raise the mast up into working position, and secure with four bolts to hold into
place.()
Figure 6.19 - Mast in Working Position

6.7 Setting Up And Using The Water Pump (Option)

NOTICE
The pump is to provide a pressurised supply of clean water to the dust suppression spray
nozzles included on the machine. The pump is permanently mounted in a suitable position on
the machine near to the water system inlet and is electrically driven. It is controlled via screen.
PROCEDURE
1. Connect a clean water supply to the pump inlet fitting (Item 1, Reference; Figure 6.20).
Figure 6.20 - Waterpump

2. On the production screen press the water pump button (Item 2, Reference; Figure 6.21)
to start the water pump.

6.8 Initial Startup And Running In

NOTICE
Checks on the machine are crucial during the first week of crushing operation.
The following section must be read and understood before starting the machine. If there are
any doubts, contact your help desk department.
PROCEDURE
1. Verify all safety signs are present and readable.
2. Ensure that all safety guards are in place and secured.
3. Check levels of oils are satisfactory.
4. Run the machine empty for a short period. Check for abnormal noises, vibration, or
excessive heat from shaft bearings, fluid leaks, and so on, including the vibrating feeder
gearbox.
5. Frequently check the oil level in the vibrating feeder.
6. All control systems must be checked for full functionality.
7. Each day during the initial days of operation, check the tension of the conveyor belts and
discharge and side conveyors and adjust if necessary.
8. Make sure that the conveyor belts are tracking correctly and that the skirt sealing rubbers
are correctly adjusted.
9. Check frequently the overall stability of the machine; recheck the level of the machine and
move to level position if necessary.
10. Regularly check crusher drive belts to ensure correct tension, particularly during the initial 2
weeks of use.
11. Avoid overloading the crusher.
12. Check for any leaks of lubricants, fuel, water, or hydraulic fluid and rectify immediately.
13. Check for any overheating of running parts.
14. Avoid overloading the machine by not using small discharge settings during the first few
days of operation.
15. Check the quality of the crushed material.
16. Check blow bars for wear.


Standard Operating Procedures 7
Table of Content
7 Standard Operating Procedures ...............................................................7-1
7.1 Pre-Operating Checks.................................................................................... 7-2
7.2 Starting The Engine ....................................................................................... 7-3
7.3 Manoeuvring .................................................................................................. 7-5
(1) Umbilical Tracking ..................................................................................... 7-7
(2) Remote Tracking (Optional)..................................................................... 7-10
7.4 Standard Operation...................................................................................... 7-13
(1) Putting the Machine into Operation (Standard Models)........................... 7-13
(a) Auto Mode........................................................................................... 7-14
7.5 Setting The Vibrating Feeder Speed ............................................................ 7-15
(1) Enabling Manual Or Auto Feeder Mode .................................................. 7-15
(a) Adjusting Feeder Speed In Manual Mode........................................... 7-17
(b) Adjusting Feeder Speed In Auto Mode ............................................... 7-18
7.6 Radio Remote Control Crushing Operation ................................................. 7-19
(1) Enabling Track Whilst Crushing............................................................... 7-21
(2) Obtaining Four Digit Security Pin ............................................................ 7-23
(3) Track Whist Crushing Function................................................................ 7-24
7.7 Introducing Material to the Machine ............................................................. 7-25
7.8 Shutdown ..................................................................................................... 7-25
(1) Shutting Down The Machine Via The Control Panel ............................... 7-26
7.9 Blocked Crusher........................................................................................... 7-27
(1) Temporary Opening of Upper Apron System........................................... 7-28
(2) Open Upper Apron using Radio Remote Control [if fitted]....................... 7-29
(3) Manually Clearing The Blockage............................................................. 7-30
7.10 Impactor Access........................................................................................... 7-31
(1) Testing Chamber Safety Switches........................................................... 7-31
(2) Activating Battery Operated Hydraulic System........................................ 7-34
(3) Accessing Inspection Door ...................................................................... 7-37
(4) Opening Impactor Body........................................................................... 7-39
(5) Closing Impactor Body ............................................................................ 7-44
7.11 Crusher Apron Adjustment........................................................................... 7-47
(1) Upper Apron Adjustment ......................................................................... 7-48
(2) Lower Apron Adjustment ......................................................................... 7-52
7.12 Detaching and Attaching the R section ........................................................ 7-56
(1) Detaching the ‘R’ Section ........................................................................ 7-56
(2) Attaching the ‘R’ Section ......................................................................... 7-60

7 Standard Operating Procedures

7.1 Pre-Operating Checks
� WARNING
Always wear personal protective equipment when working with the machine.
Lockout and tag out the machine before performing pre-operating checks.
PROCEDURE
1. Verify all safety signs are present and readable.
2. Ensure that the machine is placed on solid ground capable of carrying the machines weight.
3. Ensure that there is adequate space around the machine for operation, material stockpiles,
maintenance, and vehicular movement.
4. Ensure that the crusher is empty of material before starting.
5. Ensure the material being fed into the crusher is below the size limitations recommended
by the manufacturer.
6. Ensure that all guards are fully secured in correct/closed position.
7. Remove all loose items from the conveyor belts.
8. Ensure that all conveyor belts are sufficiently tensioned.
9. Check the engine oil level, feeder gearbox oil level, coolant level, hydraulic oil level, urea
level, and the fuel level and replenish if necessary.
10. Before start-up, padlock the engine enclosure to prevent access during operation.

7.2 Starting The Engine

NOTICE
On constant speed engines the engine can only be increased to running speed once each
time engine is started.
PROCEDURE
2. Ensure that all the emergency stop buttons have been released.
3. Locate the isolator switch (Item 1, Reference Figure 7.1) at the rear of the machine.
Figure 7.1 - Isolator Switch Location

4. Turn the isolator switch to the “ON” position (Item 1, Reference Figure 7.2).
Figure 7.2 - Isolator Switch

5. Proceed to the ignition key (Item 1, Reference Figure 7.3) on the control panel.

6. Turn the key (Reference Figure 7.4) from the “Off” position (Item 1) to the “On” position
(Item 2).
» The production screen is displayed on the control panel display screen. If any faults
are present, a warning sign is displayed.
Figure 7.4 - Ignition Key Positions

7. If no faults are present, turn the key to the crank position (Item 3, Reference Figure 7.4).
8. If the engine fails to start within 30 seconds, turn the ignition key back to the ‘On’ position
(Item 2, Reference Figure 7.4). Allow the starter motor to cool for 2 minutes before
attempting to start again.
9. When the engine starts, allow it to idle for approximately 3 minutes before operating the
machine.

7.3 Manoeuvring
� DANGER
Do not stand on any of the platforms or ladders on the machine whilst it is being manoeuvred.
When manoeuvring the machine ensure you stand well clear of the machine but are in a
position to have all-round vision to see any obstacles or hazards that may lie ahead e.g
personnel, overhead cables, ditches, unsafe roadways etc. Do not manoeuvre the machine on
a gradient steeper than 30 degrees.
� WARNING
Crush hazard from tracking machine. Ensure all personnel are clear of moving machine.
Prior to attempting any manoeuvring of the machine ensure that all material has been
processed through it and that no material is left in the feed hopper or crusher and that all
material has run off the conveyors.
NOTICE
Avoid manoeuvring the machine over extremely uneven ground as damage may occur.
In cold weather conditions before manoeuvring the machine, run the machine for approximately
10 minutes with the discharge conveyor running, but ensure it is stopped before manoeuvring.
Ensure that the tracks are free of all obstructions including crushed material and fines.
This machine has the ability to function with the umbilical handset disconnected. To use this
function the umbilical handset must be disconnected and the umbilical override plug must be
fitted. The umbilical override plug is a spare plug located in same location as the umbilical
handset.

Figure 7.5 - Machine Tracking Directions

The following list identifies the machines direction. Use the list with the diagram (Reference:
Figure 7.5)
1 Left
2 Right
3 Forward
4 Reverse
5 Right-Hand Side Track
6 Left-Hand Side Track

(1) Umbilical Tracking
� WARNING
Crush Hazard.
Death or serious injury can result from contact with the track frames.
KEEP CLEAR of track frames when the unit is in operation.
NOTICE
This machine has a maximum tracking gradient of 30 degrees and a tracking speed of 1 kph
(0.62 mph).
PROCEDURE
2. Ensure the engine stop button at the base of the handset is released.
3. Ensure that the umbilical handset is plugged into the rear GRP door.
5. On the control panel turn the setup button (Item 2, Reference Figure 7.6) to the tracks icon.

» The tracking screen will appear.
6. On the tracking screen press the umbilical handset button (Item 1, Figure 7.7).

Figure 7.7 - Tracking Screen

7. On the umbilical handset (Figure 7.8) press button 8 to activate the tracking.
» The safety siren will sound and the safety beacon will flash. The tracks will not become
enabled until the 7 second delay is completed.
Figure 7.8 - Umbilical Tracking Handset

8. Familiarise yourself with the handset directional buttons.
• (Button 1) Left Track Forward
• (Button 2) Right Track Forward
• (Button 3) Left Track Reverse
• (Button 4) Right Track Reverse
• (Button 5) Both Tracks Fast Forward
• (Button 6) Both Tracks Fast Reverse
• (Button 7) Stop Tracks
• (Button 8) Start Tracks
The button numbers are displayed on the umbilical handset.
9. Press the track direction buttons (Buttons 1-4 Reference Figure 7.8) on the umbilical
handset to manoeuvre the machine.
10. For longer track movements in a straight line the Fast Forward (Button 5 Figure 7.8) and
Fast Reverse (Button 6 Figure 7.8) can be activated.

» Steering is not possible during fast track

11. When the machine has been tracked to the desired location, Press the ‘tracks stop’ button
(Button 7 Figure 7.8) on the umbilical tracking handset.
12. On the control panel turn the setup button (Item 2, Reference Figure 7.6) to the green
icon to disable the umbilical tracking mode.

(2) Remote Tracking (Optional)
NOTICE
The remote handset must be switched ‘ON’ prior to placing the Control panel in the Remote
Control mode, if not the complete machine will shut down.
If there is a loss of radio signal, or remote stop input, the engine enable relay must shut
off immediately so that the engine is shutdown; and all potentially hazardous movement is
disabled. When radio track has been selected the beacon will flash until the radio has been
deselected or track mode has been exited.
The radio remote is fitted with an “Engine Stop” button at the bottom of the remote. This is
not an Emergency stop button. An emergency stop button should always be used in case of
an emergency.
PROCEDURE
2. Ensure the engine stop button at the base of the handset is released.
4. On the control panel turn the setup button (Item 2 Reference Figure 7.9) to the tracks icon.

» The tracking screen will appear

5. Press and hold both of the radio remote power on buttons (Items 9 & 10, Reference Figure
7.10) for 2 seconds.
» The LED Indicator on the handset flashes.
Figure 7.10 - Radio Remote Handset

6. Release the radio start buttons.
» The LED indicator illuminates green.
7. On the track mode display screen press, the antenna button (Item 2, Reference Figure
7.11) to pair the handset with the machine.
Figure 7.11 - Track Mode Screen

8. On the radio remote handset press the track start button (Item 9, Reference Figure 7.10).
» The safety siren sounds for seven seconds, pauses, and then starts again. The machine
can be maneuvered.

9. Familiarise yourself with the handset directional buttons (Reference Figure 7.10).
• (Button 1) Left Track Forward
• (Button 2) Right Track Forward
• (Button 3) Left Track Reverse
• (Button 4) Right Track Reverse
• (Button 5) Not Used
• (Button 6) Not Used
• (Button 7) Open Upper Apron
• (Button 8) Vibrating Feeder Speed
• (Button 9) Radio start button and tracks start/stop
• (Button 10) Radio start button and feeder start/stop
The button numbers are displayed on the radio remote handset.
10. Press the track directional buttons (Items 1–4, Reference Figure 7.10) on the radio handset
to manoeuvre the machine.
11. When the machine has been tracked to the desired location, Press the ‘tracks stop’ button
(Item 9, Reference Figure 7.10) on the radio remote handset.
12. On the control panel turn the setup button (Item 2 Reference Figure 7.9) to the green
icon to disable the umbilical tracking mode.
13. Press the power off button at the base of the handset to preserve battery life.

7.4 Standard Operation

(1) Putting the Machine into Operation (Standard Models)
NOTICE
The crusher must be started in the correct sequence.
• Magnetic Conveyor (If fitted)
• Bypass Conveyor (If fitted)
• Vibrating Feeder
When all components of the machine have been put into operation, allow the machine to run
empty for a short period of time to check for abnormal noises, vibration or excessive heat from
the shaft bearings, fluid leaks, etc.
Before loading material onto the hopper the entire machine must be running.
� WARNING
Nip point hazard. Do not reach into a moving machine. Flying material hazard. If flying material
hits the head or body it can cause serious injury or death. Wear personal protective equipment.

(a) Auto Mode
PROCEDURE
3. On the control panel ensure that the setup button (Item 2 Reference Figure 7.12) is at the
green icon (start position).

4. With the production screen (Reference Figure 7.13) displayed press the auto start button
(Item 3 Reference Figure 7.12) on the control panel

» The machine will start in sequence and the auto start button will light up green
5. Once the machine has started and left to run for a short period of time, press the feeder
start button (Item 5, Reference Figure 7.12) to start the vibrating feeder.
» The feeder will start and the feeder start button will light up blue.

7.5 Setting The Vibrating Feeder Speed

NOTICE
The vibrating feeder has two methods of speed adjustment:
• Manual Mode (Involves the user manually controlling the feeder speed)
• Auto Mode (Involves the user creating feeder set points on which the feeder maintains
its own set speeds)
Both feeder speed modes can be used while the machine is in operation.
(1) Enabling Manual Or Auto Feeder Mode
PROCEDURE
icon.

4. On the setup screen press the information button (Item 4 Reference Figure 7.15).

5. On the information screen (Figure 7.16) use the scroll button (Item 1 Reference Figure
7.16) to highlight the “6. Feeder” tab (Item 2 Reference Figure 7.16). Press the scroll button
to enter the feeder setup menu.
Figure 7.16 - Information Screen

6. On the feeder setup screen (Figure 7.17) use the scroll button (Item 1 Reference Figure
7.17) to highlight the “6. Feeder Working Mode” tab (Item 2 Reference Figure 7.17).
Figure 7.17 - Feeder Setup Screen

7. Press the scroll button to enable the scroll to toggle between auto and manual mode (Item
3, Reference Figure 7.17).
» The auto / manual tab changes green, indicating that the modes can be changed.
8. Select manual or auto mode and press the scroll button to select the mode.
9. On the control panel, turn the setup button (Item 2, Reference Figure 7.14) to the green
icon to return to the production screen.

(a) Adjusting Feeder Speed In Manual Mode
PROCEDURE
2. With the machine operating, use the scroll button (Item 1) to highlight the feeder speed
icon (Item 2).Figure 7.18.
Figure 7.18 - Manual Feeder Speed Adjustment

3. Press the scroll button (Item 1, Figure 7.18) to enable the feeder speed to be adjusted
using the scroll function.
4. View the feeder speed (Item 2, Figure 7.18). When turning the scroll button, the feeder
speed is increased or decreased in increments.
5. Set the feeder to the desired speed and press the scroll button to disable the adjustment
function.

(b) Adjusting Feeder Speed In Auto Mode
PROCEDURE
2. With the machine fully operating, use the scroll button (Item 1) to highlight the feeder
speed icon (Item 2). Figure 7.19.
Figure 7.19 - Auto Feeder Speed Adjustment

3. On the feeder speed adjustment icon are two set points. The set points are small arrow
icons.
• Maximum set point (Item 2, Figure 7.19).
• Minimum set point (Item 3, Figure 7.19).
4. Use the scroll button (Item 1) to highlight the maximum set point arrow (Item 2). Figure 7.19.
5. Press the scroll button to enable the feeder speed to be adjusted using the scroll function.
6. Set the feeder maximum set point to the desired speed and press the scroll button to select
the setting and disable any further adjustment.
» When the maximum set point is set to the desired speed, this set point is the maximum
speed achievable even if the crusher is running with a low engine load.
7. Use the scroll button to highlight the minimum set point arrow (Item 3, Figure 7.19).
8. Press the scroll button to enable the feeder speed to be adjusted using the scroll function.
9. Set the feeder minimum set point to the desired speed and press the scroll button to select
the setting and disable any further adjustment.
» When the minimum set point is set to the desired speed, this is the minimum speed in
which the feeder drops to until it completely pauses depending on engine load..
10. The vibrating feeder speed can vary depending on the minimum and maximum set points
that have been set or also the application settings that are being used.

7.6 Radio Remote Control Crushing Operation

In Auto mode the radio can be turned on and operated at any stage.
The radio will have the following functions:
• Engine kill button on the bottom of the remote will cause the engine enable relay to go OFF
this will not be reset until the next key-on cycle.
• Feeder ON/OFF button (Item 10, Reference Figure 7.20) will start and stop the feeder.
Feeder start / stop will only operate in manual / auto mode when the chamber is running
• Upper Apron Open Button (Item 7, Reference Figure 7.20) will open the upper apron
when pressed. When the button is released the upper apron will automatically return to
the working position.
Figure 7.20 - Remote Handset Overview

If the radio signal is lost it will have no effect.
In auto mode there is a button to enable the remote handset (Item 1, Reference Figure 7.21).
Figure 7.21 - Production Screen Remote Handset Button

When remote handset button is enabled the following will be true:

In auto mode – with radio control selected the operator will be able to stop the feeder and
then press track enable. This option will only be available when the ‘Track Whilst Crushing’
has been enabled in the configuration mode.
The 7 second delay sounder will sound and then tracking will be enabled. When the track
enable button is pressed again tracking will be disabled and the feeder start button can be
pressed to restart the feeder.
If the radio signal is lost during crushing and the radio control is enabled;
• If the signal is lost for more that 1(s) an alarm will be logged & displayed to the operator.
• If the radio signal is lost for 5(s) or more the feeder will stop.
• If the radio signal is lost for a total of 20 (s) a controlled shutdown will be initiated.

(1) Enabling Track Whilst Crushing
NOTICE
A four digit pin is required to enable the ‘ Track Whilst Crushing’ option. Once the pin has been
obtained from Terex helpdesk this function can be performed. The security pin must be entered
before trying to enable the ‘Track Whilst Crushing option.
PROCEDURE
icon.

4. On the setup screen press the information button (Item 4 Reference Figure 7.23).

5. On the information screen (Figure 7.24) use the scroll button (Item 1 Reference Figure
7.24) to highlight “7 track control” tab (Item 2 Reference Figure 7.24). Press the scroll
button to enter the track parameter setup menu.

6. On the track parameter screen (Figure 7.25) use the scroll button (Item 1 Reference Figure
7.25) to highlight the "Track whilst crushing” tab (Item 2 Reference Figure 7.25).
Figure 7.25 - Track Parameter Screen

7. Press the scroll button to enable the scroll to toggle from disable to enable.
» The disable/enable tab changes green, indicating that the selection can be changed.
8. Press the scroll button to select the enable mode.
9. On the control panel, turn the setup button (Item 2, Reference Figure 7.22) to the green
icon (start position) to return to the production screen.

(2) Obtaining Four Digit Security Pin
PROCEDURE
3. Follow the procedure for enabling track whilst crushing ((1) Enabling Track Whilst Crushing
on page 7-21).
Figure 7.26 - Track Parameter Screen

4. On the track parameter screen press button 4 (Figure 7.26)
» The password screen will display.
5. On the password screen (Reference:Figure 7.27 ) obtain the code (Item 2) at the bottom
of the screen.
Figure 7.27 - Password Screen

6. Provide this code to Terex helpdesk to obtain the four digit security pin for the machine.
7. Enter the four digit pin to allow changes to be made.

(3) Track Whist Crushing Function
PROCEDURE
3. Ensure the Track whilst crushing feature is enabled. (Reference;(1) Enabling Track Whilst
Crushing on page 7-21 ).
4. Using the remote pause the feeder, by pressing the appropriate button. (Item 10,Figure
7.28 ).
5. Enable the track function on the remote, by pressing the appropriate button. (Item 9,Figure
7.28 ).
» The siren will now sound with a 7 second countdown.
6. After the 7 second countdown, the siren tone will change with the track lamps being
enabled (If this option is selected).
» The machine can now be tracked, with the rotor and conveyors continuing to run.
7. After the tracking is completed, the track function can be disabled by pressing the
appropriate button. (Item 9,Figure 7.28 ).
8. The feeder can now be restarted with the plant running as normal, by pressing the
appropriate button on remote. (Item 10,Figure 7.28 ).

7.7 Introducing Material to the Machine

� WARNING
Before operating the machine, read, and understand the operator manual.
NOTICE
Avoid any contact with the shovel, excavator, or ramp against the side of the machine.
Some operators build a ramp at the side of the machine to give their shovel loader a better
reach into the Hopper. If you do build a ramp avoid contact with the side of the machine.
Initial feed rate should be low gradually increasing up to normal rate over first days of operation.
After initial period stop the machine and visually check belts, scrapers, skirting rubbers, blow
bars and nip guards for abnormal wear and obstructions. Conveyor belts may behave different
with material on them, re tracking may be necessary
• Check the quality of the crushed material.
• Check the crusher vee belts regularly for tension, particularly over initial few weeks of
operation.
• Frequently check the oil levels in the vibrating unit.
7.8 Shutdown
NOTICE
Before stopping the machine ensure that the feeder and crusher are empty and that the product
and bypass conveyor is clear of material.
The machine must not be shut down at the end of a working shift by only switching off the
engine, pressing an emergency stop button or switching the isolator switch to the off position.
The machine must be stopped in the correct sequence.

(1) Shutting Down The Machine Via The Control Panel
NOTICE
After, key off the isolator switch must remain in the “ON” position for a minimum of 20 seconds
to allow all systems to shut down properly.
Tier 4/Stage V machines require that the isolator switch remains in the “ON” position for 2
minutes after key off to allow the SCR system to cool.
PROCEDURE
1. With the machine operating, press the feeder stop button (Item 5, Reference; Figure 7.29)
on the front of the control panel.

» The button will be no longer blue and the feeder will stop.
2. Press the auto start/stop button (Item 3, Reference; Figure 7.29) to deactivate the auto
run mode.
» The button will be no longer green and the machine will automatically shut down in
the following sequence:
• Bypass conveyor (Optional)
• Main conveyor
• Magnetic conveyor (Optional)
• Impactor
• RPM will decrease (not on constant speed machines)
3. When the machine has completely stopped and the rotor completely stopped turning turn
the ignition key to the off position and remove the key.
4. After, key off the isolator switch must remain in the “ON” position for a minimum of 20
seconds to allow all systems to shut down properly.
5. Volvo, Tier 4 machines require that the isolator switch remains in the “ON” position for 2

7.9 Blocked Crusher

� DANGER
When manually clearing crusher always isolate the machine and lockout and tagout.
When manually clearing crusher be aware that pressure in impactor may cause movement
and create nip points.
Under no circumstances should any maintenance work be carried out on the impactor without
locking the blow bar rotor.
� WARNING
To comply with Health and Safety Law it is necessary to carry out adequate risk assessments
of the procedures for unblocking a crusher.
When clearing the crusher by hand extreme caution must be taken,
NOTICE
It is the responsibility of the Owner, Machine Operator and a nominated safety officer to provide
a safe means of unblocking a stalled crusher unit. Prior to attempting to clear a blockage
the Operator must have Read and Understood the Impactor Operation and Maintenance
Instructions supplied with the machine.
If the crusher stops during operation i.e Emergency stop activated or lack of fuel, the crusher
may not be able to continue without clearing the crusher unit. In this situation the complete
machine must be shut down and locked out. The blockage can then be cleaned manually.
If the impactor is not operating correctly due to oversize, unsuitable or non breakable material
being fed into the machine, it can lead to excessive vibration and material hitting the wrong
areas of the impactor. This can cause damage to the rotor and other impactor parts.
Under no circumstances should any maintenance work be carried out on the impactor without
locking the blow bar rotor.

(1) Temporary Opening of Upper Apron System
NOTICE
Should a situation arise where the feed material bridges between the upper apron and the
feed chute, the impactor is fitted with a control system which fully opens the upper apron to
release the material.
PROCEDURE
1. Observe all safety warnings and notices.
2. With the machine operating press the upper apron open button (Item 4 Reference Figure
7.30)

» The upper apron will open and once the button is released it will return back to closed
position.

(2) Open Upper Apron using Radio Remote Control [if fitted]
PROCEDURE
3. Prepare the machine for crushing.
4. Switch on the conveyors, impactor and feeder at the machine controls.
5. Press and hold the open upper apron button (Item 7, Reference Figure 7.31) to start the
controlled sequence of opening.

6. When the button is released, the apron will immediately close to the previous setting.

(3) Manually Clearing The Blockage
� WARNING
Nip point hazard.
Do not reach into a moving machine.
NOTICE
Any procedure developed to remove metal or any other material that has resulted in the stalling
of the crusher should be incorporated into a permit to work procedure. This procedure should
be maintained under the control of a suitably trained and competent person.
PROCEDURE
2. Stop the machine and implement the lockout procedure.
3. Check the feed for obstruction and clear any blockage.
4. If the feed is clear the impactor may be blocked with material.
5. Open the impactor, refer to impactor access.
6. Clear any obstruction and check for damage to impactor rotor.
7. In the case of a stalled impactor it should always be treated as possibly being jammed
with non breakable material such as metal.
8. A crane and hook can be used although extreme caution must be exercised to ensure that
the crane is not overloaded by trying to lift jammed material.

7.10 Impactor Access

(1) Testing Chamber Safety Switches
PROCEDURE
2. Activate the battery operated hydraulic system by turning the ignition key to position 2
(Reference: Figure 7.32). DO NOT START THE ENGINE.

3. Remove the chamber safety plugs. (Items 1, Reference: Figure 7.33).
Figure 7.33 - Impactor Safety Plugs

4. Visually check that the feeder and impactor are completely empty of material to ensure the
rotor will not be turned by falling material.
5. Visually check that the rotor is completely stationary.

6. Loosen the nuts on the toggle bolts (Items 1, Reference: Figure 7.34) using a 36mm
spanner and swing the toggle bolts to the side to allow the chamber to open.
Figure 7.34 - Impactor Toggle Bolts

7. On the control panel, turn the setup button (Item 2: Reference: Figure 7.35) to the spanners
icon.

8. On the setup screen, press the crusher setup button (Item 2, Reference: Figure 7.36).

» The battery operated hydraulic menu will appear (Reference: Figure 7.36)

9. The battery operated hydraulic menu (Reference: Figure 7.36) will now be displayed and
the following components will be able to be operated.
• Open Impactor Hood (Button 1)
• Close Impactor Hood (Button 2)
• Close Lower Apron (Button 3)
• Open Lower Apron (Button 4)
• Close Upper Apron (Button 5)
• Open Upper Apron (Button 6)
Figure 7.37 - Battery Operated Hydraulic Menu

10. Open the impactor body approximately 25 mm (1 in), by pressing and holding the impactor
body open button (Item 1, Reference: Figure 7.36)
11. Return to the setup menu by pressing the exit button.
12. Turn ignition to the 1 position (Reference: Figure 7.32)
13. Ensure all personnel are clear of the machine
14. Turn ignition to the 2 position (Reference: Figure 7.32)
15. Once the sequence of diagnostic checks is completed, fully turn the key to attempt to
start the engine.
» No engine cranking should occur.
16. Release the ignition key.
17. Providing there is no fault and the engine does not attempt to start, the safety switches are
working.

(2) Activating Battery Operated Hydraulic System
NOTICE
When opening the impactor hood, ALWAYS ensure the toggle bolts are completely open and
free of obstruction. Failure in doing so may result in damaging the locks and other components.
� DANGER
PROCEDURE
2. Disconnect the chamber safety switches (Items 1, Reference: Figure 7.38)
Figure 7.38 - Impactor Safety Switches

3. Make sure the rotor is stationary.
4. Make sure no emergency stop buttons are pressed in, including the umbilical control and, if
active, the radio control button. Re-set all emergency stops by pulling or twisting out,
depending on type fitted.
5. Turn on the ignition to the first position only (Item 2, Reference: Figure 7.39). DO NOT
START THE ENGINE.


6. On the control panel, turn the setup button (Item 2, Reference: Figure 7.40) to the spanners
icon.

7. On the setup screen press the crusher setup button (Item 2 Reference: Figure 7.41).

» The battery operated hydraulic menu will appear (Reference: Figure 7.42)
8. The battery operated hydraulic menu (Reference: Figure 7.42) will now be displayed and
the following components will be able to be operated.



9. To operate an feature, press the button required to perform the operation.

(3) Accessing Inspection Door
NOTICE
Keep inspection door closed and secured except when performing maintenance.
� DANGER
Never reach into the inspection door without the machine being locked out and tagged out.
PROCEDURE
2. Stop the machine and implement the lockout procedure.
3. Remove both safety plugs (Items 1, Reference: Figure 7.43).

4. Check visually that the feeder and impactor are completely empty of material to ensure the
rotor will not be turned by falling material.
5. Release the toggle bolt (Item 2, Reference: Figure 7.43).
6. Open the inspection door (Item 1, Reference: Figure 7.44).
Figure 7.44 - Inspection Door Open

7. Visually check that the rotor is completely stationary.

8. Once finished inspection task, close the inspection door and ensure the toggle bolt (Item 2,
Reference: Figure 7.43) is securely tightened.
9. Refit the safety plugs (Items 1, Reference:Figure 7.43 )

(4) Opening Impactor Body
� DANGER
Switch off and lockout before working at a machine.
Dangerous nip points exist. Close guards after maintenance.
� WARNING
Before maintenance you must read and understand the safety sections in this manual.
Wear personal protection equipment.
When using the lifting cradle and equipment, removing or fitting blow bars take care not
to trap fingers.
Always ensure that the rotor is locked to prevent unexpected movement.
NOTICE
When opening the impactor hood, ALWAYS ensure the toggle bolts are completely open and
After the clutch has disengaged there is a 3 minute delay before being able to perform the
function to open the impactor hood.
PROCEDURE
2. Loosen the nuts on the toggle bolts (Items 1, Reference: Figure 7.45) using a 36mm
spanner and swing the toggle bolts to the side to allow the chamber to open.

3. Disconnect the chamber safety plugs (Items 1, Reference: Figure 7.46)


» An Alarm will sound
4. Acknowledge the alarm on the control panel.
6. Remove the securing bolt (Item 1, Reference: Figure 7.47) from the rotor bar locking device.
Figure 7.47 - Rotor Locking Device

7. Rotate the rotor bar locking device so that the long section (Item 2, Reference: Figure 7.47)
can be inserted back into the recess. When reinserting the locking device, ensure it is
seated fully into the securing hole (Item 1, Reference: Figure 7.48) on the blow bar rotor.
Figure 7.48 - Impactor Rotor Locking Hole

8. If the locking device does not line up with the rotor release the toggle bolt and open the
inspection door (Reference: (3) Accessing Inspection Door on page 7-37) and rotate the
rotor by hand until it does.
9. Close the inspection door.
10. Replace the securing bolt (Item 1, Reference: Figure 7.47) back on the locking device to
secure in position.
11. Make sure no emergency stop buttons are pressed in, including the umbilical control and if
active, the radio control stop button. Re-set all emergency stops by pulling or twisting out,
START THE ENGINE.

13. On the control panel, turn the setup button (Item 2, Reference: Figure 7.50) to the spanners
icon.

14. On the setup screen, press the crusher setup button (Reference: Figure 7.51).


» The battery operated hydraulic menu will appear (Reference: Figure 7.52).
15. The battery operated hydraulic operated menu (Reference: Figure 7.52) will now be
displayed and the following components will be able to be operated.

16. Fully open the impactor body by pressing button 1 (Item 1, Reference Figure 7.52).
17. Avoid prolonged use of the pump to preserve the battery charge.
18. Secure the body in the open position using the safety support (Item 1, Reference Figure
7.53).

Figure 7.53 - Safety Supports

19. Turn the ignition to the off position (Item 1, Reference: Figure 7.49).
20. Turn the isolator switch to the off position and implement the lockout and tagout procedure.

(5) Closing Impactor Body
� WARNING
Nip point hazard.
Ensue all personnel are clear of the machine when closing the impactor body. Failure in doing
so may lead to serious injuries.
NOTICE
When closing the impactor hood ALWAYS ensure that the swing bolts are fully released and
PROCEDURE
2. Activate the battery operated hydraulic system. (Reference: Activating Battery Operated
Hydraulic System).
3. Before closing the impactor body, make sure the toggle bolts (Items 1, Reference: Figure
7.54) will not become trapped.

4. Clear all material from around the joint where the impactor will close.
5. Release the safety support (Item 1, Reference: Figure 7.55) for the impactor body.

Figure 7.55 - Safety Supports

6. On the battery operated hydraulic system, fully close the impactor body by pressing and
holding the hood close button (Item 2, Reference: Figure 7.56)

7. Avoid prolonged use of the pump to preserve the battery charge.
8. Turn off the ignition and remove the key.
9. Turn the isolator switch off and implement the lockout and tagout procedure.
10. After closing the impactor body, make sure the toggle bolts (Item 1, Reference: Figure 7.57)
are tightened securely on both sides of the impactor.

11. Remove the rotor bar locking device and rotate it so the short section can be inserted back
into the recess. (Reference: Figure 7.58).
Figure 7.58 - Rotor Locking Device

12. Refit the impactor safety plugs (Items 1, Reference: Figure 7.59)

7.11 Crusher Apron Adjustment

� DANGER
Never reach into the inspection door without the machine being locked out and tagged out.
� WARNING
Nip point hazard.
Ensue all personnel are clear of the machine when closing the impactor body. Failure in doing
so may lead to serious injuries.
Shutdown, and lockout and tag out the machine.
NOTICE
Run the crusher until the crushing chamber is completely empty. Stop the crusher drive system
and Lockout & Tagout the power source. Be sure rotor is completely stopped before working on
crusher. After adjustment of either breaker plate, be sure to visually check clearance of the
breaker plate to the rotor.
• The upper apron plate should always be set to within about 2 to 3 times the distance of
the lower breaker plate.
• The upper apron plate is factory set to within about 80mm (3.15 inches) of the rotor
circumference (shown as dimension B).
• The lower apron plate is factory set to within about 40mm (1.57 inches) of the rotor
circumference (shown as dimension A).
• The adjustment cylinders and/or nuts on the end of each apron is where the adjustment
takes place. When adjustment is completed, always look inside the machine to verify the
apron plate to rotor clearance ((closed side setting (CSS)). Make sure the apron plate is
parallel to the rotor.
Figure 7.60 - Apron Gap

(1) Upper Apron Adjustment
PROCEDURE
2. Disconnect the chamber switches. (Items 1, Reference: Figure 7.61).

START THE ENGINE.

6. Open the inspection door (Reference: Figure 7.63).


7. Rotate rotor by hand until one of the long blow bar is as close to the upper apron plate as
possible.
8. Use a measuring device to gauge the distance (Item 1, Reference: Figure 7.64) between
the blow bar / rotor circle (Item 2, Reference: Figure 7.64) and the upper apron.
Figure 7.64 - Upper Apron Adjustment

9. Proceed to the control panel and on the setup screen (Reference: Figure 7.65) press the
crusher setup button (Item 2, Reference: Figure 7.65).

» The battery operated hydraulic system screen will appear (Reference: Figure 7.66).

10. Press the upper apron open button (Item 6, Reference: Figure 7.66) to fully retract the
hydraulic cylinder. This will take pressure off the adjuster rod threads and nut and allow
adjustment.

» To adjust apron using Umbilical Controls, press button 1 or 2. (Reference: Figure 7.67)
Figure 7.67 - Umbilical Control

11. Rotate the apron adjuster nut (Item 1, Reference: Figure 7.68) 1/6 (one sixth) turns at a
time. Turning in an anti-clockwise direction will reduce the gap setting or turning it in a
clockwise direction will increase the gap setting.
Figure 7.68 - Top Apron Adjuster Nut

12. After every adjustment, return to the battery operated hydraulic menu. Press the upper
apron close button (Item 5, Reference: Figure 7.69) until the adjuster nut (Item 1,
Reference: Figure 7.68) is fully re-seated in the lockout position.

13. Return to the inspection door and repeat steps 7–12 until the desired gap is obtained.

(2) Lower Apron Adjustment
PROCEDURE
2. Disconnect the chamber switches (Items 1, Reference: Figure 7.70).

START THE ENGINE.

6. Open the inspection door (Reference: Figure 7.72).


7. Rotate rotor by hand until one of the long blow bar is as close to the lower apron plate as
possible.
8. Use a measuring device to gauge the distance (Item 1, Reference: Figure 7.73) between
the blow bar / rotor circle (Item 2, Reference: Figure 7.73) and the lower apron.
Figure 7.73 - Lower Apron Adjustment

9. Proceed to the control panel and on the setup screen (Reference: Figure 7.74) press the
crusher setup button (Item 2, Reference: Figure 7.74).

» The battery operated hydraulic system screen will appear (Reference: Figure 7.75).

10. Press the lower apron open button (Item 6, Reference: Figure 7.75) to fully retract the
hydraulic cylinder. This will take the pressure off the adjuster rod threads and nut and
allow adjustment.

» To adjust apron using Umbilical Controls, press button 3 or 4. (Reference: Figure 7.76)
Figure 7.76 - Umbilical Control

11. Rotate the apron adjuster nut (Item 1, Reference: Figure 7.77) 1/6 (one sixth) turns at a
time. Turning in an anti-clockwise direction will reduce the gap setting or turning it in a
clockwise direction will increase the gap setting.
Figure 7.77 - Lower Apron Adjuster Nut

12. After every adjustment, return to the battery operated hydraulic menu. Press the upper
apron close button (Item 5, Reference: Figure 7.78) until the adjuster nut (Item 1,
Reference: Figure 7.77) is fully re-seated in the lockout position.

13. Return to the inspection door and repeat steps 7–12 until the desired gap is obtained.

7.12 Detaching and Attaching the R section

� DANGER
� WARNING
Nip point hazard.
Do not reach into a moving machine.
Nip points exist where hydraulic fittings and rams need connected.
Keep all personnel clear of moving sub assemblies.
NOTICE
This machine has the ability to remove the complete R section. To remove the R section,
follow the procedures below.
Ensure that the locking plates are removed before running the machine.
(1) Detaching the ‘R’ Section
NOTICE
Ensure recirc conveyor is in transport mode before carrying out this procedure.
PROCEDURE
2. Find a level surface before detaching the ‘R’ section
» The recirc conveyor must be in transport mode before attempting to detach.
3. Activate the control banks (Ref:(1) Activating the Control Banks on page 5-4)
4. Remove the telescopic pins on both sides of the machine (Item 1, )

Figure 7.79 - Pin Into Transport Position

5. Use the lever to lower the ‘R’ section (Item 1, Step 5.& Figure 7.81)
Figure 7.80 - Lever Location
Figure 7.81 - Lower ‘R’ section Decal

6. Continue to hold the lever down (Item 1,Figure 7.81 ), for the telescopic to fully extend
and detach from the chassis hook on point.

Figure 7.82 - Telescopic Fully extended

7. Remove lower linkage pins on each side (Item 1, Step 7.)
Figure 7.83 - Removal of lower linkage pins

8. Deactivate control banks
9. Shut down machine and implement lockout and tagout procedure.
10. Release hydraulic quick couplers
Figure 7.84 - Location of hydraulic Quick Couplers

Figure 7.85 - Hydraulic Quick Couplers

11. Release electrical harness.(Item 1, Figure 7.86)
Figure 7.86 - Electrical harness

12. Remove lockout tagout.
13. Start the engine
14. Activate the tracks on screen and track back away from the ‘R’ section.
» Ensure machine is clear from snag zone and that main conveyor is folded into transport
position before tracking away from ‘R’ section.

(2) Attaching the ‘R’ Section
PROCEDURE
2. Ensure main conveyor is folded in transport mode.
3. Track to engage machine in line with the lower linkage pins.
4. Adjust jack legs as necessary.
5. Insert pins (Item 1,Figure 7.87 ) in lower linkage position at both sides of the machine.
Figure 7.87 - Location of lower linkage pins

6. Shut down machine, implement the lock out tagout procedure.
7. Reconnect the electrical harness (Item 1,Figure 7.88 )
Figure 7.88 - Electrical harness

8. Reconnect the hydraulic quick couplers

Figure 7.89 - Hydraulic Quick Couplers

9. Start engine
10. Activate the control banks
11. Raise lever (Item 1,Figure 7.91 )and hold to retract the telescopic rams into place.
Figure 7.90 - Lever location
Figure 7.91 - Lower ‘R’ section decal

12. Re-insert telescopic pin (Item 1, Figure 7.92)

Figure 7.92 - Telescopic Pins

13. Verify that telescopic are correctly engaged with chassis.
Figure 7.93 - Telescopic engaged with chassis

14. Deactivate the control banks
15. Machine can now be tracked into preferred position.

Emergency Operating Procedures 8
Table of Content
8 Emergency Operating Procedures............................................................8-1
8.1 Lockout and Tagout........................................................................................ 8-2
(1) Before Carrying Out Any Work On The Machine ...................................... 8-2
(2) After Carrying Out Work on the Machine................................................... 8-5
(3) Emergency Stop ........................................................................................ 8-6
(4) Restarting After an Emergency Stop ......................................................... 8-7
(5) Testing Emergency Stop............................................................................ 8-8

8 Emergency Operating Procedures

8.1 Lockout and Tagout
(1) Before Carrying Out Any Work On The Machine
� WARNING
Never give your key to anyone else. Where more than one person is working on the equipment
they must fit their lock also.
NOTICE
This procedure is designed to prevent injuries caused by the unexpected start-up or movement
of a machine. These procedures must be followed every time a machine is being cleaned,
maintained, adjusted, or repaired. When used as intended, Lockout also protects personnel
from energy stored in devices. Devices, such as springs, accumulators, batteries, and hydraulic
systems. Where the lock out and tag-out symbols appear on a safety sign it indicates that the
machine must be switched off and locked out before any work is carried out.
Depending on the type of machine, there can still be several kinds of energy remaining after the
power is turned off. Secondary energy sources are hydraulic (fluid under pressure), pneumatic
(air under pressure), kinetic (force of moving parts) and potential (force contained in weights
that have been raised).
If, the machine will not be used for periods longer than 24 hours, the machine must be locked
out and tagged out until further use is required.
After, key off the isolator switch must remain in the “ON” position for a minimum of 20 seconds
to allow all systems to shut down properly.
Tier 4/Stage V machines require that the isolator switch remains in the “ON” position for 2
PROCEDURE
2. Turn off the engine at the control panel and remove the key (Item 1, Reference; Figure 8.1).

3. Proceed to the isolator switch (Item 1, Reference Figure 8.2).
Figure 8.2 - Isolator Switch Location

4. On constant speed engines, rotate the isolator switch to the “Off” position (Item 1,
Reference Figure 8.3) after 20 seconds, and 30 minutes for Tier 4 engines.
Figure 8.3 - Isolator Switch

5. Fit the lockout and tag out hasp (Item 1, Reference Figure 8.4), followed by the unique
padlock (Item 2, Reference Figure 8.4) on the main power isolator. Always keep the key on
person, ensuring that no one can remove your lock and turn the power back on.
Figure 8.4 - Isolator Switch Off, Locked and Tagged

6. Place an operators tag (Item 3, Reference; Figure 8.4) on the lock that identifies you (by
your name, picture or number). Ensure to add the date and time you locked it out.
7. Release stored energy from the system so that the machine is in a zero energy state.
8. Try to start or activate the machine ensuring that the power is off. (Do not forget to push
the stop button again, afterward).
9. Lock the starter panel cabinet and put the key in a safe place

(2) After Carrying Out Work on the Machine
PROCEDURE
1. Secure the work area by replacing guards and shields, removing blocks, picking up tools
and inspecting the work area.
2. Take your lock and tag off the main power Isolator.
3. Unlock the operator control panel.
4. Warn others before starting the machine.
5. Start the machine and proceed with your work.

(3) Emergency Stop
� CAUTION
The stop button on the remote radio control handset, if fitted, is NOT an emergency stop as
it is not always operative.
When an emergency stop has been initiated, the ignition switch stays on. Do not attempt
to restart the engine until it is safe to do so.
In the event of an emergency stop button being pressed, a run down period of four minutes
must be allowed before approaching the machine. Failure to comply can result in injury.
NOTICE
Only in the event of an emergency situation must the emergency stop button be pressed.
PROCEDURE
1. Press any emergency stop to stop the engine and the machine. Emergency stops are
located on both the left hand side (Reference: Figure 8.5) and the right hand side of the
machine (Figure 8.6).
» The safety alarm will sound until it is acknowledged and cancelled.
Figure 8.5 - Emergency Stop Locations Left-Hand Side
Figure 8.6 - Emergency Stop Locations Right-Hand Side

2. Turn the ignition key to the off position as soon as possible, after run down period of four
minutes.
3. Remove the ignition key.
4. Place the isolator switch to the off position.
5. When safe, release the emergency stop button by pulling or twisting.
(4) Restarting After an Emergency Stop
NOTICE
The machine must not be restarted if there is any material in and/or on the machine. Ensure
that there is no material in the machine before restarting.
� WARNING
Ensure that the problem has been solved and all personnel are clear of the machine. Before
restarting, ensure that all guards are correctly fitted and fully functional. Do not restart until it is
safe to do so.
PROCEDURE
1. Release the emergency stop button by pulling or twisting.
2. Start the machine, Reference: Chapter 7.

(5) Testing Emergency Stop
NOTICE
The machine must not be restarted if there is any material in and/or on the machine. Ensure
that there is no material in the machine before restarting.
PROCEDURE
2. Push in an emergency stop button.
» The engine stops, the safety alarm sounds and alarm messages are shown on the
display screen.
3. Acknowledge the alarm.
4. Reset the emergency stop by pulling or twisting, depending on the type fitted.
5. Turn the ignition key to the ‘Off’ position.
6. Turn ignition key to the first position again.
7. Wait for the pre-start warning to complete.
8. Turn ignition key to start the engine again.
9. Repeat the procedure for all other emergency stops.

Maintenance 9
Table of Content
9 Maintenance ................................................................................................9-1
9.1 Safety Before and During Maintenance ......................................................... 9-4
(1) Main Discharge Conveyor ......................................................................... 9-6
(2) Diesel Engine ............................................................................................ 9-6
(3) Crusher...................................................................................................... 9-7
(4) Feeder ....................................................................................................... 9-7
(5) Bypass Conveyor ...................................................................................... 9-7
(6) Recirculating Conveyor (R Model) ............................................................ 9-8
(7) Transfer Conveyor (R MODEL) ................................................................. 9-8
(8) Fines Conveyor ( R Model) ....................................................................... 9-8
(9) Screen Box (R Model) .............................................................................. 9-8
9.3 Maintenance Schedules................................................................................. 9-9
(1) User Maintenance Schedule ..................................................................... 9-9
(2) Service Maintenance Schedule ............................................................... 9-13
(3) Extended Service Schedule .................................................................... 9-16
9.4 Greasing Schedule....................................................................................... 9-17
9.5 Lubricants, Oils, and Fluids.......................................................................... 9-20
(1) Lubrication, Quantities and Levels .......................................................... 9-20
(2) Machine Grease Lubrication.................................................................... 9-22
(a) Standard Viscosity Option................................................................... 9-22
9.6 Hydraulic Maintenance................................................................................. 9-23
(1) Hydraulic System Overview..................................................................... 9-23
(a) Hydraulic Fluids .................................................................................. 9-24
(b) Oil Tank, Pipes & Fittings .................................................................... 9-24
(2) Hydraulic Filtration................................................................................... 9-25
(a) Hydraulic Tank .................................................................................... 9-25
(b) Suction Line Filters ............................................................................. 9-26
(c) Return Line Filter ................................................................................ 9-26
(d) Pressure Filter..................................................................................... 9-27
(e) Hydraulic Oil Tank Breather ................................................................ 9-27
(3) Changing Hydraulic Filters and Oil .......................................................... 9-28
(a) Changing Return Filter........................................................................ 9-28
(b) Changing ‘R’ System suction filter ...................................................... 9-30
(c) Changing Suction Filter....................................................................... 9-32
(d) Changing Pressure Filter .................................................................... 9-34
(e) Changing Hydraulic Oil ....................................................................... 9-36
(f) Changing Condensation Control Breather .......................................... 9-38
9.7 Conveyor Maintenance ................................................................................ 9-39
(1) Conveyor Checks .................................................................................... 9-39
(2) Conveyor Belt Adjustment and Tensioning.............................................. 9-41
(3) Belt tracking on Transfer Conveyor (R Model Only) ............................... 9-42
(a) Belt Tensioning on the Recirculating Conveyor ................................. 9-43
(4) Belt tracking on Fines Conveyor ............................................................. 9-44
(a) Belt Tensioning on the Fines Conveyor ............................................. 9-45
(5) Belt Tracking on Discharge Conveyor ..................................................... 9-46
(a) Belt Tensioning On Discharge Conveyor ............................................ 9-47
(6) Belt Tracking On Bypass Conveyor......................................................... 9-48

9 Maintenance
(a) Belt Tensioning on Bypass Conveyor ................................................. 9-49

(7) Cleaning Conveyor Belts ......................................................................... 9-50
(8) Checking the Skirting Rubber and Skirting Clamps for Wear .................. 9-51
9.8 Vibrating Feeder Maintenance ..................................................................... 9-52
(1) Checking Feeder Oil Level And Refilling ................................................. 9-52
(2) Changing Feeder Oil ............................................................................... 9-52
9.9 Vibrating screen box maintenance (R Model) .............................................. 9-53
(1) Changing Screen Box Mesh ................................................................... 9-53
9.10 Volvo Engine Overview ................................................................................ 9-54
(1) Changing Engine Filters and Oil.............................................................. 9-55
(a) Checking the Engine Oil ..................................................................... 9-55
(b) Changing the Engine Oil ..................................................................... 9-56
(c) Volvo Crankcase Breather Filter Change............................................ 9-57
(d) Changing the Air Cleaner Elements.................................................... 9-59
(2) Cooling System Maintenance.................................................................. 9-60
(a) Checking Engine Coolant Level.......................................................... 9-60
(b) Checking Antifreeze and Corrosion Inhibitor ...................................... 9-62
(c) Draining Coolant ................................................................................. 9-63
(d) Filling the Engine Coolant ................................................................... 9-64
(3) Fuel System............................................................................................. 9-65
(a) Bleeding the Fuel System ................................................................... 9-65
(b) Changing the Fuel Pre-filter ................................................................ 9-67
(c) Changing the Fuel Cleaner ................................................................. 9-68
(d) Changing the Final Fuel Filter............................................................. 9-69
(e) Draining the Water Trap...................................................................... 9-72
(4) Servicing the DEF (Diesel Exhaust Fluid) System (Tier 4 Machines
Only) ........................................................................................................ 9-73
(a) DEF Tank Location.............................................................................. 9-73
(b) Changing the DEF Pump Filter ........................................................... 9-74
(c) DEF Tank Flush .................................................................................. 9-75
(d) Refilling the DEF (Diesel exhaust fluid) System ................................. 9-77
9.11 Clutch Maintenance ..................................................................................... 9-79
9.12 Refuelling ..................................................................................................... 9-80
(1) Refuelling the Machine ............................................................................ 9-81
9.13 Track Maintenance....................................................................................... 9-83
(1) Changing Track Gear Box Oil.................................................................. 9-84
(2) Track Adjustments ................................................................................... 9-85
(a) To Release Track Tension................................................................... 9-86
(b) To Increase Track Tension .................................................................. 9-87
9.14 Impactor Maintenance.................................................................................. 9-88
(1) Checking Components For Wear ............................................................ 9-88
(a) Daily Component Checks ................................................................... 9-88
(2) Impactor Checks...................................................................................... 9-89
(3) Blow Bar Wear Profiles............................................................................ 9-90
(4) Hard Facing Rotors ................................................................................. 9-93
(5) Replacing Impactor Blow Bars ................................................................ 9-94
(a) Removing Impactor Blow Bars............................................................ 9-95
(b) Turning Blow Bars............................................................................... 9-97
(c) Fitting the Impactor Blow Bars ............................................................ 9-98
(d) Replacing the Impactor Wear Plates ................................................ 9-102

Maintenance 9
(e) Replacing Inlet Chains and Curtains................................................. 9-105

9.15 Crusher Drive Belt Maintenance ................................................................ 9-106
(1) Aligning The Belt ................................................................................... 9-108
(2) Belt Tensioning Measurements ............................................................. 9-110
(3) Belt Tensioning Adjustment ................................................................... 9-112
(4) Replacement Of Vee Belts .................................................................... 9-113
9.16 Electrical Maintenance ............................................................................... 9-115
(1) Prior To Welding .................................................................................... 9-115
(2) Battery Removal And Installation .......................................................... 9-117
9.17 Dust Suppression Maintenance ................................................................. 9-119
9.18 Hydraulic Cylinder Maintenance ................................................................ 9-119
9.19 Washing The Machine................................................................................ 9-119

9 Maintenance
9 Maintenance
9.1 Safety Before and During Maintenance
� WARNING
Practice safe maintenance. Read and understand the operators manual before doing any work.
Failure to do so can result in serious injuries.
Ensure the lockout and tag out procedure is implemented before performing any maintenance
procedures. Failure to comply can result in serious injury.
PROCEDURE
1. Whenever maintenance or service is being carried out a minimum of two (2) persons must
be present always. NEVER WORK ALONE.
2. Prepare yourself. Wear a hard hat, safety goggles, hearing protection, and other protective
equipment as required by job conditions. Do not wear loose clothing or jewelry that can
catch on controls or moving parts. Long hair must be tied back.
3. Prepare the machine. Move the machine onto a level surface and apply parking brakes
and/or wheel chocks (if applicable). Shut off the engine and remove the key. Relieve
all hydraulic pressure by returning controls to neutral. Secure all hydraulically operated
attachments with pins provided.
4. Isolate all electrical supplies to the machine before starting any maintenance work.
5. Only remove the engine canopy padlocks when machine is completely isolated and safe
to do so. Always replace the engine canopy padlocks when the maintenance tasks are
completed.
6. Never attempt repairs or adjustments to the machine while it is running.
7. Remove only guards or covers that provide access. Wipe away excess grease and oil.
8. Never leave guards off or access doors open when unattended. Keep bystanders away if
access doors are open.
9. When working beneath raised equipment, always use blocks, jack-stands, or other rigid and
stable supports. Never work under unsupported equipment.
10. When working at height make sure you take all necessary precautions in line with local
regulations and use approved PPE, safety harnesses and maintenance platforms. If you
are not aware of working at height requirements speak to your manager before starting
any work. Keep all handles, steps, handrails, platforms, landing and ladders free from dirt,
oil, snow and ice..
11. Never operate any type of engine without proper ventilation – EXHAUST FUMES CAN
KILL. (See Electrical and Engine Safety for more detailed checklist).
12. Checking for hydraulic leaks. Beware hydraulic fluid under pressure can penetrate the skin
or damage eyes. Fluid leaks under pressure are not always visible. When searching for
leaks use a piece of cardboard. Do not use bare hand.
13. Wear safety goggles for eye protection. If fluid enters skin or eye, get immediate medical
attention. (See Hydraulic Safety for more detailed checklist).
14. Clean or replace damaged, missing, or painted over safety signs that cannot be read.

Maintenance 9
15. Rotating and moving parts must be inspected during maintenance and replaced if cracked
or damaged. Excessively worn or damaged parts can fail and cause injury or death.
16. 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 that the machine is functioning properly. After testing, shut down, check the work
you performed (any missing cotter pins, washers, locknuts, and so on). Recheck all fluid
levels before releasing machine for operation.
17. Do not make modification to the machine, additions, or conversions which can affect safety
without supplier approval.
18. To prevent any burns or scalds allow the hydraulic oil to cool down before carrying out any
maintenance tasks (approximately 3 hours).

9 Maintenance

� DANGER
Automatic Startup
Conveyors and related equipment can start at any time without warning. Serious injury or
death could result.
Unauthorised persons prohibited.
Switch off, and lockout all energy sources before performing maintenance or servicing.
� WARNING
Implement lockout and tag out procedure. Isolate the electrical supply. Allow the machinery to
cool.
Dangerous nip points exist. Keep hands, feet, and clothing clear of power-driven parts and
in-running nip points.
Never lubricate, clean, service, or adjust machine while it is moving.
Securely support any machine elements that must be raised for service work.
NOTICE
The arduous task of continuously crushing stone and the harsh environment in which the
machine has to operate calls for reasonable care. Consideration to be taken to keep the
machine in good working order.
Machinery breakdown caused by insufficient or improper maintenance causes high repair costs
and long-term standstill. Therefore, regular maintenance is imperative.
The following section contains maintenance instructions and maintenance schedules for normal
operating conditions.
Understand service procedures before doing any work. Keep the area clean and dry.
Keep all parts in good condition and properly installed. Attend to damage immediately. Replace
worn or broken parts.
Remove any buildup of stones, dust, grease, oil, or other debris from the machine.
(1) Main Discharge Conveyor

The main discharge conveyor is height adjustable and has a plain troughed belt with a
vulcanized joint, with hydraulic motor drive at a pre-set speed. The conveyor is fully skirted and
enclosed from collection point to magnet separator. Aluminium type removable dust covers
are fitted at the head end (optional).
(2) Diesel Engine

The diesel engine is the heart of your machine and a great deal of care and thought has
gone into its selection. In the interest of continued peak performance from your machine the
engine must be maintained and cared for with meticulous attention in accordance with the
manufacturers instructions as detailed in the “Operators Handbook”, a copy of which is included
with this manual.

Maintenance 9
Figure 9.1 - Water Cooled Diesel Engine
(3) Crusher
The best way to keep the crusher in good operating condition is to adopt a planned program of
inspection and preventative maintenance. It is recommended that a record be kept of the actual
operating hours of the crusher, the inspection intervals, and the maintenance required. A new
crusher should be examined after a relatively short period of operation.
Figure 9.2 - Impact Crusher
(4) Feeder
The greatest single factor extending the life of the vibrating feeder is proper lubrication.
Insufficient lubrication quickly damages the bearings. Also, excess oil in the vibrating
unit increases oil agitation causing high operating temperature and higher horse power
requirements. Cleanliness is vitally important. Dust and dirt will cause premature failure of
the bearings. Clean all dirt from openings before removing caps. Use only clean oil to fill
the vibrator housing.
(5) Bypass Conveyor

The side discharge bypass conveyor has a plain belt and hydraulic folding facility for
transportation and is fitted with a hydraulic motor at a pre-set speed. The bypass conveyor
is fed by the smaller material that falls through the feeder, with the coarser material being
fed into the impactor.

9 Maintenance
(6) Recirculating Conveyor (R Model)

Returns material from top of the upper screen to the crusher inlet. The conveyor is fitted with
a chevron cleated belt with a vulcanized joint and driven by hydraulic motor at a fixed speed.
Optional alloy type dust covers are available.
(7) Transfer Conveyor (R MODEL)
The transfer conveyor transfers oversized material from upper screen, sideways to the
recirculating conveyor to be re-crushed. The conveyor is driven by a hydraulic motor at a
fixed speed.
(8) Fines Conveyor ( R Model)
The fines conveyor transfers material from beneath the screens for final output at the end of the
machine. The conveyor is fitted with a plain troughed belt with a vulcanized joint and driven by
hydraulic motor at a fixed speed. It also comes fitted with a removable dust cover.
(9) Screen Box (R Model)
The vibrating mesh inclined screen mounted beneath the crusher discharge conveyor is driven
by hydraulic motor at a fixed speed. The screen normally has a wire mesh fitted, various
sizes are available.

Maintenance 9
9.3 Maintenance Schedules

(1) User Maintenance Schedule
50 Hours
Hourly Intervals. 10 Hours (Daily). (Weekly).
General
Material build up Check / Remove ✔
Bolts and pins Check / Fasten / Replace ✔
Safety signs either missing or damaged Check / Replace ✔
Emergency stop system Check / Repair ✔
Safety guards are in place Check / Replace ✔
Electrical defects Check / Replace ✔
Loose parts, missing nuts & bolts Tighten / Replace ✔
Def-Urea level in tank (Tier 4 only) Check / Refill ✔
Diesel level in fuel tank Check / Refill ✔
Check Grease Lines Check/Tighten/Replace ✔
Automatic Greasing Unit (Option) Check Grease level ✔
Hydraulic System
Hydraulic hoses Check / Tighten / Replace ✔
Hydraulic cylinders Check / Tighten / Replace ✔
Hydraulic pumps & motors Check / Tighten / Replace ✔
Hydraulic oil level Check / Top-up ✔
VGF Feeder Hopper
Screening media Check / Tighten / Replace ✔
Hopper wear plates Check / Tighten / Replace ✔
Condition of springs Check / Replace ✔
Gearbox bolts Check / Tighten / Replace ✔
Mesh wear Check / Replace ✔
VGF Bypass Chute
Wear plate liners Check / Tighten / Replace ✔
Bolts Check / Tighten / Replace ✔
Chamber
Loose bolts and parts Check / Tighten / Replace ✔
Impact Aprons — Wear Check/ Turn if Necessary ✔
Check / Replace if necessary ✔
Impact Aprons — Gap Check / Adjust if Necessary ✔
Impact Apron — Mounting Check / Replace if Necessary ✔
Impact Aprons — Spindles Grease ✔
Impact Aprons — Cylinder Check / Tighten / Replace ✔
Blow Bar — Wear Check / Turn if necessary ✔
Blow Bar lifting device straight and undamaged Check / Replace if necessary ✔

9 Maintenance
50 Hours
Rotor Check / Hard Weld ✔
Check / Balance ✔
Rotor — Wedge Check / Replace if necessary ✔
Rotor — Hard Facing Check / Hard Weld ✔
Rotor locking pin in serviceable condition Check / Replace if necessary ✔
Liner wear plates Check / Tighten ✔
Vee belts Check / Tension ✔
Pillow Blocks/Bearings Check Temperature & record ✔
Check / Tighten ✔
Grease when warm ✔
Unusual noise while operating Check / Repair ✔
Inspection panels and hatches undamaged Check / Repair ✔
Chamber opening mechanical lock undamaged Check / Replace if necessary ✔
Chamber interlock switches in good working Check / Replace if necessary ✔
condition
Material build up Check / Remove ✔
Labyrinth seal Grease ✔
Remove Shaft Guard Check buildup/Ensure ✔
labyrinths purge when greased
Curtain chain and rubber Check Replace ✔
Under Crusher Chute
Wear Plate Liners Check Replace ✔
Bolts Check / Tighten / Replace ✔
Tracks
Tension of chains Check / Tension ✔
Oil leaks Check / Repair ✔
Run machine forwards and backwards 10m Perform ✔
Material build up Check / Clean ✔
Engine Maintenance
Engine oil level Check / Top up ✔
Coolant system level Check / Top up ✔
Engine air cleaner service indicator Check / Clean air filters ✔
Check Fuel level Check / Top up ✔
V Belts Check / Adjust / Replace ✔
Radiator and aftercooler core Check / Clean ✔
Battery electrolyte level Check / Top up ✔
Oil Cooler Check / Clean ✔
Fuel tank water and water trap Drain ✔
Alternator belt Check / Adjust / Replace ✔
Fan belt driven equipment Check ✔

Maintenance 9
50 Hours
Engine air pre-cleaner Check / Clean ✔
Hoses & Clamps Check / Replace ✔

9 Maintenance
50 Hours
Clutch (If Applicable)
Oil Check for leaks ✔
Conveyor Belts / Magnet
Conveyor belts for rips and tears Check / Repair ✔
Conveyor belt tension Check / Tension ✔
Belt alignment Check / Align ✔
Rollers are free moving and unobstructed Check / Free ✔
Belt Scraper Check / Adjust / Replace ✔
Skirting rubbers Check / Adjust / Replace ✔
Obstruction to drums Check / Remove ✔
Slider Pads Check / Replace ✔
Drum Bearings Grease ✔

Maintenance 9
(2) Service Maintenance Schedule

A = Volvo Tier 3 Initial
100 250 500 1000 2000
B = Volvo Tier 4/Stage V Hourly Intervals. Hours. Hours. Hours. Hours. Hours.
Hydraulic System
Hydraulic oil Analysis / Replace if ✔ ✔ ✔
necessary
Replace ✔
Hydraulic relief pressures Check / Adjust ✔ ✔
Hydraulic Pressure Filters (1st replace at Remove / Replace ✔ ✔ ✔ ✔
100 hours)
Hydraulic Return Filter (1st replace at 100 Replace ✔ ✔ ✔ ✔
hours)
Hydraulic Oil Tank Breather Replace ✔ ✔ ✔
Hydraulic Oil Suction Filter (1st replace at Remove & Replace ✔ ✔ ✔
100 hours)
VGF Feeder Hopper
Hopper pins Check / Replace ✔
Grease ✔
Motor coupling drive Check / Replace ✔
Vibrating Feeder gearbox oil (1st replace at Check / Top up ✔ ✔ ✔ ✔ ✔
100 hours)
Replace ✔ ✔ ✔
VGF Bypass Chute
By pass door operational Check Operational ✔ ✔
Chamber
Proximity switch Check / Adjust if necessary ✔ ✔
Operational pillar bearing temperature Check / Record ✔ ✔ ✔ ✔ ✔
Cable installation, terminals Check / Repair ✔ ✔
Mounting plates Check / Replace ✔ ✔ ✔ ✔
Side liner bolts Check / Torque ✔ ✔ ✔ ✔
Toggle bolts for wear and cracking Check / Replace ✔ ✔ ✔ ✔
Tightness of bearing housing bolts Check / Tighten ✔ ✔ ✔ ✔ ✔
Main components & drive pulley for damage Check / Repair ✔ ✔ ✔ ✔
Under Crusher Chute
Rock shelf (if applicable) Check / Replace ✔
Sealing rubbers Replace ✔ ✔
Skirting Rubbers ** Check / Replace ✔ ✔ ✔ ✔
(** Reference: (8) Checking the Skirting
Rubber and Skirting Clamps for Wear on
page 9-51)
Skirting Rubber Clamps** Check / Replace ✔ ✔ ✔ ✔
(** Reference: (8) Checking the Skirting
Rubber and Skirting Clamps for Wear on
page 9-51)
Conveyor Belts / Magnet
Guards Check / Replace ✔ ✔ ✔ ✔
Tail & Drive drum bearings Check / Clean ✔ ✔ ✔ ✔
Belt Adjusters Grease ✔ ✔ ✔

9 Maintenance

100 250 500 1000 2000
Impact bars / Rollers Check / Replace ✔
Motor coupling drive Check / Replace ✔
Spray Nozzle operation Check operation ✔ ✔ ✔
Hydraulic cylinder pivots, conveyor Grease ✔ ✔ ✔ ✔
adjustment pivots and conveyor belt
tensioners

Maintenance 9

100 250 500 1000 2000
Tracks
Visual wear on components Check / Replace ✔ ✔ ✔ ✔
Gearbox oil (1st replace at 100 hours) Check top up ✔ ✔ ✔
Replace ✔ ✔ ✔
Engine Maintenance
Engine oil (analyse oil at oil change) Replace ✔ ✔ ✔

Engine oil filter Replace ✔ ✔ ✔
A
Engine air cleaner service indicator Replace ✔
Coolant Analyse / Replace ✔ ✔ ✔ ✔
if necessary
Fan clearance Check / Set ✔ ✔ ✔
Fuel filters Replace ✔ ✔ ✔
Fuel tank breather Check / Replace ✔ ✔ ✔
Check fuel level gauge operation Check / Replace ✔
Engine air cleaner element (or as required) Replace ✔ ✔ ✔ ✔
Radiator Check / Clean ✔ ✔ ✔ ✔
Oil cooler Check / Clean ✔ ✔ ✔ ✔
Water Pump Check ✔
Aftercooler Check ✔
Belt Tensioner Check ✔
Exhaust Manifold Check ✔
Alternator and starter motor Check ✔
Check air inlet pipes Check / Adjust / Replace ✔ ✔ ✔
Turbocharger Check ✔
Coolant Corrosion protection level Check / Replace ✔
Fanbelt Check / Adjust / Replace ✔
Engine mounts Check ✔
Reductant Filter B Replace ✔ ✔
Reductant tank filler filter B Clean ✔ ✔ ✔
Reductant tank ventilation filter B Clean ✔ ✔
Clutch
Clutch oil leaks Check / Repair ✔ ✔
HPTO housing breather Replace ✔ ✔ ✔
Pump drive gears Inspect ✔ ✔
Clutch oil Analysis ✔ ✔ ✔

9 Maintenance
Engine Maintenance Initial

100 250 500 1000 1500
Hourly Intervals Hours Hours Hours Hours Hours
Crankcase Breather Filter* Change ✔

Diesel Particulate Filter (DPF) Check/Replace ✔
*1500 Hours or 12 Months, Whichever comes first.
(3) Extended Service Schedule

A = Volvo Tier 3 and 4
Coolant Replace 8000 Hours
A
Clutch (Continued)
Clutch Internally inspect & service 5000 Hours

Maintenance 9
9.4 Greasing Schedule

It is important that a strict routine of regular servicing is undertaken from the start of operation of
the plant. Regular checks on the lubrication of the machine in accordance with the schedule is
essential.
Figure 9.3 - Grease Schedule Diagram

9 Maintenance
Figure 9.4 - Greasing Decal

Maintenance 9

Location Quantity Frequency Capacity
1. Main Conveyor Belt Adjusters 2 500 Hours 4 Grams
(0.141oz)
2. Main Conveyor Idler Drum 2 50 Hours 4 Grams
(0.141oz)
3. Main Conveyor Drive Drum 2 50 Hours 4 Grams
(0.141oz)
4. Bypass Conveyor Idler Drum 2 50 Hours 4 Grams
(0.141oz)
5. Bypass Conveyor Drive Drum 2 50 Hours 4 Grams
(0.141oz)
6. Impactor Shaft Bearings 2 10 Hours 4 Grams
(0.141oz)
7. Crusher Labyrinth 3 10 Hours 5 Grams
(0.176oz)
8. Apron Adjustment Spindles 2 20 Hours 1 Gram
(0.035oz)
9. Trunnion Mounts 2 20 Hours 1 Gram
(0.035oz)
10. Magnet Drive Side Bearings 2 50 Hours 4 Grams
(0.141oz)
11. Magnet Non-Drive Side Bearings 2 50 Hours 4 Grams
(0.141oz)
12. Tracks Tension 2 When Required
13. Belt Tensioner 2 50 Hours 25 Grams
(0.881oz)
14. Fan Drive Bearings 2 50 Hours 4 Grams
(0.141oz)

9 Maintenance
9.5 Lubricants, Oils, and Fluids

� WARNING
Injection Hazard.
not use hand.
� CAUTION
Maintenance must only be performed by trained and qualified personnel.
NOTICE
The following tables must be used in accordance with the routine maintenance schedules.
Routine checks/replenishments/changes of lubricants, oils, coolant, and so forth, must be
carried out to the machine. If the hydraulic oil is not analyzed/changed at the correct interval, it
can damage the machines components and void the warranty.
For, correct oil specifications refer to Appendix D.
(1) Lubrication, Quantities and Levels
NOTICE
If in doubt about quantities or oil grade specifications contact your local oil supplier for more
details. Never use unspecified oils in the machine, doing so can result in machine failure and
warranty void.
For correct lubrication specifications refer to: "Appendix D Oil Specification".
Table 9.1 - Standard Oils (Recommended for ambient temperatures between -5 to +30 °C / 23
to 86 °F)
Description Capacity Liters (US Standard
Gallons)
Hydraulic Oil 310 (81.9) Hydramax 46 Hydraulic Oil
Engine Oil (Volvo- Tier 3 / Tier 27 (7.1) Maxol Truck Line LSP
4/ Stage V) 15W-40 Heavy Duty Oil
Vibrating Feeder Oil 5 (1.3) Maxol Indusol EP 100 Gear
oil
Track Gear Box Oil 14 (3.7) Maxol indusol EP220 Gear oil

Maintenance 9
Table 9.2 - Hot Climate Oils (Recommended for ambient temperatures between +15 to +50 °C
/ 59 to 122 °F)
Gallons)
Hydraulic Oil 310 (81.9) Multivis 68 (High VI) Hydraulic
oil
Engine Oil (Volvo- Tier 3 / Tier 27 (7.1) Maxol Truck Line LSP
4/ Stage V) 15W-40 Heavy Duty Oil
Vibrating Feeder Oil 5 (1.3) Maxol Indusol EP 100 Gear
oil
Track Gear Box Oil 14 (3.7) ISO VG 320 Gear Oil
Table 9.3 - Cold Climate Oils (Recommended for ambient temperatures between -20 to +30
°C / -4 to 86 °F)
Gallons)
Hydraulic Oil 310 (81.9) Maxol Polar 32
Engine Oil (Volvo- Tier 3 / Tier 27 (7.1) Maxol super UHPD 5W-30
4/ Stage V)
Vibrating Feeder Oil 5 (1.3) Fuchs Renolin CLP 68
Track Gear Box Oil 14 (3.7) Maxol Unigear 75W/90 LD

9 Maintenance
(2) Machine Grease Lubrication
NOTICE
Incorrect grease and/or lubrication schedules results in premature wear and damage to
bearings. The following grease specification must be used throughout the machine. Failure to
do so can result in premature failures.
Grease must not contain solid lubricants such as molybdenum disulphide.
Avoid mixing grease types on installation once selected.
(a) Standard Viscosity Option

• Grade: NLGI 2.
• Type: EP2 GREASE (no solid lubricants).
• Base oil type: MINERAL.
• Thickener type: LITHIUM SOAP (lithium complex can also be considered if supplier
guarantees compatible and approved by Terex).
• Base oil minimum viscosity (din 51561-1) @ 40°c (104°f) = 220 mm2/s.
• Base oil minimum viscosity (din 51561-1) @ 100° (212°f) = 17 mm2/s.
• Advised operating temperature: -25°c to +130°c.
Extra typical Information:
• Drop point (din ISO 2176) ≥177°C.
• Worked penetration (din ISO 2137 - 60 strokes, 0.1mm) = 265–295.
• Four ball weld load (din 51350) = ≥2400n.
Table 9.4 - Grease Compatibility Chart (guidance only – discuss with suppliers)
Type Of Lithium Calcium Lithium Calcium Calcium
Thickener / Complex Complex Sulphonate
Soap Complex
Lithium + 0 + - +
Calcium 0 + + - +
Lithium + + + + +
Complex
Calcium - - + + +
Complex
Calcium + + + + +
Sulphonate
Complex
+ = Compatible 0 = Test Required - = Incompatible

Maintenance 9
9.6 Hydraulic Maintenance

NOTICE
Hydraulic fluids play an important part in any hydraulic system. They have two main functions to
transmit power and to lubricate moving parts. As a power transmitting medium the fluid must
flow easily and be as incompressible as possible.
In most hydraulic components, the fluid provides internal lubrication only. For long component
life, fluids are available containing additives that have high anti-wear properties. The fluids are
known as anti-wear type hydraulic oils, which are recommended for your machine. In, most
cases the fluid is the only oil seal present. For example, there are no sealing rings between
the spool and the body of the directional valve. Sealing characteristics of the fluid depend on
its retaining viscosity. It is important that the oils selected have the capabilities of maintaining
the minimum viscosity change over a wide range of operating temperatures. Driven by pumps
are the hydraulic functions of the machine, these pumps are powered from the engine. The
hydraulic system as a whole must be inspected at regular intervals for damage or leaks. For,
best operating results it is recommended that the hydraulic fluid used is selected from the
recommended range listed in “Recommended Lubricants”.
In, the service it is recommended that the hydraulic system is analyzed every 500 hours and the
oil changed if necessary. The hydraulic fluid must be changed after the machine has stopped
work. If pump or motor failure occurs, both suction line and return line filters must be changed.
It is essential when replenishing hydraulic fluid, attending to filters, and so forth, to apply the
greatest degree of cleanliness. It is most important that contaminants are not allowed to enter
the system.
Maintain in accordance with the reservoir level, filter changes, schedules, and fluid types. ONLY
USE A RECOMMENDED FLUID.
� WARNING
THIS IS A HIGH PRESSURE SYSTEM. Never carry out any maintenance work without
ensuring the hydraulic system is depressurized and the machine is locked out and tagged out..
Check the pressure gauges and control screen to view the current system pressure. Do not
amend the hydraulic system. In the event of any problems these should only be dealt with by
suitably experienced and qualified engineers.
(1) Hydraulic System Overview

The Hydraulic system which is used in your machine was chosen for its effectiveness and
resistance to climatic and operating conditions.
This must be kept topped up with the correct hydraulic fluid and regular checks must be made
to ensure this.
The filter element requires changing when the indicator is in the red at operating temperature.
The system should be checked for leaks and the hydraulic oil analyzed after 1000 hours and
every 500 hours afterwards and replaced if necessary.

9 Maintenance
(a) Hydraulic Fluids

Hydraulic fluids play an important part in any hydraulic system. They have two main functions.
• To transmit power
• To lubricate moving parts
As a power transmitting medium the fluid must flow easily and be as incompressible as possible.
In most hydraulic components, the fluid provides internal lubrication only. For long component
life, fluids are available containing additives that have high anti wear properties. The fluids are
known as anti-wear type hydraulic oils, which are recommended for your machine.
In most cases the fluid is the only oil seal present. For example, there are no sealing rings
between the spool and the body of the directional valve. As the sealing characteristics of
the fluid depend on its retaining viscosity, it is important that the oil selected is capable of
maintaining the minimum viscosity change over a wide range of operating temperatures.
Some adverse effects of incorrect viscosity are:
• Increased power consumption
• High oil temperatures
• Entrapment of air in oil
• Increase pressure drop
• Excessive wear or even seizure under heavy loads
• Poor pump performance
In addition to the qualities outlined earlier the selected fluid should also:
• Prevent rot
• Depress foaming
• Prevent formation of sludge, gum and varnish
• Retain its own stability, thereby reducing fluid replacement
• Prevent corrosion and pitting
For best operating results it is strongly recommended that the hydraulic fluid used is selected
from the recommended range listed (Reference )
In the service it is recommended that the hydraulic system is analyzed every 500 hours and the
oil changed if necessary. The hydraulic fluid should be changed after the machine has stopped
work. The drain plug for the hydraulic system is mounted underneath the tank. In the event of
pump or motor failure, both suction line and return line filters must be changed.
(b) Oil Tank, Pipes & Fittings

In order to prevent contamination, the Oil Tank on your machine is of sealed construction.
Access to the tank, if required, is via inspection covers which are mounted on the top of the
tank, underneath the filler cap. The outside of the tank must be thoroughly cleaned before
the removal of any of these covers.
It is very important that hydraulic pipes and hoses are checked regularly for leaks, scuffing and
wear. Loose fittings should be securely tightened. Worn or leaking hoses should be replaced.
Replacement hoses are available on request.

Maintenance 9
(2) Hydraulic Filtration
NOTICE
In order to maintain the hydraulic oil at its peak performance, three different types of filters
are fitted to the hydraulic system. The filters that are used consist of; suction filters, return
line filters, and pressure filters. All these filters must be changed in accordance with all the
maintenance schedules within this manual.
� WARNING
Injection Hazard.
not use hand.
(a) Hydraulic Tank

The hydraulic tank is located at the back of your machine, under the feeder and access to the
filters can be gained from the side panels.
Figure 9.7 - Hydraulic Tank

9 Maintenance
(b) Suction Line Filters

A filter (Item 1, Reference Figure 9.8) which is matched to pump capacity, is fitted to the
hydraulic tank where it is readily accessible.
New filter elements should be fitted at regular intervals (see routine maintenance schedule
for frequency).
Figure 9.8 - Suction Filters
(c) Return Line Filter

The return filter (Item 1, Reference Figure 9.9)which is fitted on the tank, removes any tiny
particles which can cause damage to the pumps and motors etc.
The filter element should be changed in accordance with the routine maintenance schedule.
Figure 9.9 - Return Line Filter

Maintenance 9
(d) Pressure Filter

The pressure filter (Item 1, Reference: Figure 9.10) removes any tiny particles which can cause
damage to the pumps and motors in the closed loop system.
The filter element should be changed in accordance with the routine maintenance schedule or
when the indicator turns red when at operating temperature.
Figure 9.10 - Pressure Filter
(e) Hydraulic Oil Tank Breather

The breather (Item 1, Reference Figure 9.11) is also a filter and should be changed in
accordance with the routine maintenance schedule, but in dusty atmosphere it is recommended
to change more frequently depending upon conditions.
Figure 9.11 - Hydraulic Oil Tank Breather

9 Maintenance
(3) Changing Hydraulic Filters and Oil

(a) Changing Return Filter
� WARNING
Injection Hazard.
not use hand.
NOTICE
It is strongly recommended to change hydraulic filter elements when the Hydraulic oil is being
changed.
The hydraulic fluid filters have condition indicators to show when the filter element needs
to be renewed.
When the gauge changes from green to red whilst the system is running at normal operating
temperature the filter must be renewed.
In cold ambient temperatures the filter indicators may show an incorrect red condition until the
system reaches normal operating temperature.
PROCEDURE
2. Locate the hydraulic return line filter (Item 1, Reference; Figure 9.12)
Figure 9.12 - Hydraulic Tank Return Line Filter

3. Shut down the machine and implement the lockout and tag out procedure.
4. Make sure the fluid has cooled before changing the filter.
5. Clean the area around the return filters to prevent dirt contaminating the hydraulic oil when
the filters are removed.

Maintenance 9
6. Using a 13 mm spanner remove the four bolts (Items 1, Reference Figure 9.13) securing
the filter covers.
Figure 9.13 - Return Line Filter Removal

7. Rotate the top plate slightly to remove the cover along with internal spring.
8. Remove the filter element (Item 2, Reference; Figure Figure 9.13) by pulling the removal
handles. Dispose of the old filter safely.
9. Insert new filter elements of approved pattern and specification.
10. Replace the spring which holds the filter in place.
11. Lightly smear the ‘O’ ring with fluid and make sure it is properly seated in the groove
12. Replace the cover plate and screws evenly to ensure a good seal.
13. Remove the lockout and tag out.

9 Maintenance
(b) Changing ‘R’ System suction filter
� WARNING
Injection Hazard.
not use hand.
Fluid injected into the skin must be surgically removed within a few hours by a doctor familiar
with this type of injury, or gangrene will result.
Always wear appropriate personnel protective equipment.
Shutdown, and lockout and tag out the machine.
Falling hazard. Do not climb onto the machine. Always use the walkways and platforms
provided.
PROCEDURE
2. Return all hydraulic cylinder to their closed position to return a much hydraulic oil back to
the tank a possible.
3. Shut down the machine and implement lockout and tagout procedure
4. Open the hydraulic oil tank filler cap
5. It relieves any pressure in the hydraulic tank
6. Locate the drain plug (Item 1, Figure 9.14) at the base of the tank
Figure 9.14 - Hydraulic Oil Drain Plug

7. Remove the drain plug and connect a suitable hose transfer the oil to an external container.
8. Drain the hydraulic oil to an external container large enough to hold all of the oil. (Hydraulic
Tank Capacity: 285 liters or 75 US Gallons).
9. Remove the inspection plate (item 1, Figure 9.15) and flush the tank out with hydraulic oil
to remove dirt or other particles.

Maintenance 9
Figure 9.15 - Hydraulic Tank Inspection Plate

10. Refill tank and prime system.
11. When the oil tank is cleaned satisfactory, replace the drain plug (Item 1, ) and refit the
inspection plate (Item 1Figure 9.15 ).
12. Refill the tank until the oil is between the minimum and maximum marks on the tank
gauge.(Item 1, Figure 9.16)
Figure 9.16 - Hydraulic Tank Oil Gauge

13. Pumps must be primed after the oil change.
15. Run the machine and operate the hydraulic equipment to circulate oil.
16. Stop the machine and top up the hydraulic system as required.

9 Maintenance
(c) Changing Suction Filter
� WARNING
Injection Hazard.
not use hand.
NOTICE
changed.
to be renewed.
When removing or replacing the suction filters use only hand tools as excessive adjustment will
cause filter to disassemble.
PROCEDURE
2. Locate the hydraulic suction filter (Item 1, Reference; Figure 9.17)
Figure 9.17 - Hydraulic Tank Suction Filter

3. Make sure the oil has cooled before changing the filter.

Maintenance 9
4. Fully screw out the shut off valve (Item 1, Reference; Figure 9.18) on the suction filter.
Figure 9.18 - Suction Filter Cover Plates

5. Remove the six bolts (Items 2, Reference; Figure 9.18) around the cover plates.
6. Inspect the bolts and replace any worn or damaged.
7. Remove the cover plate (Item 3, Reference Figure 9.18) to gain access to the suction filter.
8. Remove the used filter element.
9. Using a lint free cloth clean inside the filter housing.
10. Fit the new filter of the approved pattern and specification.
11. Replace the cover plate (Item 3, Reference; Figure 9.18) and bolts (Items 2, Reference;
Figure 9.18), and screw in fully the shut off valve (Item 1, Reference; Figure 9.18).
12. Remove the lockout and tag out

9 Maintenance
(d) Changing Pressure Filter
� WARNING
Injection Hazard.
not use hand.
NOTICE
changed.
to be renewed.
PROCEDURE
3. Locate the hydraulic pressure filter (Item 1, Reference: Figure 9.19) beside the hydraulic
tank at the back of the machine.
Figure 9.19 - Pressure Filter

4. Make sure the fluid has cooled before changing filter.
5. Place container below filters to collect spillage of fluid.

Maintenance 9
6. Unscrew the filter bowl (Item 1, Reference: Figure 9.20), turn anti-clockwise looking from
below.
Figure 9.20 - Pressure Filter Bowl

7. Remove the old filter and clean inside the bowl and housing with a lint free cloth.
8. Fit new filter and small ‘O’ ring of the approved pattern and specification.
9. Lightly smear the ‘O’ ring with fluid and place on it’s seating in the bowl making sure it
is properly seated.
10. Replace and secure the filter bowl to ensure a good seal, taking care as it has a fine thread.

9 Maintenance
(e) Changing Hydraulic Oil
� WARNING
Injection Hazard.
not use hand.
NOTICE
It is recommended that the machines hydraulic oil is warm. This will enable the oil to flow
more easily.
PROCEDURE
2. Return all hydraulic cylinders to their closed position to return as much hydraulic oil back
to the tank as possible.
4. Open the hydraulic oil tank filler cap.
» It relieves any pressure in the hydraulic oil tank.
5. Locate the drain plug (Item 1, Reference; Figure 9.21) at the base of the tank
Figure 9.21 - Hydraulic Oil Drain Plug

6. Remove the drain plug and connect a suitable hose to transfer the oil to an external
container.
7. Drain the hydraulic oil to an external container large enough to hold all of the oil. (Hydraulic
Tank Capacity: 310 liters or 82 US gallons).

Maintenance 9
8. Remove the inspection plate (Item 1, Reference; Figure 9.22) and flush the tank out with
hydraulic oil to remove dirt or other particles.
Figure 9.22 - Hydraulic Tank Inspection Plate

9. When the oil tank is cleaned satisfactory replace the drain plug (Item 1, Reference; Figure
9.21) and refit inspection plate (Item 1, Reference; Figure 9.22).
10. Refill the tank until the oil is between the minimum and maximum marks on the tank gauge
(Item 1, Reference; Figure 9.23)
Figure 9.23 - Hydraulic Oil Tank Gauge

11. Pumps must be primed after the oil change.
13. Run the machine and operate hydraulic equipment to circulate oil.
14. Stop the machine and top up the hydraulic system as required.

9 Maintenance
(f) Changing Condensation Control Breather
NOTICE
The breather is also a filter and should be changed after the first 100 hours of operating
and thereafter after 1000 hours but in dusty atmosphere it is recommended to change more
frequently depending upon conditions.
PROCEDURE
2. Close down the machine and implement the lockout and tag out procedure.
3. Locate the hydraulic oil tank breather (Item 1, Reference; Figure 9.24)
Figure 9.24 - Condensation Control Breather

4. Unscrew and renew the breather.

Maintenance 9
9.7 Conveyor Maintenance

� WARNING
Under no circumstances should any check on the belt tension be made whilst the machine is
running. There is an entanglement hazard and risk of trapping parts of the body.
NOTICE
Conveyor belts must be fitted by qualified and competent suppliers only.
NOTICE
An external company/personnel are responsible for the changing, replacing and repairing of
the conveyor belts on the machine.
(1) Conveyor Checks
� DANGER
Automatic Startup
death could result.
� WARNING
Shutdown, lockout and tagout the machine.
NOTICE
Do not use clip joints for belt repairs or replacements, as they can be hazardous. Belt
repairs/replacements must be performed by vulcanizing only.
PROCEDURE
2. Shut down the machine and implement the lockout and tagout procedure.
3. Inspect all skirt plate sealing strips. Ensure that they are adjusted close enough to the belt
preventing spillage or material jamming between the seals and the belt. At the same time,
not bearing hard on the belt. Replace if worn.
4. Check that the belt generally is running centrally and straight on both the carrying strand
and the return strand. If not, refer to ‘Tracking and Tensioning of Belts’.
5. Check that there is no evidence of belt slip at the driving drum, as belt slip causes
premature wear on the belt. Check also for undue sag between idlers. Both would indicate
lack of belt tension.
6. Check regularly that the idler rollers are rotating freely. If not either free them or replace the
idler. Failure to do so results in belt wear and tracking problems.

9 Maintenance
7. Check that the belt cleaning equipment is operating correctly and efficiently. In the cases of
scrapers ensure that they are not choked with a build-up of material. Also check that the
blades are not bearing on the belt any more than necessary. Blades which are unevenly
worn or in a condition likely to damage the belt and should be renewed immediately.
8. Set roller nips guards to within 5 mm of the roller.
9. Inspect the condition of the conveyor belt regularly and arrange for the earliest possible
repair of any damage which has occurred. Doing so can make a worthwhile extension of
the useful life of the belt. Repair a cut or tear in the rubber by cleaning with benzine and
plugging with a rubber repair compound.
10. Use the greasing schedule for greasing the head and tail drum bearings.

Maintenance 9
(2) Conveyor Belt Adjustment and Tensioning
� DANGER
Automatic Startup
death could result.
� WARNING
Fall Hazard.
Falling from this machine can result in serious injury or even death.
Do not climb on machine.
Use a suitable lifting platform to service machine.
NOTICE
To perform belt tensioning, the machine must be locked out and tagged out for every time the
belt adjuster is being adjusted. Once the adjuster has been turned, the lockout and tag can be
removed, the machine started and the conveyor put into operation to view the belt alignment.
Under no circumstances should anyone be adjusting the conveyor belt whilst in operation.

9 Maintenance
Reasons for Oblique Travel Remedies Examples of Oblique Travel

a. Align all drums, carrying
idlers and return idlers at
right angles to the traveling
direction of the belt.
b. Check that all drums and
idlers are level to each other.
Figure 1. Turning carrying
idlers
If, a & b are as above then
carry out the following.
Adjustments are made as
indicated on Figures. 1, 2
1. Insufficient aligning of
& 3 by turning drums and
drums and Idlers
carrying idlers in direction of
arrow until the belt is running Figure 2. Turn drums
straight and centered on the
conveyor.
Return idlers can cause
oblique belt travel. Therefore
they must be aligned at
right angles to the traveling
direction of the belt and after
that adjustment can be made.
Figure 3. Turning both drum
and carrying idlers
Oblique travel can be reduced
by turning forward outer
carrying idlers 1-3 degrees
in traveling direction of the
2. Misalignment of frame belt. See Figure 4. If it does
not correct the oblique travel,
then align the frame.
Figure 4. Turning forward
carrying idlers
Clean idlers and drums.
3. Material built up on drums Check belt cleaners and
and idlers. replace if necessary. Possibly
change to more efficient type.
(3) Belt tracking on Transfer Conveyor (R Model Only)
NOTICE
Belt tracking is performed at the head section of the transfer conveyor. Both sides of the head
section are adjustable.
A small movement in the adjuster i.e Less than 10 mm should be sufficient. A greater movement
will affect the tension of the belt.
To maintain the adjusters, it is recommended that the adjusters are regularly checked for any
dirt or debris.
The belt must be sufficiently tight to prevent slippage at the drive drum. If overtightened, the
life of the belt decreases.

Maintenance 9
PROCEDURE
2. Shut down the machine and implement the lockout and tag out procedure
3. Determine which side needs adjustment.
4. Gain safe access to the belt adjuster
Figure 9.25 - Transfer Conveyor Adjuster

5. Rotate the adjuster nut (Item 1,Figure 9.25 ) on the drum adjuster. Rotate in small
increments.
6. Remove the lockout and tag out
7. Start the machine and place the transfer conveyor into operation and view the belt
alignment.
8. If satisfied with the alignment, shut down the machine and implement the lockout and tag
out procedure. Tighten the lock nut (Item 1, Figure 9.25)
9. If unsatisfied with the alignment, shut down the machine and implement the lockout and tag
out procedure and repeat steps 4-8 until alignment is satisfactory
(a) Belt Tensioning on the Recirculating Conveyor
PROCEDURE
2. Shut down the machine and implement the lockout and tagout procedure
3. Proceed to the belt adjusters. (Item 1 )
4. Rotate the adjuster nut, on both idler drum adjusters equally. You can either tighten or
loosen the belt.

9 Maintenance
(4) Belt tracking on Fines Conveyor
NOTICE
Belt tracking is performed at the drive drum and idler drum of the Fines conveyor. Both sides of
the drum are adjustable.
A small movement in the adjuster i.e Less than 10 mm should be sufficient. A greater movement
will affect the tension of the belt.
dirt or debris. Ensure that the belt adjusters are filled to maximum capacity with grease to
prevent water from entering into them.
The belt must be sufficiently tight to prevent slippage at the drum. If overtightened, the life of
the belt decreases.
PROCEDURE
3. Determine which side requires adjustment.
4. Gain Safe access to the belt adjuster (Item 1,Figure 9.26 )and loosen the lock nuts
Figure 9.26 - Fines Conveyor Drum Adjuster

5. Rotate the adjuster nut on the drum adjuster. Rotate in small increments.
6. Remove the lockout and tag out procedure
7. Start the machine and place the fines conveyor into operation and view the belt adjustment.
8. If satisfied with the alignment, shut down the machine and implement the lockout tag out
procedure. Tighten the lockout nut.
» The conveyor is ready to use
9. If unsatisfied with alignment, shut down the machine and implement the lockout and tag out
procedure and repeat steps 4-8 until alignment is satisfactory.
10. To adjust the idler drum end of the conveyor, proceed to the belt adjuster located in front of
the tracks just inside the chassis.
12. Determine which side of the conveyor needs adjusting.

Maintenance 9
13. Rotate the adjuster nut (Item 1, Figure 9.27) on either side of the conveyor. Rotate in small
increments. When satisfied with alignment, the task is complete.
Figure 9.27 - Idler Drum Adjuster Location
Figure 9.28 - Idler Drum Adjuster

15. Start the machine and place the fines conveyor into operation and view the belt alignment.
16. if satisfied with alignment, the conveyor is ready to use
out procedure and repeat step 11-16 until alignment is satisfactory.
(a) Belt Tensioning on the Fines Conveyor
PROCEDURE
2. Shut down the machine and implement the lockout and tagout procedure
3. Proceed to the belt adjusters and loosen the nuts.
4. Rotate the adjuster nut on both drive drums adjuster equally. You can either tighten or
loosen the belts
5. To adjust the belt at idler drum, rotate the adjuster nut on both drive drum adjuster equally.
You can either tighten or loosen the belt.

9 Maintenance
(5) Belt Tracking on Discharge Conveyor
NOTICE
Belt tracking the discharge conveyor is performed at the drive and idler drums of the conveyor.
Both sides of the drive and idler drums are adjustable.
A small movement in the adjuster that is, Less than 10 mm can be sufficient. A greater
movement can affect the tension of the belt.
dirt or debris.
The belt must be sufficiently tight to prevent slippage at the drive drum. If, over tightened the
PROCEDURE
2. Shut down the machine and implement the lockout and tag out.
4. Gain safe access to the belt adjusters using a suitable platform.
5. To adjust the belt at the discharge end of the conveyor, loosen nut (Item 2, Reference;
Figure 9.29).
Figure 9.29 - Discharge Conveyor Drum Adjuster

6. Rotate the square bar (Item 1, Reference; Figure 9.29) on the end of the drum adjuster.
Rotate in small increments.
8. Start the machine and place the main conveyor into operation and view the belt alignment.
out procedure. Tighten the nut (Item 2, Reference; Figure 9.29).
» The conveyor is ready for use.
out procedure and repeat steps 3-9 until alignment is satisfactory.
11. To adjust the idler drum end of the conveyor, proceed to the belt adjusters located at the
front of the tracks just inside the chassis.
12. Shut down the machine and implement the lockout and tag.

Maintenance 9

14. Rotate the adjuster nut (Item 1, Reference; Figure 9.30) on either side of the conveyor.
Rotate in small increments. When satisfied with the alignment, the task is complete.
Figure 9.30 - Idler Drum Belt Adjusters

16. Start the machine and place the main conveyor into operation and view the belt alignment.
17. If satisfied with the alignment, the conveyor is ready for use.
(a) Belt Tensioning On Discharge Conveyor

Belt tensioning is performed at the drive drum on the discharge conveyor. Both sides of the
drum are adjustable.
By releasing the nut (Item 2, Reference; Figure 9.29) and rotating the square bar (Item 1,
Reference; Figure 9.29) on both drum adjusters equally, you can either tighten or loosen the belt.

9 Maintenance
(6) Belt Tracking On Bypass Conveyor
NOTICE
Belt tracking the Bypass Conveyor is performed at the drive and idler drums of the conveyor.
Both sides of the drive and idler drums are adjustable.
A small movement in the adjuster that is, Less than 10 mm can be sufficient. A greater
movement can affect the tension of the belt.
dirt or debris.
PROCEDURE
4. Gain safe access to the belt adjusters using a suitable platform.
5. To adjust the belt at the discharge end of the conveyor, loosen nut (Item 1, Reference;
Figure 9.31).
Figure 9.31 - Bypass Conveyor Drum Adjuster

6. Rotate the adjuster nut (Item 2, Reference; Figure 9.31) on the end of the drum adjuster.
Rotate in small increments.
8. Start the machine and place the bypass conveyor into operation and view the belt alignment.
out procedure. Tighten the lock nut (Item 1, Reference; Figure 9.31).
» The conveyor is ready for use.
11. To adjust the idler drum end of the conveyor, shut down the machine and implement the
lockout and tagout.
12. Gain safe access to the belt adjusters located behind the control panel.

Maintenance 9

14. Rotate the adjuster nut (Item 1, Reference; Figure 9.32) on either side of the conveyor.
Rotate in small increments. When satisfied with the alignment, the task is complete.
Figure 9.32 - Idler Drum Belt Adjusters

16. Start the machine and place the bypass conveyor into operation and view the belt alignment.
17. If satisfied with the alignment, the conveyor is ready for use.
(a) Belt Tensioning on Bypass Conveyor

Belt tensioning is performed at the drive drum on the dirt conveyor. Both sides of the drum
are adjustable.
By releasing the nut (Item 1, Reference; Figure 9.31) and rotating the adjuster nut (Item 2,
Reference; Figure 9.31) on both drum adjusters equally, you can either tighten or loosen the belt.

9 Maintenance
(7) Cleaning Conveyor Belts
NOTICE
Ensure that the machine is shut down and locked out before performing the following procedure.
In, the case of a blockage at a drive or tail drum it can be necessary to loosen the tension on the
conveyor belt. Doing so can make the removal of the blockage easier. When work is complete,
make sure that all guards are closed/replaced and secured before restarting the machine. The
conveyor belts can be cleaned using a number of methods. Before commencing, make sure
that all afore mentioned procedures have been followed.
PROCEDURE
1. The equipment must be switched off and isolated with the lockout and tag out procedure
before the commencement of any work.
2. Use suitable personal protective equipment. That is, eye, foot, hand, and head protection,
and so forth, as it can be required or necessary to undertake the task.
3. Gloves to protect the skin against abrasive materials, sharp surfaces, or penetration of the
skin must be worn.
4. Goggles must be worn to protect from fragments, particles, or dust that could be ejected
into the eyes.
5. Not only the worker cleaning the belts but also others close by who can be affected, must
also wear protective equipment.
Consider factors such as:
• Using a high-pressure air hose
• Using a water hose
• Using a rod with scraper attached, or a brush or shovel

Maintenance 9
(8) Checking the Skirting Rubber and Skirting Clamps for Wear
PROCEDURE
1. Locate the inspection plates at both sides of the machine.
Figure 9.33 - Inspection Plate Location LHS
Figure 9.34 - Inspection Plate

2. Remove inspection plate cover bolts and cover to view skirting rubber and skirting clamps.
3. Inspect skirting rubber and skirting clamps for wear.Figure 9.34
4. Change if required.

9 Maintenance
9.8 Vibrating Feeder Maintenance

NOTICE
After the initial 100 hours of operation, renew the oil in the feed hopper vibrating unit oil baths.
Do not overfill the gearbox. Doing so can result in gearbox failure.
(1) Checking Feeder Oil Level And Refilling
PROCEDURE
3. Locate the feeder gearbox at the rear of the machine behind the rear guard.
4. Allow the vibrating feeder gear oil time to cool.
» Proper oil level can only be determined when unit is level and cold.
5. View the oil level sight glass (Item 1, Reference; Figure 9.35).
» The oil level must be half way on the sight glass.
Figure 9.35 - Vibrating Feeder Gearbox

6. If needed, add recommended lubricant as necessary through the refill plug (Item 2,
Reference; Figure 9.35). Allow time for oil to flow into the gearbox.
7. Once the oil is at the proper level, reinstall the refill plug.
(2) Changing Feeder Oil
PROCEDURE
3. Remove the drain plug (Item 3, Reference; Figure 9.35) and drain to a container capable of
holding the oil. Dispose of the oil safely. Reinsert drain plug.
4. Follow the same procedure (Reference; (1) Checking Feeder Oil Level And Refilling on
page 9-52) to fill the gearbox.

Maintenance 9
9.9 Vibrating screen box maintenance (R Model)

(1) Changing Screen Box Mesh
PROCEDURE
2. Operate the machine normally until the screens and all conveyors are empty of material.
3. Carry out “1–5 of procedure of detaching of the R section
5. Remove the mesh clamp bolts (Item 1, Figure 9.36) from both sides of the screen box.
(There are 7 on each side of the screen box)
Figure 9.36 - Screen box mesh clamp bolts

6. Remove the mesh clamps
7. Remove old screen meshes, clean and prepare the mesh frames for new meshes to be
fitted.
8. Fit new screen meshes
9. Fit the mesh clamps
10. Fit mesh clamps bolts and securely tighten, ensuring meshes are fully secured into position.
11. Carry out steps 5–7 of procedure
12. Deactivate the control banks.

9 Maintenance
9.10 Volvo Engine Overview

Shown below is an illustration which shows a normal version of a Volvo Penta Engine. The
actual Engine may have different equipment.
Figure 9.37 - Volvo Engine
Item Descriptions
1 Fuel Filters 5 Turbocharger
2 Oil Filler Cap 6 Crank Mechanism
3 Fuel Pre Filter 7 Oil Plug
4 Oil Dipstick 8 Oil Filter

Maintenance 9
(1) Changing Engine Filters and Oil
� WARNING
Injection Hazard.
not use hand.
Fluid injected into the skin must be surgically removed within a few hours by a doctor familiar
with this type of injury, or gangrene will result.
NOTICE
Used oil filters must be drained of all free-flowing fuel before they are discarded or recycled.
Dispose of filters in a safe and corrective manner.
(a) Checking the Engine Oil
PROCEDURE
2. If the engine is running turn off the engine and allow a minimum of 3 minutes to allow
the oil to run back into the sump.
3. Remove dipstick (Item 1, Reference; Figure 9.38) from the engine and clean. Re-insert
the dipstick fully.
Figure 9.38 - Oil Dipstick Location

4. Remove the dipstick again and observe that the oil level is between the minimum and
maximum levels. If the level is below the minimum mark oil must be added through the
filler cap (Item 2, Reference; Figure 9.38).
5. It is important that the oil level is not above the maximum levels. If this happens some oil
must be removed.

9 Maintenance
(b) Changing the Engine Oil
PROCEDURE
3. Open the engine oil filler cap (Item 1, Reference;Figure 9.39)
Figure 9.39 - Oil drain plug location.

4. Remove the engine oil drain plug (Item 2, Reference; Figure 9.39) and connect a suitable
hose to drain the oil to a suitable container.
5. Drain the oil from the engine to the container.
6. When all the oil has drained refit the drain plug.
7. Refill the engine with the correct grade and quantity of oil.
8. Close the engine oil filler cap.

Maintenance 9
(c) Volvo Crankcase Breather Filter Change
PROCEDURE
2. Shut down the machine and implement the lock out and tag out procedure.
3. Drain the engine oil.
4. Locate the volvo crankcase breather filter.
Figure 9.40 - Volvo Crankcase Breather Location

5. Clean around the filter.
6. Remove the filter cover. (Item 1, Ref:Figure 9.41 ).
Figure 9.41 - Volvo Crankcase Breather Filter

7. Remove the O-ring (Item 2, Ref: Figure 9.42) and filter (Item 3, Ref: Figure 9.42) from the
cover (Item 1, Ref: Figure 9.42)

9 Maintenance
Figure 9.42 - Oil Filter

8. Let the excess oil drip into a collection vessel.
9. Lubricate the new O-ring and the gasket of the new filter before installation.
10. Fit the new filter and new o-ring in the filter cover.
11. Fit the filter cover and filter in the bracket and tight the cover to 40Nm (29.5 lbf.ft)
12. Fill with required volume of oil.
13. Start the engine and check there is no oil leaking from the filter cover or drain nipple.
14. Stop the engine and check the oil level after a few minutes. Top up with oil as necessary.

Maintenance 9
(d) Changing the Air Cleaner Elements
NOTICE
For more details of Engine Air Filter Maintenance view the Engine Operators Manual.
Do not start the engine without the air filter as this could cause injury and severe engine damage.
Check the air filter indicator on a daily basis. The Air filter service indicator sends a signal to the
control panel when the filter element needs changed. When this happens the machine must
be stopped and the Filter should be changed immediately. Otherwise change the element
every 500Hrs.
The filter element must not be washed in water. The filter element can only be cleaned a
maximum of 4 times. After cleaning it will have a lower capacity than a new filter element. There
is always a risk the filter element will be damaged when it is cleaned.
PROCEDURE
3. Open the catches (Items 3, Reference; Figure 9.43) on the air filter cover.
4. Remove the filter elements (Items 1 & 2, Reference; Figure 9.43) and replace with new
elements of same specification. The safety filter element (Item 1, Reference; (d) Changing
the Air Cleaner Elements on page 9-59) must only be changed if necessary.
Figure 9.43 - Air Filter Elements

5. To clean the filter elements remove (Items 1&2, Reference; Figure 9.43) and carefully
blow the inside with dry compressed air.
6. Mark the filter element when it has been cleaned.

9 Maintenance
(2) Cooling System Maintenance
� DANGER
Consumption of ethylene glycol can be fatal or cause serious injury. If ingested seek medical
advice immediately.
� WARNING
Burn Hazard.
Release of hot fluid under pressure can result in death or serious injury.
Do not loosen cap until cool.
NOTICE
For, more details of approved engine coolant and coolant levels refer your local engine
manufacturer.
(a) Checking Engine Coolant Level
NOTICE
This machine has a low coolant sensor installed and if the coolant falls below the minimum
level the machine automatically shuts down.
Never fill a large amount of cold coolant in a hot engine. There is great risk of cracks forming in
the cylinder block and cylinder heads.
Check the engine coolant level when the engine is stopped and cool.
Do not top up large quantities of coolant through the expansion tank. Top up in accordance with
the instructions in the section headed Changing coolant instead.
Only pour pre-mixed coolant into the cooling system.
� WARNING
Never open the coolant filler cap when the engine is hot. Hot coolant and steam can spray
out and cause burns.
If the cap has to be opened, do it slowly and carefully to release the pressure before removing
the cap. Wear gloves and eye protection as the coolant is still hot.
NOTICE
A hinged cooling pack is installed on this machine for the ease of cleaning.
PROCEDURE
2. Turn off the engine and implement the lockout and tag out procedure.
3. Open the cooling inspection door (Item 1, Reference: Figure Figure 9.44).
4. Open the coolant cover on top of the expansion tank (Item 2, Reference Figure 9.44)
slowly, relieving the pressure.

Maintenance 9
Figure 9.44 - Coolant Inspection Cover

5. View the coolant level through the sight glass (Item 3, Ref: Figure 9.44). The top of the
slight glass is the maximum fill level.
6. Top up with coolant as necessary
7. Refit the filler cap (Item 2, Reference: Figure 9.44)

9 Maintenance
(b) Checking Antifreeze and Corrosion Inhibitor
NOTICE
Use only pure fresh water that is free from particles, sludge, and other impurities.
The following rules apply to ethylene glycol-based coolant:
• The antifreeze and corrosion inhibitor content must be minimum 35 percent by volume for
corrosion protection to be sufficient.
• An antifreeze and corrosion inhibitor content greater than 55 percent by volume impairs
the ability to protect against frost.
• If ice forms in the coolant, there are disruptions initially, but there is no immediate risk of
damage. The engine must not be subjected to heavy loads when ice starts to form.
PROCEDURE
1. Lockout and tag out the machine.
2. Pour a small amount of coolant into a container and check that the coolant is pure and clean.
3. Change the coolant if it is contaminated or cloudy.
4. Measure the content of antifreeze and corrosion inhibitor using a refractometer.

Maintenance 9
(c) Draining Coolant
NOTICE
Avoid spillage and use a suitable container. Used coolant must be disposed of as specified
in national and international law.
Ensure that coolant is mixed to the correct specification. Contact your local engine manufacturer
for more information.
PROCEDURE
2. Shut down machine and implement the lockout and tag out procedure.
3. Ensure that engine has cooled.
4. Open the cooling system inspection door.
5. Open the coolant expansion tank slowly, relieving pressure. (Item 1, Reference: Figure
9.45)
Figure 9.45 - Radiator Inspection Cover

6. Release the toggle bolts (Item 2, Reference: Figure 9.45) to allow the radiator to swing out
from the machine.
7. Remove the drain plug (Item 3, Reference: Figure 9.45) to allow the coolant to drain to a
suitable container.

9 Maintenance
(d) Filling the Engine Coolant
NOTICE
When it is necessary to fill a large quantity of coolant, it is important to check often and
regularly the coolant level after filling. Failure to do so will result in serious machine damage
from overheating.
PROCEDURE
2. Ensure that the radiator drain plug (Item 3, Reference:Figure 9.46 ) is in place so the
coolant doesn’t escape.
Figure 9.46 - Filling Engine Coolant

3. Fill the coolant through the filler point (Item 1, Reference Figure 9.46) of the expansion tank.
4. Make sure adequate time is left to get the air out of the cooling system.
5. Refit the radiator filler cap.
6. Start the engine and let idle for 15 minutes.
7. Let the engine cool again and check the coolant level.
8. Top up coolant level if necessary.
9. Close the panel on the side of the machine to protect the radiator.

Maintenance 9
(3) Fuel System
� CAUTION
Avoid naked flames when working on the fuel system. Do not smoke.
AdBlue®/DEF System (Tier 4 Only)

The solution that is added to the exhaust gases is a clear, transparent liquid with a faint odor of
ammonia; it consists of de-ionized water mixed with 32.5% urea (the solution must meet ISO
22241 standards). The urea in the exhaust is broken down into ammonia which reacts with NOx
to form harmless nitrogen and water vapor, which occur naturally in our surroundings.
NOTICE
The system is monitored to ensure that all system components are working as they should, that
the quality of the AdBlue®/DEF solution fulfills set standards and that the tank level is not too
low. Should the system detect deviations, the maximum engine torque and engine speed will be
reduced and a fault code stored in the control unit.
(a) Bleeding the Fuel System
PROCEDURE
3. Locate the pre fuel filter (Item 1, Reference; Figure 9.47)
Figure 9.47 - Pre filter location.

4. Ensure that the filter is clean and free from dirt.
5. Loosen the nipple (Item 1, Reference; Figure 9.48) two full turns by hand.

9 Maintenance
Figure 9.48 - Pre filter hand pump.

6. Position an appropriate collection vessel below the pre filter.
7. Connect a transparent hose and operate the hand pump (Item 2, Reference; Figure 9.48)
until the fuel flows without air bubbles.
8. Tighten the nipple as the fuel flows.
9. Close the bleed nipple and remove the hose.
10. Start the engine
» The engine should be easy to start.

Maintenance 9
(b) Changing the Fuel Pre-filter
PROCEDURE
3. Locate the pre-fuel filter on the right hand side of the machine (Item 1, Reference; Figure
9.49).
Figure 9.49 - Pre-filter location.

4. Close the 2 fuel valves which are located behind the diesel tanks.
5. Clean around the pre-fuel filter and water separator.
6. Open the drain valve (Item 4, Reference; Figure 9.50) and drain the water trap into a
suitable container.
Figure 9.50 - Fuel Pre-filter

7. Retighten the drain valve.
8. Remove the pre filter and O-ring with the water separator (Item 3, Reference; Figure 9.50)
attached.
9. Remove the water separator from the filter and dispose of the filter safely. Clean the water
separator.
10. Lubricate the new O-ring with diesel and install onto the lower section of the water separator.
11. Install the new filter to the water separator.

9 Maintenance
(c) Changing the Fuel Cleaner
PROCEDURE
3. Remove the fuel filter lid (Item 2, Reference; Figure 9.51) and the filter by unscrewing the
T-handle (Item 1, Reference; Figure 9.51) by hand.
Figure 9.51 - Fuel Filter

4. Remove the O-ring from the filter lid (Item 2, Reference; Figure 9.51) and the filter from the
filter housing and dispose of safely
5. Lubricate the new O-ring with diesel and fit into filter lid and make sure that the O-ring
does not get twisted.
6. Install the new filter in the filter housing (Item 3, Reference; Figure 9.51)
7. Secure the filter lid (Item 2, Reference; Figure 9.51)using the T-handle (Item 1, Reference;
Figure 9.51) and tighten by hand until secure.
8. Bleed the fuel system before attempting to start the engine

Maintenance 9
(d) Changing the Final Fuel Filter
� WARNING
Heavy Load
Two person lift required.
PROCEDURE
3. Open the back door, being careful due to heavy weight of door (heavy load- 2 persons)
4. Locate the final fuel filter. (Item 1, Reference Figure 9.52).
Figure 9.52 - Final Fuel Filter

5. Clean around the fuel filter cover and housing.
6. Carefully remove the fuel filter cover and filter (Items 1 & 3, Reference: Figure 9.53) from
the housing (Item 4).
Figure 9.53 - Fuel Filter

7. Remove the O-ring and the fuel filter (Items 1 & 3, Reference: Figure 9.53) from the filter
cover (Item 1) and dispose of it safely.
8. If the new filter housing is completely empty, lubricate it with diesel around the inner section
of the filter sealing surface.

9 Maintenance
9. Lubricate the new O-ring (Item 2) with diesel before installing it on the filter cover (Item 1).
10. Install the new filter (Item 3) in the filter cover and make sure the filter seats properly in
the cover.

Maintenance 9
11. Install the filter cover and filter in the housing. Carefully screw in the cover and check that
the O-ring does not get twisted. Re-lubricate the seal as necessary. Tighten the cover to
25Nm (18.4 lbf. ft).
12. Bleed the fuel system before attempting to start the engine.

9 Maintenance
(e) Draining the Water Trap
PROCEDURE
3. Locate the water trap on the base of the fuel pre filter (Item 1, Reference: Figure 9.54) on
the right hand side of the machine.
Figure 9.54 - Water Trap Location

4. Loosen the drain tap (Item 1, Reference: Figure 9.55) on the base of the water trap.
Figure 9.55 - Water Trap

5. Allow the water to drain off into a suitable container.
6. Tighten the drain tap when all excess water has been drained off.
7. Bleed the final fuel system before attempting to start the engine.

Maintenance 9
(4) Servicing the DEF (Diesel Exhaust Fluid) System (Tier 4 Machines Only)
� WARNING
Hot Surface Hazard
Beware of hot DEF and surfaces.
DEF is corrosive and therefore must be stored in tanks constructed of approved materials.
(Refer to engine manual for more details)
NOTICE
It is recommended that filter elements are not cleaned or reused, but replaced with new items.
Do not run the engine with the filter elements removed.
Do not run the engine with the filter elements removed.
Do not use agricultural grade urea solutions. Do not use any fluids that do not meet ISO 22241
requirements in SCR emissions reduction systems. Use of these Fluids can result in numerous
problems including damage to SCR equipment and a reduction in NOx conversion efficiency.
(a) DEF Tank Location

The DEF Tank is located behind a protective panel on the side of the machine (Item 1,
Reference; Figure 9.56)
Figure 9.56 - DEF Tank Location

9 Maintenance
(b) Changing the DEF Pump Filter
PROCEDURE
2. Shut down the machine and implements the lockout and tag out procedure.
Wait until the pump unit has stopped running as it automatically empties the DEF hoses.
3. Disconnect the battery negative terminal.
4. Place a suitable container under filter cover.
Figure 9.57 - DEF Pump Filter Cover

5. Undo the filter cover (Item 1, Reference; Figure 9.57)
6. Use the puller which is supplied with replacement kit to pull out the filter by first pressing
it into the filter hole until it clicks.
Figure 9.58 - DEF Filter

7. Pull out the used filter (Item 2, Reference; Figure 9.58), and dispose of safely.
8. Install the new filter and rubber gasket. Then screw on the filter cover.
9. Tighten the cover to 20Nm (14.8 lbf ft)
10. Reconnect the battery negative terminal.

Maintenance 9
(c) DEF Tank Flush
� WARNING
Switch off the machine and implement the lockout and tag out procedure.
Hot surface Hazard
Beware of hot DEF and surfaces DEF is corrosive and therefore must be stored in tanks
constructed of approved materials. (Refer to engine manual for more details.)
Care should be taken when dispensing DEF. Spills should be cleaned immediately. All surfaces
should be wiped cleaned and rinsed with water.
DEF that has been spilt with crystallize when the water within the liquid evaporates. Spilt DEF
will attack paint and metal. If DEF is spilt, wash the area with water immediately.
Caution should be used when dispensing DEF near an engine that has recently been running.
Spilling DEF onto hot components may cause the release of ammonia vapors. Do not breathe
ammonia vapors. Do not clean up any spills with bleach.
NOTICE
If contamination of the Diesel Exhaust Fluid (DEF) is suspected, the DEF tank will need to be
drained and the DEF tank flushed.
Ensure that the vessel that will be used is large enough to collect the fluid to be drained.
Dispose of the drained fluid in accordance with the local regulations.
PROCEDURE
1. Ensure that the purging of the DEF system has been completed.
2. Position a suitable vessel below the drain plug (Item 1, Reference;Figure 9.59 ). Remove
the tank filler cap (Item 4, Reference; Figure 9.59).
Figure 9.59 - DEF Drain Plug

3. Remove the drain plug (Item 1, Reference; Figure 9.59) and allow the fluid to drain.
4. Remove the manifold (DEF header) (Item 3, Reference; Figure 9.59) after draining the fluid.

9 Maintenance
5. Install the drain plug and tighten. Remove the vessel used for draining.
6. Reinstall the manifold in to the tank.
7. Refill the DEF tank.

Maintenance 9
(d) Refilling the DEF (Diesel exhaust fluid) System
NOTICE
Never fill with AdBlue®/DEF solution other than ISO 22241 as specified by Volvo.
When the level in the DEF tank falls to 15%, a warning lamp lights up.
When the tank level has dropped to around 6% the warning lamp will flash. Maximum available
engine torque will ramp down to 75%.
7 minutes after the tank level reaches 6% the engine will ramp down to 50% torque, engine
speed will ramp down to idle speed.
If the engine is restarted when the tank level is below 6%, the engine will be limited to 50%
torque and idle speed.
For the engine to revert to full power the tank level must be above 12%. The tank level must be
above 21% for the system to extinguish the warning lamp and cancel the fault message.
PROCEDURE
1. Switch on the machine and view the DEF level on the main screen (Item 1, Reference;
Figure 9.60)
Figure 9.60 - DEF Level Screen

2. Switch off the machine and locate the DEF tank (Reference; Figure 9.61).
Figure 9.61 - DEF Tank Location

3. Clean off any dirt and debris from around the filler cap (Item 2, Reference; Figure 9.62.)

9 Maintenance
Figure 9.62 - DEF Tank Filler Cap

4. Remove the filler cap and top up DEF level as required. Refer to the engine manufactures
operation manual.
5. Refit the filler cap
6. Switch on the machine and re-check that the DEF level on the screen display is satisfactory.

Maintenance 9
9.11 Clutch Maintenance

NOTICE
The drive from the engine to the crusher is through a PT Tech hydraulic oil driven clutch. This
enclosed unit has the outer driving ring connected to the diesel engine flywheel. The output shaft
supported by a spherical roller bearing is fitted in a cover flanged to the engine flywheel housing.
Engage the clutch ONLY at engine speed (900 rpm and 1000 rpm for machines fitted with a
constant speed engine). At ambient temperature close to or below 0 ºC, keep engine running at
idling speed for 5 minutes, at least.
If the clutch is allowed to operate beyond 5000 hours without servicing, the drive torque can
reduce rapidly and possibly damage the clutch.
Refer to the manufacturers handbook or contact your local PT Tech clutch supplier for full
information on maintenance and procedures of this component.
1 After the first 10 Hours of operation:

• Check all clutch hydraulic fittings.
• Check all bolts and fittings.
• Baseline oil sample analysis.
2 Daily Checks:
• Check oil supply level is adequate.
3 Every 5000 Hours:
• Internally inspect and service the clutch. Contact your local technical support.

9 Maintenance
9.12 Refuelling
� DANGER
Explosion/Burn Hazard.
Fuel and fumes can explode and burn, resulting in death or serious injury.
No smoking.
Keep all open flames and sparks away.
Stop engine before adding fuel.
� WARNING
Always wear personal protective equipment when working with the machine.
Lockout and tag out the machine before performing pre-operating checks.
NOTICE
Do not fill the tank to capacity.
Allow room for expansion and wipe up spilled fuel immediately, otherwise paint work can be
damaged.
Ensure that correct diesel specification is used for Stage V, Tier 4 and Tier 3 machines. For,
more information, contact your local engine manufacturer.

Maintenance 9
(1) Refuelling the Machine
PROCEDURE
1. Observe all safety warning.
2. Switch on the machine and observe the diesel level on the production screen (Item 1,
Reference; Figure 9.63)
Figure 9.63 - Production Screen (Fuel Level)

3. Switch off the machine and implement the lockout and tag out procedure.
4. Open the diesel tank access door (Item 1, Reference: Figure 9.64) on the right hand side of
the machine beside the chamber.
Figure 9.64 - Diesel Tank Access Door

5. Unlock and remove the filler cap (Item 1, Reference; Figure 9.65) and fill the tank with diesel.

9 Maintenance
Figure 9.65 - Refuelling Diesel Tank

6. Replace and lock the filler cap.
7. Remove the lock out and tag out procedure.
9. Observe the diesel level gauge (Item 1, Reference: Figure 9.66) and ensure it is satisfactory.
Figure 9.66 - Diesel Level Gauge

Maintenance 9
9.13 Track Maintenance

NOTICE
When traveling up a gradient, the tracks must be driven forward (that is, Idlers first, drive
sprocket to the rear). When traveling down a gradient, tracks must be driven sprocket first
(Figure 9.67). The maximum climbing gradient for this machine is 30º.
� WARNING
Nip Point Hazard
Hazardous nip points exist.
Ensure that personnel are clear of the machine before tracking.
Figure 9.67 - Up and Downhill Tracking

Always
• Park the machine on flat, level ground. If it is necessary to park the machine on a gradient,
the tracks must be solidly blocked.
• Ensure the terrain the machine is working on is firm enough to support the machine.
• Ensure that the machine is tracked at least 10 m in either direction on a daily basis, doing
so minimize risk of track chain seizure.
• Ensure that the track systems are free from debris before moving the machine.
• Ensure that the tracks are not frozen to the ground before moving the machine.
• Ensure no leakage of oil from gearbox, roller, and idler before and during tracking.
• When tracking for 30 minutes stop tracking and allow 30 minutes for the track gearboxes
to cool down.
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 when the tracks are frozen to the ground.
• Push or tow the machine when unable to free itself.
• Track the machine constantly more than 30 minutes without providing adequate rest.

9 Maintenance
(1) Changing Track Gear Box Oil
PROCEDURE
2. Turn off the engine and implement the lockout and tag out.
3. Clean the area around the gearbox drain and refill plugs.
4. Position the drain and refill plugs (Items 1 & 2) into the drain position (Figure 9.68).
Figure 9.68 - Gear Box Plugs in Drain Position

5. Remove the filler plug (Item 1, Figure 9.68) allowing air into the gearbox for drainage.
6. Remove the Drain plug (Item 2, Figure 9.68) and drain the oil to an external container large
enough to hold all the oil (10 ltr container required).
7. Start the engine and move the tracks until the gearbox plugs (Items 1 & 2, Figure 9.69)
are in the fill position.
Figure 9.69 - Track Gear Box Fill Position

8. Refill the gearbox through the filler Plug (Item 1) until the oil begins to flow from the level
plug (Item 2). Figure 9.69
9. Replace the plugs (Item 1 & 2, Figure 9.69)
10. After a short period of operation, visually check the oil level.

Maintenance 9
(2) Track Adjustments
NOTICE
As the track wears, they become slack, and must be checked daily. To establish if the tracks
require adjustment move the machine, a few meters, backwards and forwards on level ground,
in a straight line. Doing so enables the track to adopt its natural degree of tension. Measure the
droop (Item 1, Figure 9.70). The measurement must be between 5-20 mm.
Figure 9.70 - Track Droop

9 Maintenance
(a) To Release Track Tension
PROCEDURE
2. Turn off the engine and Implement the lockout and tag out procedure.
3. Remove the adjuster cover plate (Item 1, Reference: Figure 9.71).
Figure 9.71 - Track Adjustment Access Plate

4. Loosen the grease fitting (Item 2, Reference: Figure 9.72) on the end of the track tensioning
cylinder by one half turn only. (Use a 22 mm Spanner). Allow grease to leave the tension
cylinder therefore reducing the track tension.
Figure 9.72 - Track Adjustment Grease Fitting

5. Retighten the grease fitting (Item 2, Reference:Figure 9.72 ) and replace the cover plate
(Item 1, Reference:Figure 9.71 ).

Maintenance 9
(b) To Increase Track Tension
PROCEDURE
2. Turn off the engine and implement the lockout and tag out.
3. Remove the adjuster cover plate (Item 1, Reference; Figure 9.71).
4. Attach the track grease gun adaptor provided in the tool box to a standard grease gun and
place over the tensioning cylinder grease fitting.
5. Pump the track out to the correct adjustment ((2) Track Adjustments on page 9-85).
6. When the track droop appears to be correct, move the machine backwards and forwards,
and recheck the droop.
7. Replace the cover plate (Item 1, Reference; Figure 9.71).

9 Maintenance
9.14 Impactor Maintenance

� WARNING
Once the machine has been shut down and the lockout and tagout procedure implemented,
allow 5 minutes of run down time for the impactor rotor to become completely stationary before
performing any maintenance tasks. Failure in doing so may result in death or serious injuries.
(1) Checking Components For Wear

(a) Daily Component Checks
PROCEDURE
1. Check the wearing components daily to determine the wear rates. Monitor and record wear
from new to estimate the component life.
2. Examine all wearing components for cracks or breakage and renew items if necessary.
3. Check for any components becoming loose and secure them if necessary to prevent
damage.
4. Check that the chain curtain and rubber are in good condition.
5. Visually check that the apron cylinder mountings are not loose and there are no signs
of hydraulic leaks.
6. Check main crusher components and drive pulleys for damage.
7. Check bearing housing for signs of movement or bolts coming loose, Tighten as necessary.

Maintenance 9
(2) Impactor Checks
NOTICE
It is important that designed replaceable wearing parts are renewed before the underlying
supporting part is subjected to wear. They must be turned or renewed as using them beyond
this point could result in damage to the support surfaces of the rotor.
Under no circumstances is the amount of the blow bar protrusion (Reference; Item 1 below) to
be less than 10mm (0.4in) as this could expose the rotor to unacceptable wear.
Use only genuine Terex replacement wear parts.
PROCEDURE
1. Check for daily wear on all parts affected, particularly where the material being crushed
is known to be abrasive.
2. Check and ensure that under no circumstance that the amount of the blow bar protrusion
is less than 10mm (0.4) (Item 1, Reference: Figure 9.73).
Figure 9.73 - Blow Bar Wear

3. Check the maximum wear blow profile with typical wear profile shown (Item 2, Reference:
Figure 9.73).
4. Check the minimum contact dimension in the rotor is 49mm (1.9in) (Item 3, Reference:
Figure 9.73).

9 Maintenance
(3) Blow Bar Wear Profiles
NOTICE
Always monitor and record the blow bar wear rate from new.
If the blow bars wear unevenly or do not retain a crushing tip as they wear down, the feed into
the crusher is too large, or being fed too quickly or the rotor speed is too high. Operating the
impactor at an incorrect speed will effect wear profile.
Material feed rates that are too high will also give undesirable wear profiles.
Take necessary corrective action to achieve the ideal wear profile.
Check for incorrect wear profiles as in the following examples below.
PROCEDURE
1. The ideal wear profile shown (Item 1, Reference; Figure 9.74) means blow bars can be
turned over after becoming worn.
Figure 9.74 - Ideal Wear Profile

2. If the material feed rate into the impactor is too low the wear on the blow bars (Item 2,
Reference; Figure 9.75) will appear.
Figure 9.75 - Feed Rate Too Low

3. If the material feed rate into the impactor is too high the wear on the blow bars (Item 3,
Reference; Figure 9.76) will appear.

Maintenance 9
Figure 9.76 - Feed Rate Too High

4. For wear taking place too low on the blow bar (Item 4, Reference; Figure 9.77), increase
the rotational speed of the impactor.
Figure 9.77 - Wear On The Lower Section Of The Blow Bar

5. For wear taking place too high on the blow bar and on the edge (Item 5, Reference; Figure
9.78), decrease the rotational speed of the impactor.
Figure 9.78 - Wear Too High On Blow Bar Edge

9 Maintenance
6. Damage may occur (Item 6, Reference; Figure 9.79) due to steel or other non crushable
material in the feed material.
Figure 9.79 - Blow Bar Damage

7. If wear occurs on one side (Item 7, Reference; Figure 9.80) due to material only on one
side of feeder, level the machine and supply material evenly across the feeder width.
Figure 9.80 - Blow Bar Wear On One Side

Maintenance 9
(4) Hard Facing Rotors
� WARNING
Once the machine has been shut down and the lockout and tagout procedure implemented
allow 5 minutes of run down time for the impactor rotor to become completely stationary before
performing any maintenance tasks. Failure in doing so may result in death or serious injuries.
NOTICE
Hard facing of the rotors should only be done by competent and professional personnel. Terex
can not be held responsible if the improper hard facing procedure is carried out.
It is recommended that the welding equipment supplier is contacted for information regarding
the usage of the particular welding material.
The analysis of the new electrodes or welding rods is given in the following table.
258–Tic-0
C 1.7
Mn 1.5
Si 0.5
Cr 7
Mo 1
Ti 5
To prevent heat cracks occourring in the base material, it should be preheated to 70-800C
(1580F-1760F) prior to hard facing.
The wear implements should be inspected at regular intervals for signs of wear or chipping
caused by tramp metal, etc. The frequency of inspection is provided in the maintenance tables
but could differ from this depending on the operating conditions, ie. type of feed material or
capacity of the machine.
The location of the hard facing is shown below. (Reference; Figure 9.81)
Figure 9.81 - Hard Facing The Rotor

9 Maintenance
(5) Replacing Impactor Blow Bars
� DANGER
Switch off and lockout and tagout before working at a machine.
Dangerous nip points exist. Close guards after maintenance.
Never climb into / place any limbs into the crushing chamber whilst carrying out maintenance
work. Failure in doing so may result in serious injuries or death.
� WARNING
Failure to secure the rotor in place via a sling or similar holding device when removing the rotor
lock pin could result in severe personal injury or death due to rotor movement from imbalance.
NOTICE
If using a mallet or hammer to break the wedging force between the blow bar and the rotor it
must be of a “Soft Tip” type such as a Hyde or Nylon. DO NOT USE STEEL.
The blowbars must remain within 0.5kg of each other to remain balanced.
The lifting cradle is designed to be stored on the rear of the chamber.

Maintenance 9
(a) Removing Impactor Blow Bars
PROCEDURE
2. Shut down the machine and implement the lockout procedure.
3. Connect suitable lifting equipment to the blow bar lifting cradle at the lifting point (Item 1,
Reference: Figure 9.82) and remove from the chamber.
Figure 9.82 - Blow Bar Lifting Cradle

4. Open the impactor (Reference: (4) Opening Impactor Body on page 7-39).
5. Lock the rotor. (Reference: (4) Opening Impactor Body on page 7-39)
6. To lift bar, remove the pin (Item 2, Reference: Figure 9.83) and move item the bar (Item 4,
Reference: Figure 9.83) into preferred position, then reinsert the pin (Item 2, Reference:
Figure 9.83).
7. The safety pin (Item 1, Reference: Figure 9.83) can then be removed and rotate bar (Item
3, Figure 9.83) to preferred position.
Figure 9.83 - Lifting Cradle- Pins Removed

8. Carefully lower the lifting cradle over the blow bar and ensure that the lifting pin (Item 1,
Reference: Figure 9.84) is located securely in the blowbar lifting point.

9 Maintenance
Figure 9.84 - Blow Bar and Lifting Cradle Fixed

9. Raise the lifting equipment just enough to remove the slack from the chain / steel rope.
10. Remove the wedge bolts. (Items 1, Reference: Figure 9.85).
Figure 9.85 - Impactor Blow Bar Wedge Bolts

11. Carefully raise the blow bar (Item 1, Reference: Figure 9.86) out of the rotor.
Figure 9.86 - Blow Bar Removal

Maintenance 9
(b) Turning Blow Bars
� WARNING
When using the lifting cradle and equipment, removing or fitting blow bars take care not
to trap fingers.
NOTICE
Only turn or replace blow bars as matched opposite pairs to maintain the correct rotor balance.
Take care when turning a half worn blow bar in the cradle.
The lifting cradle is designed to be stored flat on the floor for stability.
PROCEDURE
2. Remove the blow bar (Reference: (a) Removing Impactor Blow Bars on page 9-95).
3. Lower the Blow Bar onto level solid ground.
4. Remove the securing pin (Item 1, Reference: Figure 9.87) and rotate the cradle (Item 2,
Reference: Figure 9.87) 180° in the direction shown.
Figure 9.87 - Rotating Blow Bar

5. Refit the securing pin (Item 1, Reference: Figure 9.87) to secure the cradle in the new
lifting position.
6. Carefully raise the blow bar using suitable lifting equipment back into the chamber.
7. Refer to (c) Fitting the Impactor Blow Bars on page 9-98 for fitting procedure.

9 Maintenance
(c) Fitting the Impactor Blow Bars
� DANGER
Hazardous nip points exist.
When fitting new blow bars the rotor will be significantly out of balance until all four are changed.
When removing the rotor locking device ensure all personnel are clear of the rotor. Take extreme
caution as the rotor will rotate, the new blow bar rotating to the bottom and the old to the top.
� WARNING
Practice safe maintenance. Read and understand the operators manual before doing any work.
Failure to do so can result in serious injuries.
Ensure the lockout and tag out procedure is implemented before performing any maintenance
procedures. Failure to comply can result in serious injury.
NOTICE
When fitting the blow bar ensure that the apron and blow bar gap is 20mm larger than desired
to account for the blow bar moving and locating itself centrifugally during operation.
PROCEDURE
2. Ensure the rotor is locked and unable to move.
3. Thoroughly clean the rotor of compacted debris, especially on mating surfaces where the
blow bar locates and is clamped.
4. Connect suitable lifting equipment to the blow bar lifting cradle at the lifting point (Item 3,
Reference: ).
5. Lock the rotor. (Reference: (4) Opening Impactor Body on page 7-39)
6. To lift bar, remove the pin (Item 2, Reference: Figure 9.88) and move item the bar (Item 4,
Reference: Figure 9.88) into preferred position, then reinsert the pin (Item 2, Reference:
Figure 9.88).
7. The safety pin (Item 1, Reference: Figure 9.88) can then be removed and rotate bar (Item
3, Figure 9.88) to preferred position.

Maintenance 9
Figure 9.88 - Lifting Cradle- Pins Removed

8. Carefully lower the lifting cradle over the blow bar and ensure that the lifting pin (Item 1,
Reference: Figure 9.89) is located securely in the blowbar lifting point.
Figure 9.89 - Blow Bar and Lifting Cradle Fixed

9. Slide the lifting pin (Item 1, Reference: ) back into the cradle making sure it is located firmly
within the blow bar lifting point. Secure in place with safety pin (Item 1, Reference: ).
10. Raise the lifting equipment just enough to remove the slack from the chain / steel rope.
11. Carefully raise the cradle and blow bar into the vertical position. (Item 1, Reference: Figure
9.90)
Figure 9.90 - Cradle and Blow Bar Vertical

9 Maintenance
12. Clean the rotor location surfaces.

13. Carefully lower the blow bar (Item 1, Reference: Figure 9.91) into the rotor and set into
position.
Figure 9.91 - Blow Bar Fitting

14. When fitting the blow bar into position, ensure that the apron and blow bar gap is 5mm
larger than desired to account for the blow bar moving and locating itself centrifugally
during operation.
15. Fit the wedges (Item 1, Reference: Figure 9.92) and ensure correctly seated.
Figure 9.92 - Blow Bar Wedges

16. Fit new wedge bolts and nylock lock nuts (Items 1, Reference: Figure 9.93) and tighten
each screw to 350Nm.

Maintenance 9
Figure 9.93 - Impactor Blow Bar Wedge Bolts

17. Remove the securing bolt from the rotor locking device. (Item 1, Reference: Figure 9.94).
Figure 9.94 - Impactor Rotor Locked

18. Remove the rotor bar locking device from the recess and rotate and replace. When
replacing, ensure the short section of the locking device is inserted into the recess leaving
the long section (Item 2, Reference: Figure 9.94) to the outside of the chamber.
When fitting new blow bars the rotor will be significantly out of balance until all four are
changed. When removing the rotor locking devices ensure all personnel are clear of the
rotor. Take extreme caution as the rotor will rotate, the new blow bar rotating to the bottom
and the old to the top.

9 Maintenance
(d) Replacing the Impactor Wear Plates
� WARNING
NOTICE
The wear plates can be turned around to expose the unworn side one time only. If the wear
plates have previously been turned they must be replaced.
It is recommended that this procedure is carried out by a minimum of 2 people. The wear
plates should be held from inside the chamber while the bolts are being removed to prevent
them falling into the chamber.
PROCEDURE
2. Shut down the machine and implement the Lockout procedure.
3. Open the Impactor. (Reference: (4) Opening Impactor Body on page 7-39).
4. To remove the side liners (Item 1, Reference: Figure 9.95) on the chamber, remove the
corresponding bolts (Item 2, Reference: Figure 9.95) on the outside of the liner. There are
2 bolts holding each liner in place.
Figure 9.95 - Chamber Side Wear Plates

5. Repeat this step for the chamber hood side wear plates (Item 1, Reference: Figure 9.96).

Maintenance 9
Figure 9.96 - Hood Side Wear Plates

6. To gain access to the lower apron wear plate bolts by removing the inspection door, the latch
bar must first be removed. (Item 1, Reference: Figure 9.97). To remove the latch bar, the
bolt (Item 2, Reference: Figure 9.98) must be taken out and the latch bar can be removed.
Figure 9.97 - Remove Inspection Door Latch Bar
Figure 9.98 - Latch Bar Bolt

7. Access to the lower apron wear plate bolts (Item 1, Reference: Figure 9.99) can now be
gained by removing the inspection cover (Item 2, Reference: Figure 9.99) on the outside of
the chamber.

9 Maintenance
Figure 9.99 - Lower Apron Wear Plate Bolts

Maintenance 9
(e) Replacing Inlet Chains and Curtains
� WARNING
PROCEDURE
2. Shut down the machine and implement the lockout procedure.
3. Lift each curtain (Item 1, Reference: Figure 9.100) from the slot.
Figure 9.100 - Removing Inlet Curtains

4. Remove the bolt (Item 1, Reference: Figure 9.101) in order to remove the chain cover
(Item 2, Reference: Figure 9.101).
Figure 9.101 - Inlet Chain Cover

5. Remove the securing bolts on both sides (Item 4: Reference: Figure 9.101).
6. Slide the chain link retaining bar (Item 3: Reference: Figure 9.101) to release each chain.
7. When fitting the chain cover, tighten screws to 420Nm (310 lbf-ft).

9 Maintenance
9.15 Crusher Drive Belt Maintenance

The drive belt drive is a highly efficient power transmission medium, but optimum performance
cannot be achieved without correct tensioning and alignment. Belt drives are used on the
engine and crusher.
� WARNING
Do not inspect or carry out work on belt drives before closing down the machine and
implementing the lockout and tag out procedure. Never operate the machine without effective
drive guarding in place.
NOTICE
Drive belts must be inspected regularly for wear and also to monitor any pattern in the wear if it
is occurring. Insufficient belt tension causes slippage leading to loss of drive efficiency, heat
generation, and belt failure. Over tensioning exerts excessive loading on the shaft bearings
and can lead to premature failure.
When replacing a multi-belt drive always use a set of ‘matched’ new belts so that equal force
can be applied to all the belts. Ensure that any ventilation provided in the drive guarding is kept
clear to avoid overheating.
Do not allow contaminating material to come into contact with the drive elements.
Good alignment of the flywheel and drive pulley is important otherwise the belt flanks wear
quickly. Ensure that axis is parallel when viewed from all planes (Figure 9.102).

Maintenance 9
Figure 9.102 - Belt Pulley Alignment

1 Angular misalignment
2 Composite misalignment
3 Axial misalignment
4 Correct installation-both shafts and pulleys are parallel and in alignment

9 Maintenance
(1) Aligning The Belt
PROCEDURE
2. Close down the machine and implement the lockout procedure.
3. Remove guarding as necessary to gain access to the Vee belt drive and tensioner element
4. Use a digital inclinometer on the driven and idler pulley to check for parallelism between
the two pulleys.
5. Loosen the 4 outside bolts (Items 2, Reference; Figure 9.103) on the vertical adjustment
joint until loose and the centre bolt until almost tight.
Figure 9.103 - Vertical Adjustment Joint

6. Adjust alignment bolts (Items 1, Reference; Figure 9.103) to achieve vertical idler
parallelism to main driven pulley.
7. Tighten the bolts (Items 2, Reference; Figure 9.103) when two pulleys are parallel and
recheck vertical alignment and readjust as necessary.
8. Loosen the 4 outside bolts (Items 1, Reference; Figure 9.104) on the horizontal adjustment
joint until loose and the centre bolt until almost tight.
Figure 9.104 - Horizontal Adjustment Joint

9. Adjust alignment bolts (Items 2, Reference; Figure 9.104) to achieve horizontal alignment
from idler to driven pulley.
10. Use a straight edge along with B.M.S. Spacers and digital callipers to check/ adjust
horizontal alignment

Maintenance 9
11. Tighten all adjustment bolts and recheck alignment.

12. Replace all guarding removed
13. Remove the lock out and tag out procedure.

9 Maintenance
(2) Belt Tensioning Measurements
� WARNING
Do not inspect or carry out work on belt drives before closing down the machine and
implementing the Lockout Procedure. Never operate the machine without effective drive
guarding in place.
NOTICE
This machine has a high performance drive belt fitted as standard. The purpose of this drive
belt is that it is service free. When renewing the belt it is HIGHLY recommended replacing
with one of the same specification
It is highly recommended for better accuracy that a frequency tension tester is used to obtain
the following values.
If in doubt contact your local Terex dealer for more information.
It is highly recommended for better accuracy that a frequency tension tester is used to obtain
the frequency values. However if not available a belt tension gauge may be used to obtain belt
tension. After the drive has been running for 15 to 20 minutes, the machine should be stopped
and the tension checked. If necessary, re-adjusted to the basic setting force value.
NOTICE
The belt frequency must be measured at the point as illustrated (Item 1, Ref: Figure 9.165).
Figure 9.105 - Belt Tensioning Measurements

Table 9.5 - Belt Measurements
Tensioning Recommendations 6 Banded Belt
1 Frequency (Using Frequency 9 Hz
Tester)

Maintenance 9
PROCEDURE
2. Close down the machine and implement the Lockout and Tagout Procedure.
3. Gain access to the centre of the belt (Item 1, Reference; Figure 9.106) from behind the
control panel door (Item 2, Reference; Figure 9.106).
Figure 9.106 - Belt Access

Using Frequency Tester:
• Hit or snap the belt at the centre of the largest span (Item 1, Reference; Figure 9.106) and
quickly point the frequency at the same location to obtain frequency of belt.
• Repeat this 3 times and obtain an average frequency of the belts.
Using Belt Tension Gauge:
• Set the lower marker ring at the deflection distance required on the lower scale.
• Set the upper marker ring against the bottom edge of the top tube.
• Place the belt tension indicator on top of the belt at the centre of the belt span, and apply
a force at right angles to the belt deflecting it to the point where the lower marker ring
is level with the top of the adjacent belt.
• Read off the setting force value indicated by the top edge of the upper marker ring.
• Compare this value to the value shown in the table.
• If a belt tension indicator is not available:
• Use a spring balance to pull the belt down at the centre of the span.
• When the belt has been pulled down [measure using a rule] by the deflection calculated in
step 4, read off the force from the spring balance.
• If the measured force falls within the values given, the drive should be satisfactory. A
measured force below the lower value indicates under-tensioning. Some new drive belts
are tensioned to the x1.25 Setting Force value to allow for the normal drop in tension during
the running-in period. This is not recommended for all belts.

9 Maintenance
(3) Belt Tensioning Adjustment
PROCEDURE
1. To increase or decrease the tension in the drive belts, gain access to the belt tensioner (Item
2, Reference; Figure 9.107) behind the inspection door (Item 1, Reference; Figure 9.107).
Figure 9.107 - Belt Inspection Door and Tensioner

2. Loosen the locking nut (Item 1, Reference; Figure 9.108) and rotate the adjusting bar
(Item 2, Reference; Figure 9.108) using a 55mm spanner in the correct direction to tighten
or slacken the belts.
Figure 9.108 - Lock Nut And Adjuster

3. Re-check the tension of the belts using the frequency tester and when the correct frequency
is obtained secure the locking nut (Item 1, Reference; Figure 9.108) against the adjusting
bar (Item 2, Reference; Figure 9.108).
4. Replace all guards before start-up.

Maintenance 9
(4) Replacement Of Vee Belts
� WARNING
Entanglement hazard.
Risk of trapping parts of the body.
NOTICE
The Vee belts must be of the same type, size, and number to those originally fitted and specified.
PROCEDURE
2. Close down the machine and implement the Lockout and Tagout Procedure.
3. Gain access to the belt tensioner (Item 2, Reference; Figure 9.109) behind the inspection
door (Item 1, Reference; Figure 9.109).
Figure 9.109 - Belt Inspection Door And Tensioner

4. Loosen the locking nut (Item 1, Reference; Figure 9.110) and rotate the adjusting bar
(Item 2, Reference; Figure 9.110) using a 55mm spanner in the correct direction to fully
slacken the belts.
Figure 9.110 - Locking Nut and Adjuster

9 Maintenance
5. Remove the belts from the driving pulley first and then the driven pulley. Pull the belts
down and out through the door (Item 1, Reference; Figure 9.111) behind the control panel
(Item 2, Reference; Figure 9.111).
Figure 9.111 - Belt Removal

6. Before fitting new belts, check the pulley grooves are free from score marks or sharp edges.
Also check the grooves for wear. Ensure the pulleys are tight on their shafts.
7. Replace the new belts in the reverse of this procedure.
8. Under no circumstance must belts be prised into the grooves as belts and pulley grooves
can be damaged by using sharp tools to stretch the belts over the pulley rim.
9. If replacement of the belts is necessary due to premature failure, the cause should be
investigated and rectified before fitting new belts.
10. Replace all guarding removed throughout procedure.
11. Refer to belt tensioning measurements (Reference; (2) Belt Tensioning Measurements on
page 9-110) to properly set tension on belts after replacement.

Maintenance 9
9.16 Electrical Maintenance

NOTICE
All electrical equipment must be maintained in a safe condition. All electrical systems must
be subject to appropriate inspection, examination, testing, and preventative maintenance by
competent people. Good visual inspection picks up a large percentage of common faults, but
some faults cannot be found solely with such an inspection.
(1) Prior To Welding
NOTICE
Before, any welding work can be carried out at this machine a number of electrical components
must be disconnected to prevent potential damage.
PROCEDURE
2. Switch off the machine and implement the lockout procedure.
3. Disconnect the plug going to the control panel (Item 1, Reference; Figure 9.112)
Figure 9.112 - Plug On Control Panel

4. Disconnect the plugs from the clutch controller (Item 1 Reference; Figure 9.113).
Figure 9.113 - Cables To Disconnect

9 Maintenance
5. Disconnect the 3 cables from the back of the control box (Item 2, Reference; Figure 9.113).
6. Disconnect the cable to the radio receiver (if fitted) at the first connection from the box
(Item 3, Reference; Figure 9.113).
7. Disconnect the ECU plugs from the engine (Item 1, Reference; Figure 9.114 & Figure 9.115)
Figure 9.114 - John Deere ECU Plugs

Figure 9.115 - Volvo ECU Plugs
8. Disconnect the ground negative [-] battery cable (Items 1, Reference; Figure 9.116) on
the batteries.
Figure 9.116 - Batteries

9. Reconnect all connections after welding work is completed.

Maintenance 9
(2) Battery Removal And Installation
� DANGER
Explosion / Burn Hazard.
Death, burns, blindness, or serious injury can result from release of pressurized liquids or due
to ignition of explosive gases and corrosive acid.
Keep all open flames and sparks away.
Wear personal protective equipment, including shield, gloves, and long sleeve shirt.
Read all manuals prior operation.
NOTICE
Never give your key to anyone else and where more than one person is working on the
equipment they must fit their lock also.
Dumping the battery is a hazard to the environment. Dispose of the battery by special disposal
or at a recycling center
When purchasing a new battery, confirm that the negative and positive terminal posts are on
the same side of the battery as your old one.
PROCEDURE
3. Locate the battery compartment on the left side of the machine.
Figure 9.117 - Battery Location

9 Maintenance
4. The battery terminals are labeled + (red/positive) and – (blue/negative). Disconnect the
negative terminal first (Items 1, Reference; Figure 9.118) and flex the cables away from
the batteries.
Figure 9.118 - Batteries

5. Disconnect the positive terminal (Items 2, Reference; Figure 9.118) and flex the cables
away from the batteries.
6. Remove the top clamp that holds the batteries down (Item 3, Reference; Figure 9.118).
7. Lift the battery straight up and out by holding it at opposite corners. As the battery weighs
approximately 29 kg (65 pounds) or more, it must be lifted out with extreme care by 2
operators. Do not tip or drop the battery.
8. Clean the battery cables, pan, and clamp. If there is corrosion present (white powder),
neutralize it with a mixture of baking soda and water using an old toothbrush.
9. Carefully lower the new battery into place. Make sure that it is sitting flat in the battery
pan, and not on the lip.
10. Position the top clamp (Item 3, Reference; Figure 9.118) into place and secure the battery
by tightening down the bolts.
11. Reconnect the positive terminal first, followed by the negative terminal.

Maintenance 9
9.17 Dust Suppression Maintenance

NOTICE
The machine is fitted with a plain water dust suppression system. This system contains 2 flat
fan nozzles. The spray nozzles are located at the end of the main conveyor.
It is the responsibility of the customer to supply the system with clean water. Water is supplied
at the left side of the machine on the side of the chassis if the optional electric water pump
is added.
All nozzles should be kept free of dirt and blockages. Each nozzle should be checked every
time the dust suppression is switched off.
The system can be drained after operation by disconnecting the nozzle feed pipe at the chassis
bulk head and allow to drain by gravity. This is particularly important in winter time when there
is the likelihood of the system freezing.
9.18 Hydraulic Cylinder Maintenance

� WARNING
Injection Hazard.
not use hand.
NOTICE
As part of the finish process in our chrome rod manufacturing a natural lubricant is rolled into
the surface. To prolong the life of hydraulic cylinder, we recommend that any cylinders that are
exposed for more than one week must have the chrome rod coated. When coating, use a
suitable good quality water resistant grease.
9.19 Washing The Machine

NOTICE
When washing the machine with high powered washing equipment, extreme care must be taken.
Spraying high powered washing equipment into machine bearings, seals, and electrical
equipment can cause machine failures.
Some high pressure cleaning systems are sufficiently powerful enough to damage paint.

9 Maintenance

Troubleshooting 10
Table of Content
10 Troubleshooting........................................................................................10-1
10.1 Crusher Troubleshooting Guide ................................................................... 10-2
(1) General Troubleshooting ......................................................................... 10-2
(2) VGF Troubleshooting............................................................................... 10-3
(3) Conveyor Troubleshooting....................................................................... 10-4
(4) Component Troubleshooting ................................................................... 10-5
(5) Hydraulic Troubleshooting ....................................................................... 10-6
(6) Tracks Troubleshooting ........................................................................... 10-9
(7) Electrical Troubleshooting ..................................................................... 10-11
(8) Impactor Chamber Troubleshooting ...................................................... 10-12
10.2 Diagnostic Information ............................................................................... 10-13
10.3 Engine Troubleshooting ............................................................................. 10-14
(1) Viewing The Engine Information Screen ............................................... 10-14
(2) Viewing SPN And FMI Codes................................................................ 10-16
(3) Accessing Stage V Information ............................................................. 10-18
10.4 Stage V Engine Fault Code........................................................................ 10-20
(1) SPN and FMI Fault Codes..................................................................... 10-20
10.5 Constant Speed Engine Fault Codes......................................................... 10-37
(1) SPN and FMI Fault Codes For Constant Speed ................................... 10-37
10.6 Machine Troubleshooting ........................................................................... 10-41
(1) Accessing Active Alarms And Alarm History ......................................... 10-41
(2) Machine Diagnostic Fault List................................................................ 10-43
10.7 Clutch Diagnostic Data............................................................................... 10-47
(1) Accessing The PT Tech Status Screen ................................................. 10-47
(2) PT Tech Clutch Symbols Explained....................................................... 10-49
(3) PT Tech SPN and FMI Fault Codes ...................................................... 10-52
10.8 Vee Belt Troubleshooting ........................................................................... 10-56

10 Troubleshooting
10 Troubleshooting
10.1 Crusher Troubleshooting Guide
(1) General Troubleshooting
Fault Cause Correct Measure
Fuel Top up as necessary
Coolant level Top up as necessary
Clean Radiator / check fan
High coolant temperature
operation
Hydraulic oil level Top up as necessary
Machine Stops
Packing in crushing
Clear discharge chute
chamber
High Hydraulic oil
Clean oil cooler / Replace
temperature
Emergency stop depressed Check all Emergency stops
Check clutch code and refer
Clutch Disengage
to PT Tech manual
Check running parameters
Engine load
and adjust accordingly
Isolate the machine and
Chamber block
Crusher stops remove the blockage
Build up in discharge chute Clear blockage, check chute
Broken drive belts Check / Replace
Refer to trouble shooting
SCR fault section of the Manual (engine
derates)

Troubleshooting 10
(2) VGF Troubleshooting

Rock moves down one side Machine not level (side to Ensure machine is on a level
of feeder side) surface
Material jam Remove material jam
Hydraulic motor drive
Feeder completely stops Replace drive coupling
coupling failure
Hydraulic motor faulty Replace motor
Rumbling noise from Bearing lacking lubricant Follow lubrication procedure
gearbox Bearings are damaged Replace bearings
Rock moves across screen
VGF speed too high Decrease Speed
too fast
Rock moves across screen
VGF speed too low Increase Speed
too slow
Excessive vibration Coil springs, fatigued,
sagging springs bottoming Replace springs
out
Seal damaged between Remove motor and replace
gearbox and motor seals
Seal damage may be Check oil operating
caused by excessive oil temperature and
Excessive oil leaking temperatures environmental conditions
around drive assembly
Too much oil in housing Adjust oil to correct level
Seal damage may be Check and clean the case
caused by pressurised breather before replacing the
casing new seal

10 Troubleshooting
(3) Conveyor Troubleshooting

Too much load on belt Reduce load on belt
Incorrectly tensioned belt Tension belt
Drive drum turns but belt
Worn belt Replace belt
does not move
Worn drum lagging Replace drum lagging
Rollers cannot rotate freely Clean/check/replace rollers
Material jam Remove material jam
Taper lock is not tight or
Tighten or replace taper lock
Belt completely stopped broken
Replace hydraulic motor as
Hydraulic motor failure
necessary
Ensure machine is on level
Machine is not level
ground
Belts are not aligned Align belts
Belts are tracking off
Belts are not being fed
evenly, material is tending Ensure conveyor is fed more
to be fed to one side of the evenly
conveyor
Tighten or replace as
Conveyor belt is loose
necessary
Material collects under belt Conveyor belt misaligned Align conveyor belt
Skirting rubbers not
Adjust skirting rubbers
adjusted
Bearing lacking lubricant Follow greasing procedure
Rumbling noise from
Incorrectly aligned bearing Align bearing
bearing
Bearing is damaged Replace bearing
Conveyor belt wedged or Clear obstruction, adjust and
Screeching noise when rubbing against fixed parts align conveyor belt
conveyor is running Belt scraper too tightly
Re-adjust belt scraper
placed against belt

Troubleshooting 10
(4) Component Troubleshooting

Faulty switch Check for power
Replace switch
Components do not start PVG solenoid Check for power
Replace solenoid
Wiring connection (loose) Carry out visual inspection
Obstruction (e.g stone, Clear obstruction
material build up etc)
Check general condition Correct problem if possible
of machine (eg oil leaks,
excessive heat, hose
blockages etc)
Low engine speed Correct engine speed
Engine performance Consult engine manual
Low hydraulic oil level Top up hydraulic oil level
Return line filter blockage Replace return line filter
Pressure filter blockage Replace pressure filter
Machine components Loose or damaged drive Tighten/replace drive
running slowly couplings couplings
Machine is overloaded Check setting parameters
Worn or damaged drive Replace motor
motor
Worn or damaged pump Replace pump
Incorrect relief pressure Check and correct relief
settings pressure settings
Pump cavitation, suction Check oil level and gate valve
line is collapsed is open fully (if applicable)
Flow at pump is not as Check flow after pump, after
expected control valve and after motor
Suction line filter blockage Replace suction filter

10 Troubleshooting
(5) Hydraulic Troubleshooting

Low oil level causing
Top up oil level
cavitation
Blockage at pressure filter Replace pressure filter
Drain hydraulic oil and replace
Incorrect hydraulic oil
with correct oil
Hydraulic oil tank breather Disassemble and clean/
clogged Replace as necessary
Excessively noisy pump Disassemble, clean or replace
Pressure relief valve stuck
the spring nozzle/ Replace as
in open position
necessary
Drain tank and replace
Contaminated hydraulic oil
hydraulic oil
Damaged pump Replace pump
Suction line filter blockage Replace suction filter
Obstruction at inlet pipe Remove obstruction
Contaminants in hydraulic Drain tank and replace
oil hydraulic oil
Worn or sticking relief valve Replace relief valve
Low or erratic pressure Dirt or chip holding valve Clean around valve. Replace
partially open valve
Control valve relief pressure Set relief pressure to correct
set too low level
Check the piping, hose and
Irregular motion of the Air mixed in the cylinder coupling. After checking and
cylinder repair, remove air
Filters blocked Replace
Low oil level Top up hydraulic oil level
Return line element is
clogged (check blockage Replace return line element
indicator)
Damaged suction line Replace suction line pipe
No response from any
hydraulic system Retighten couplings and
Air mixed from the suction replace the piping as
necessary
Blockage at pressure filter Replace pressure filter
Pressure relief valve stuck
Contact Terex
in open position

Troubleshooting 10

Check the rotating direction
Rotating direction error
and reconnect
Low oil level Top up oil level
The pump does not start Check and tighten hydraulic
Air in the system
suction hose connections
Check that the pump shaft
Pump seized
rotates, fit replacement if faulty
Check for symptoms of
Oil in system becomes Pump running continuously pressure build up
excessively hot under pressure Check pressure on all
hydraulic circuits
Low oil level Top up hydraulic oil level
Drain tank and replace
Incorrect hydraulic oil
hydraulic oil
Engine performance Consult engine manual
Machine operating slowly.
(No external oil leaks) Loose or damaged taper
Tighten / replace taper lock
locks
Worn or damaged drive
Replace motor
motor
Worn or damaged pump Replace pump

10 Troubleshooting

Unseated unloader valve Replace valve
Check operation of solenoid,
replace if necessary.
Directional control valve Check for possible sticking
inoperative spool on valve, dismantle,
clean and replace parts or
complete assembly.
Check operation of solenoid ,
Solenoid - operation
replace as necessary
Mechanical blockage on
Investigate crusher
crusher
Make visual inspection.
Tighten connections
Crusher CSS adjustments External leakages
not possible Renew pipes, hoses or
couplings as necessary
Mechanical failure of the Visually check the machine for
crusher mechanical damage
Low oil level Top up oil level
Screw the adjuster out a few
original setting. It dislodges
dirt under the ball seat.
Dirt in relief valve If no response, remove
unit, dismantle and clean
particularly the jet.
Replace in system
Check valve spring, renew as
Faulty relief valve
necessary

Troubleshooting 10
(6) Tracks Troubleshooting

Seal damaged between
Remove motion control block
Motion control block and
and replace seals
motor
Excessive oil leaking Seal damaged between Remove motor and replace
around drive assembly motor and gearbox seal
Seal damage may be Check oil operating
caused by excessive oil temperature and
temperatures environmental conditions
Check that the track adjuster
grease valve is tight, has a
properly fitted seal and that
there is no grease leaking past
it
Track will not stay tensioned Grease escaping Check around the tensioning
Cylinder for escaping grease.
This will indicate that the seals
are damaged in the tensioning
cylinder. Replace with a new
cylinder immediately
Replace with a new Track
Track roller leaking oil Damaged or worn seals
Roller
Track group too loose Check track tension
Check alignment of Sprocket
Track group running off Excessive misalignment
Idler and track rollers
Sprocket and / or idler
Excessive component wear Check wear limits
Twisted track frame Check track frame

10 Troubleshooting

Check parameter setting
within the PLC screen
Parameter settings
and adjust if necessary
(independently)
Check if the brake is releasing.
Fit a pressure clock to the
Brake jammed brake hose. A pressure of
at least 285 PSI / 20 bar is
required to release the brakes
Check that the same size of
Different sizes of motors
motors have been fitted to
fitted to tracks
both tracks
Oil flow going to the tracks
not flowing evenly and
Check oil flow to tracks,
allowing a motor to turn
swap hoses between both
quicker in one direction.
tracks to eliminate final drive
This will cause the Machine
mechanical issues. Replace
to ‘crab’ in one direction.
pump/ solenoid as necessary
Track brakes not fully
released
Swap the pressure regulator
from the opposite block to
Brake pressure regulator see if the problem is in the
One track not operating or valve jammed due to debris brake valve. If the valves
operating slower than the will stop the motor turning continue to jam then the oil
other on one side in the hydraulic system is not
being filtered to the required
level of cleanliness
Swap over the motors on the
two tracks. If the fault is in
Motor Fault
the motor, replace with a new
motor
Remove the motor and
look into the gearbox for
heat discolouration and/or
Faulty brake fragments of brake disc. If
the fault is in the brakes the
complete gearbox will have to
be replaced
Remove the motor. If there
is hydraulic oil in the gearbox
entrance then the seals
are damaged. While it
may be possible to replace
Faulty brake piston seals these seals on-site we
strongly recommended that
a replacement gearbox is
fitted and an overhaul of the
damaged gearbox be carried
out off-site

Troubleshooting 10
(7) Electrical Troubleshooting

Faulty ignition switch Replace ignition switch
Low engine oil level
(warning light should Top up oil level
be on)
Control panel lights up but
Low engine coolant level
engine does not start Top up coolant level
(warning light should be on)
Emergency stop buttons Check all emergency stop
depressed buttons
Faulty starter motor Replace starter motor
Top up electrolyte level
Low battery voltage
Charge up battery
Control panel does not light Isolator on turn off isolator
up
Faulty ignition switch
Correct connections/replace
terminals
Damaged battery Replace battery
Top up electrolyte level
Low battery voltage
Charge up battery
Battery goes flat while
Faulty Alternator Replace alternator
engine is running
Loose alternator belt Adjust tension
Faulty starter motor Replace starter motor
Remote control is out of Move remote control to within
range 100 m of the machine
Track radio remote control Batteries are dead Charge or replace batteries
does not work
Remote control not
programmed to receiver Program receiver box
box
Faulty switch Check for power
Components do not start PVG solenoid Replace solenoid
wiring connection (loose) carry out visual inspection

10 Troubleshooting
(8) Impactor Chamber Troubleshooting

Check clutch fault code and
Clutch disengage
refer to PT Tech manual
Check running parameters
Engine stall
and adjust accordingly
Isolate the machine and
Chamber blocked remove the blockage as per
Crusher stops recommendations
Chamber interlock switch Check electrical connections
Refer to trouble shooting
SCR fault section of the Manual (engine
de-rates)
Broken Drive Belts Check/Replace
Wait for bars to ‘bed in’ ie build

Abnormal noises Loose blowbars
up with dirt.
Check bearing for wear and

Potential Low Lubrication
grease for contamination.
Pillar block bearing
temperature running hot Lubrication contaminated Change grease
Bearing damaged Replace bearing
Excessive machine Check that the blowbars are
Bolwbars
vibration not out of balance
Machine not set level Set machine level
Toggle bolts not fastening Material build up in chamber
Open hood and clean
hood interface.
Electric hydraulic pump Replace motor
Hood not opening
Pressure relief setting Check all pressure settings
Crusher speed not being
Drivebelts slippage Tension drive belts
achieved
Feed material not constant Feed material at constant
(stop start) speed and level
Feed material at constant
Uneven blowbar wear Overload of feed material
speed and level
Machine not laterally
Level machine
(side-to-side) level

Troubleshooting 10
10.2 Diagnostic Information

NOTICE
The diagnostic codes may alert the operator to conditions that may damage the machines
components. Never ignore a Machine fault if one occurs. Always investigate thoroughly or if in
doubt contact your Terex supplier.
Procedure to Address the Occurrence of Codes

Whenever a diagnostic code occurs, try to note all operating conditions of the engine. It is
especially critical to take note of the operating conditions for intermittent codes. This information
provides the technicians with the operating conditions at the time of the intermittent code. This
will enhance the technician’s ability to produce the code again. This will also enhance the
technician’s ability to diagnose the problem. The codes are recorded in the ECM and the codes
may be recovered with the electronic service tool.
Diagnostic Code and Event Code Chart
The charts on the following pages are provided in order to help determine the action that should
be taken if a particular diagnostic code is active. The current operating conditions will determine
the reaction of the operator to the codes. As an example, only intermittent service codes that
are a persistent problem should be serviced.

10 Troubleshooting
10.3 Engine Troubleshooting

(1) Viewing The Engine Information Screen
PROCEDURE
3. On the setup screen press, the information button (Item 3, Reference; Figure 10.1).

4. With the information screen displayed, press the engine information button (Item 2,
Reference; Figure 10.2).

Troubleshooting 10
5. The engine information display screen (Reference; Figure 10.3) is numbered in

correspondence with the table.
Figure 10.3 - Engine Information Screen

Engine Information
1 SPN & FMI Access Button
2 Coolant Temperature
3 Intake Manifold Temperature
4 Oil Pressure
5 Inlet Pressure
6 Urea Level (Tier 4 Only)
7 PT Tech Clutch Information
8 Lower Engine Speed (Not available on constant speed machines)
9 Raise Engine Speed (Not available on constant speed machines)
10 Battery Voltage
11 Percentage Load on the Engine
12 Engine Hours
13 Engine Speed

10 Troubleshooting
(2) Viewing SPN And FMI Codes
PROCEDURE


5. On the engine information screen press the SPN and FMI button (Item 1, Reference; Figure
10.6).

Troubleshooting 10

6. When viewing the SPN & FMI screen (Reference; Figure 10.7), buttons 1 & 2 can be used
to scroll through the list of codes.
Figure 10.7 - SPN & FMI Screen

7. Use the escape button at anytime to return to the main menu.

10 Troubleshooting
(3) Accessing Stage V Information
PROCEDURE
1. The Stage V screen can be accessed by pressing button 1, (Reference: Figure 10.8) on
the engine data screen.
Figure 10.8 - Engine Data Screen

2. After pressing button 1 on the engine data screen (Reference: Figure 10.8), the Stage V
screen will appear (Reference: Figure 10.9).
Figure 10.9 - Stage V Regen Screen

Troubleshooting 10
3. After pressing the FORCE regenerate button, (Item 1, Reference: Figure 10.9) the following
screen will appear: (Reference: Figure 10.10) and the machine will stop and regenerate
to allow the DGF to be cleaned.
Figure 10.10 - FORCE button activated

4. To enable the INHIBIT screen, press Item 2, Reference: Figure 10.11).
Figure 10.11 - Stage V Regen Screen

5. When the INHIBIT button is pressed (Item 2, Reference: Figure 10.11), it will disable the
possibility for the FORCE button to be used. (Reference: Figure 10.12).
Figure 10.12 - Inhibit Button Selected

10 Troubleshooting
10.4 Stage V Engine Fault Code

(1) SPN and FMI Fault Codes
Table 10.1 - SPN Descriptions
SPN SPN Name SPN Explanation FMI a
46 Pneumatic Supply The pneumatic 1,19
Pressure pressure in the main
reservoir, sometimes
referred to as the wet
tank.
51 Engine Throttle The position of the 3,4,7,8,9
Position valve used to regulate
the supply of a fluid,
usually air, or fuel/air
mixture, to an engine.
91 Accelerator Pedal The ratio of actual 2,9,10,19
Position 1 position of the
analog engine
speed/torque request
input device (such as
an accelerator pedal
or throttle lever) to the
maximum position of
the input device. This
parameter is intended
for the primary
accelerator control
in an application. If
an application has
only one accelerator
control, use SPN 91.
94 Engine Fuel Delivery Gauge pressure of 0
Pressure fuel in system as
delivered from supply
pump to the injection
pump.
97 Water in Fuel Signal which indicates
Indicator the presence of water
in the fuel.
98 Engine Oil Level Ratio of current 2,3,4,10
volume of engine
sump oil to maximum
required volume.
100 Engine Oil Pressure Gauge pressure of oil 1,2,3,4,13,16,17,18
in engine lubrication
system as provided
by oil pump.
102 Engine Intake The gauge pressure 0,1,3,4,7,8,9,10,15,1
Manifold #1 Pressure measurement of the 6,18,21
air intake manifold.

Troubleshooting 10

103 Engine Turbocharger Rotational velocity 0,2,3,4,5,9,20,21
1 Speed of rotor in the
turbocharger.
105 Engine Intake Temperature of 0,1,2,3,4,9,15,16,17,
Manifold 1 precombustion air 20,21
Temperature found in intake
manifold number 1
of engine air supply
system.
107 Engine Air Filter 1 Change in engine 1,2
Differential Pressure air system pressure,
measured across the
filter, due to the filter
and any accumulation
of solid foreign matter
on or in the filter.
108 Barometric Pressure Absolute air pressure 2,3,4,15,16,20,21
of the atmosphere.
110 Engine Coolant Temperature of liquid 0,1,2,3,4,8,9,10,16,1
Temperature found in engine 7,18,20,21
cooling system.
111 Engine Coolant Level Ratio of volume of 1,3,4
liquid found in engine
cooling system to
total cooling system
volume.
131 Engine Exhaust Back 2,3,4,7,8,9,10,15,16,
Pressure 18,20,21
132 Engine Intake Air Mass flow rate of fresh 0,1,2,3,4,5,7
Mass Flow Rate air entering the engine
air intake, before any
EGR mixer, if used.
Flow rate of fresh
air conducted to the
engine cylinders to
support combustion.
156 Engine Injector The gauge pressure 0,1,2,3,4,8,9,18
Timing Rail 1 of fuel in the timing
Pressure rail delivered from the
supply pump to the
injector timing inlet.

10 Troubleshooting

167 Charging System Electrical potential 2,5,4,5,6,9,10
Potential (Voltage) measured at the
charging system
output. The charging
system can be any
device charging
the batteries. It
includes alternators,
generators,
solid-state charger,
and other charging
devices.
168 Battery Potential / This parameter 0,1,4,5,15,16,17,18
Power Input 1 measures the first
source of battery
potential as measured
at the input of the
ECM / actuator, and
so forth. It comes from
one or more batteries,
irrespective of the
distance between the
component and the
battery.
171 Ambient Air Temperature of air 0,1,2,3,4,7,9,15,16,1
Temperature surrounding vehicle. 7,18,19,20,21
172 Engine Intake Air Temperature of air 2,3,4,7
Temperature entering vehicle air
induction system.
174 Engine Fuel Temperature of fuel
Temperature 1 passing through
the first fuel control
system.
175 Engine Oil Temperature of air 3,4,11
Temperature 1 entering vehicle air
induction system
188 Engine Speed At Idle, Stationary low idle 14
Point 1 speed of engine which
includes influences
due to engine
temperature (after
power-up) and other
stationary changes
(calibration offsets,
sensor failures, and
so on)
190 Engine Speed Actual engine speed 0,10,15,16,20
which is calculated
over a minimum
crankshaft angle of
720º divided by the
number of cylinders.

Troubleshooting 10

234 Software Software identification 2,19
Identification of an electronic
module.
532 Engine Speed At High Engine speed of high 14
Idle, Point 6 idle.
558 Accelerator Pedal 1 Switch signal which 2
Low Idle Switch indicates the state
of the accelerator
pedal 1 low idle
switch. The low idle
switch is defined in
SAE Recommended
Practice J1843.
559 Accelerator Pedal Switch signal which 2,9,10
Kick down Switch indicates whether
the accelerator pedal
kick down switch is
opened or closed.
590 Engine Idle Shutdown Status signal which 2
Timer State indicates the current
mode of operation
of the idle shutdown
timer system.
597 Brake Switch Switch signal which 2
indicates that the
driver operated brake
foot pedal is being
pressed.
598 Clutch Switch Switch signal which 2,7,19
indicates that the
clutch pedal is being
pressed.
636 Engine Position 1,2,3,4,5,7,8
Sensor
641 Engine Variable Actuator that controls 2,4,5,7,8,9,10,11,12,
Geometry the variable geometry 13,15,16,19
Turbocharger turbocharger
Actuator #1 geometry.
645 Engine Tachometer 19
Signal Output
651 Engine Injector 1,2,4,5,6,7,8,10,13,1
Cylinder #01 5,16,18,20,21
652 Engine Injector 1,2,4,5,6,7,8,10,13,1
Cylinder #02 5,16,18,20,21
653 Engine Injector 1,2,4,5,6,7,8,10,13,1
Cylinder #03 5,16,18,20,21
654 Engine Injector 1,2,4,5,6,7,8,10,13,1
Cylinder #04 5,16,18,20,21

10 Troubleshooting

655 Engine Injector 1,2,4,5,6,7,8,10,13,1
Cylinder #05 5,16,18,20,21
656 Engine Injector 1,2,4,5,6,7,8,10,13,1
Cylinder #06 5,16,18,20,21
657 Engine Injector 1,2,4,5,6,7,8,10,13,1
Cylinder #07 5,16,18,20,21
658 Engine Injector 1,2,4,5,6,7,8,10,13,1
Cylinder #08 5,16,18,20,21
677 Engine Starter Motor Activates the starter. 0,2,3,4,5,7,19
Relay
723 Engine Speed 2 The engine speed as 2,4,7,8,9,10,14
measured by speed
sensor 2.
788 Transmission Clutch Identifies the status
Actuator of the actuator that
controls the clutch.
968 Engine Idle Increment Switch signal which
Switch indicates the position
of the idle increment
switch.
972 Accelerator Interlock Switch signal used
Switch to disable the
accelerator and
remote accelerator
inputs, causing the
engine to return to
idle
974 Remote Accelerator The ratio of actual 0,1
Pedal Position position of the
remote analog engine
speed/torque request
input device (such as
an accelerator pedal
or throttle lever) to the
maximum position of
the input device.
986 Requested Percent Fan speed as a ratio 2,3,4,5,7
Fan Speed of the actual fan drive
(current speed) to
the fully engaged fan
drive (maximum fan
speed).
1086 Parking and/or Trailer The pneumatic 2
Air Pressure pressure in the circuit
or reservoir for the
parking brake and/or
the trailer supply.

Troubleshooting 10

1108 Engine Protection Status signal which 14
System Timer indicates the status of
Override the override feature of
the engine protection
system timer.
1110 Engine Protection Status signal which 14
System has indicates whether
Shutdown Engine the engine protection
system has shutdown
the engine.
1135 Engine Oil Temperature of the
Temperature 2 engine lubricant.
1239 Engine Fuel Leakage Status signal which 7
1 indicates fuel leakage
in the fuel rail of the
engine. Location can
be either before or
after the fuel pump.
1322 Engine Misfire for When a misfire occurs 7
Multiple Cylinders in any one of the
cylinders.
1323 Engine Misfire Engine misfire, 7
Cylinder #1 detected in cylinder.
Cylinder #5 detected in cylinder
1442 Engine Fuel Valve 1 The position of a 2,3,5,7,8,10
Position gaseous fuel valve
that is metering the
fuel flow to the engine.
1443 Engine Fuel Valve 2 The position of a 1,6
Position gaseous fuel valve
that is metering the
fuel flow to the engine

10 Troubleshooting

1483 Source Address of The source address of 2,8,9,11
Controlling Device for the SAE J1939 device
Engine Control currently controlling
the engine.
1484 Other ECUs Have 9,10,16,18,19,20,21
Reported Diagnostic
Trouble Codes
Affecting Operation
1485 ECM Main Relay 16,18
1569 Engine Protection Torque has been 14
Torque Derate de-rated for protection
of the engine.
1632 Engine Torque Limit Torque limit rating
Feature described in the
current record.
1639 Fan Speed The speed of the 3,4,8
fan associated
with engine coolant
system.
1675 Engine Starter Mode There are several 2,9,12,13,19
phases in a starting
action and different
reasons why a start
cannot take place.
1761 After treatment 1 SCR A special catalyst 1,2,3,5,18
Catalyst Tank Level uses a chemical
reagent to reach
legal requirement for
NOX emissions. This
parameter indicates
the reagent level
within that catalyst
tank.
2609 Cab A/C Refrigerant This is the gage 2,3,4,5
Compressor Outlet pressure at the
Pressure compressor outlet
in the cab air
conditioning system.
2791 Engine Exhaust Gas Desired percentage 2,3,4,5,7,8,10,11,16,
Recirculation 1 Valve of maximum Exhaust 20,21
1 Control 1 Gas Recirculation
(EGR) valve 1
opening.
2797 Engine Injector Group A first collection of 2,3,4,5,8
1 fuel injector circuits
that are grouped.
2798 Engine Injector Group A second collection 2,3,4,5,8
2 of fuel injector circuits
that are grouped.

Troubleshooting 10

2858 Machine Data There is a problem 13
Configuration 1 involving the
parameter list (along
with the parameter
locating information)
for the data structure
for configuring
operations within the
Controller Application
being communicated
with.
Configuration 2 involving one
(or more) of the
PGNs within the
parameter list for
the data structure
for configuring
being communicated
with.
Configuration 3 involving the first
output control list for
the data structure
for configuring
being communicated
with.
Configuration 4 involving the second
the data structure
for configuring
being communicated
with.
Configuration 5 involving the third
the data structure
for configuring
being communicated
with.
3031 After treatment 1 Temperature of the 0
SCR Catalyst Tank reagent in the storage
Temperature tank.

10 Troubleshooting

3216 After treatment 1 The amount of 4,5,7,8,9,10,17,18,19
Selective Catalytic combined NO and ,20
Reduction Intake NO2 in the exhaust
NOx entering the after
treatment system
measured by a NOx
sensor at the after
treatment intake,
represented in NOx
molecule parts per
million non-NOx
molecules in exhaust
bank 1.
3226 After treatment 1 The amount of 4,5,7,8,9,10,17,18,19
Outlet NOx combined NO and ,20
NO2 in the exhaust
entering the after
treatment system.
Measured by a NOx
sensor at the after
treatment outlet,
represented in NOx
molecule parts per
million non-NOx
molecules in exhaust
bank 1.
3241 After treatment The reading from 2,3,4,5,8,10,16,18,19
1 Exhaust Gas the exhaust gas
Temperature 1 temperature sensor
located farthest
upstream in the after
treatment system in
exhaust bank 1.
3242 After treatment 1 Temperature of 0,7,9,10,16
Diesel Particulate engine combustion
Filter Intake by products entering
Temperature the diesel particulate
filter in exhaust bank
1.
3245 After treatment 1 The reading from the 19
Exhaust Temperature exhaust temperature
3 sensor located
farthest downstream
in the after treatment
system in exhaust
bank 1.
3246 After treatment 1 Temperature of 2,3,4,9,15,16
Diesel Particulate engine combustion by
Filter Outlet products leaving the
Temperature diesel particulate filter
exhaust in exhaust
bank 1.

Troubleshooting 10

3249 Aftertreatment The reading from
located midstream
of the other two
temperature sensors
in the aftertreatment
system in exhaust
bank 1.
3251 After treatment 1 Exhaust differential 2,7,8,9
Diesel Particulate pressure measured
Filter Differential between the intake
Pressure and exhaust of a
diesel particulate filter
in exhaust bank 1.
located farthest
upstream in the
aftertreatment system
in exhaust bank 2.
located farthest
downstream in the
in exhaust bank 2.
located midstream
of the other two
temperature sensors
in the aftertreatment
system in exhaust
bank 2.
3340 Engine Charge Air Pressure of air at 1,3,4,7,9,10,15,16,20
Cooler 1 Intake intake to first or only ,21
Pressure charge air cooler, from
multiple first stage
turbochargers being
cooled and feeding
multiple second stage
turbochargers.

10 Troubleshooting

3360 After treatment 1 The catalyst tank 0,1,2,3,4,5,6,7,9,10,1
SCR Catalyst Tank controller can read 2,16,19
Controller the attributes of the
catalyst reagent.
Such as the catalyst
reagent level, catalyst
reagent temperature,
and catalyst reagent
quality.
3361 After treatment 1 SCR The catalyst dosing 3,5,10
Catalyst Dosing Unit unit is a device that
mixes the catalyst
reagent and air, and
delivers a metered
quantity of this mixture
to the exhaust stream.
3362 After treatment 1 The diesel exhaust 2
Diesel Exhaust Fluid fluid dosing unit is a
Dosing Unit Input device that mixes the
Lines diesel exhaust fluid
and air. Such that it
contains an input line
from the air tank and
an input line from the
diesel exhaust fluid
tank.
3363 After treatment 1 SCR Percentage of heating 0,2,3,4,5,8,15,16,17,
Catalyst Tank Heater applied to the catalyst 18
tank heater.
3464 Engine Throttle The control command 2,3,4,5,6,7,8
Actuator 1 Control to throttle actuator 1,
Command normalized to percent,
where 0% represents
fully closed and 100%
represents fully open.
3468 Engine Fuel Temperature 2 of fuel.
Temperature 2
3471 Aftertreatment 1 Fuel Diagnostic SPN
Pressure Control for the actuator
Actuator controlling
aftertreatment 1 fuel
pressure.
3472 Aftertreatment 1 Air Diagnostic SPN
Pressure Control for the actuator
Actuator controlling
aftertreatment 1 air
pressure.
3480 Aftertreatment 1 Fuel First fuel pressure
Pressure 1 measurement for
the aftertreatment 1
system.

Troubleshooting 10

3485 After treatment 1 Pressure of the supply 1,2,3,4,7,9,18,20
Supply Air Pressure air for after treatment
1. Supply air is the
air supplied from a
pneumatic line for
an air-assisted or
pneumatic actuator.
3515 Aftertreatment 1 Temperature of the
Diesel Exhaust Fluid diesel exhaust fluid at
Temperature 2 the device measuring
quality.
3516 Aftertreatment 1 A measure of the
Diesel Exhaust Fluid concentration of urea
Concentration in water.
3563 Engine Intake The absolute 11,15,17
Manifold #1 Absolute pressure
Pressure measurement of the
air intake manifold.
If there are multiple
air pressure sensors
in the intake stream,
it is the last one
in flow direction
before entering the
combustion chamber.
3606 Engine Controlled A signal issued by
Shutdown Request the engine control
system to a user
or external system
requesting for a
controlled shutdown.
3607 Engine Emergency A signal issued by the 2
(Immediate) engine control system
Shutdown Indication to a user or external
system indicating
that it is immediately
shutting the engine
down. This indication
is made when engine
protection diagnostics
determine a condition
necessitates an
immediate shutdown.
3673 Engine Throttle Valve The sensed position 3,4
2 Position feedback of the valve,
coming from a second
electrical actuator
for a second throttle
plate, used to regulate
the supply of a fluid,
usually air, or fuel / air
mixture.

10 Troubleshooting

3822 Engine Exhaust Gas The position of the 3,4,7,8,12,13,16,19,2
Recirculation 1 Valve second exhaust gas 0,21
2 Position recirculation valve
expressed as a
percentage of full
travel. Zero percent
means that the valve
is closed and no
exhaust gas is flowing
into the intake air
stream. One hundred
percent means that
the valve is fully
opened.
3936 After treatment Diesel Indicates non-specific 2,6,10
Particulate Filter failures of the after
System treatment diesel
particulate filter
system.
4090 NOx limits exceeded, Indicates that 0,11,16
root causes unknown On-Board Diagnostics
has determined that
the limits for NOx in
the exhaust stream
have been exceeded.
The root cause,
cannot be determined
by the OBD system.
4094 NOx limits exceeded On-Board Diagnostics
due to Insufficient has determined that
Diesel Exhaust Fluid the limits for NOx in
Quality the exhaust stream
have been exceeded
due to an insufficient
quality.
4095 NOx limits exceeded Indicates that 2
due to Interrupted On-Board Diagnostics
Reagent Dosing has determined that
the exhaust stream
have been exceeded
due to an Interruption
in reagent dosing
activity.
due to Empty On-Board Diagnostics
Reagent Tank has determined that
the exhaust stream
have been exceeded
due to the reagent
tank being empty.

Troubleshooting 10

4201 Engine Speed 1 The engine speed as 2,4,7,8,9,10
measured by speed
sensor 1.
4202 Engine Speed 3 The engine speed as 2
measured by speed
sensor 3.
due to error in the On-Board Diagnostics
NOx control system has determined that
the exhaust stream
have been exceeded
due to an error in the
NOx control system.
4301 Aftertreatment 1 Fuel Heating level that
Injector 1 Heater the controller is
Control commanding the
aftertreatment 1 fuel
injector 1 heater
control to maintain.
4334 After treatment 1 The SCR dosing 0,1,2,3,6
SCR Dosing Reagent reagent absolute
Absolute Pressure pressure (measured
closest to dosing
valve) for after
treatment system
1 (exhaust bank 1).
4337 Aftertreatment 1 The diesel exhaust
Diesel Exhaust Fluid fluid dosing
Dosing Temperature temperature
(measured closest
to dosing valve) for
1 (exhaust bank 1).
4341 Aftertreatment 1 Used to identify the
Diesel Exhaust applicable J1939-73
Fluid Line Heater FMI detected in the
1 Preliminary FMI diesel exhaust fluid
line heater 1, by
the manufacturer’s
control software in
exhaust bank 1.
line heater 2, by
control software in
exhaust bank 1.

10 Troubleshooting

line heater 3, by
control software in
exhaust bank 1.
line heater 4, by
control software in
exhaust bank 1.
4374 After treatment 1 SCR Rotational speed of 0,1
Catalyst Reagent the motor driving a
Pump Motor Speed pump for reagent
used in an after
treatment system.
4427 Aftertreatment 2 Temperature of the
Diesel Exhaust Fluid diesel exhaust fluid in
Tank Temperature the storage tank.
4782 After treatment 1 Soot density in diesel 0,16
Diesel Particulate particulate filter 1.
Filter Soot Density
4809 After treatment 1 It is the temperature 2,7,8,9,16,18
Warm Up Diesel measured at the
Oxidation Catalyst intake of the warm-up
Intake Temperature oxidation catalytic
converter in exhaust
bank 1.
4810 After treatment 1 After treatment 1 9,18
Warm Up Diesel Warm Up Diesel
Oxidation Catalyst Oxidation Catalyst
Outlet Temperature Outlet Temperature
4814 Engine Coolant Pump Command for a 2,3,4,7,8,10
Command coolant pump that can
be driven at varying
output level.
5264 Engine Exhaust Desired percentage
Gas Recirculation 2 of maximum Exhaust
(EGR2) Valve Control Gas Recirculation
2 (EGR2) valve
opening. 0%
means the valve is
closed. 100% means
maximum opening
(full gas flow).

Troubleshooting 10

5265 Engine Exhaust Desired percentage
Gas Recirculation of maximum Exhaust
2 (EGR2) Valve 2 Gas Recirculation
Control 2 (EGR2) valve
2 opening. 0%
means the valve is
closed. 100% means
maximum opening
(full gas flow).
5285 Engine Charge Air Engine charge air 1
Cooler 1 Efficiency cooler 1(CAC1)
efficiency is an
indication of the CACs
ability to reduce the
temperature of the
combustion air that is
being routed through
the CAC1.
5401 Engine Turbocharger Diagnostic SPN 2,3,4,5
Turbine Bypass for the actuator
Actuator controlling the engine
turbocharger turbine
bypass valve.
5419 Engine Throttle Device used to control 2,3,5,6,9,10,11,12,13
Actuator 1 the flow of air or ,14,16,19,31
air/fuel mix to the
engine.
5421 Engine Turbocharger Primary device used 3,4,5,6
1 Waste gate Actuator to control the waste
1 gate on turbocharger
1.
5435 Aftertreatment 1 State of
Diesel Exhaust Fluid Aftertreatment 1
Pump State Diesel Exhaust Fluid
dosing pump.
5485 Aftertreatment 1 The Exhaust
Diesel Exhaust Fluid Emission Controller
Pump Orifice Flow aftertreatment
reagent pump orifice
flow. Could indicate
that the flow is being
restricted.
5541 Engine Turbocharger Gage pressure of
1 Turbine Outlet the combustion
Pressure by-products exiting
the turbine side of the
turbocharger 1.

10 Troubleshooting

5543 Engine Exhaust The control command 2,3,4,5,6,7,12,13,16,
Brake Actuator applied to the engine 19,21
Command exhaust brake
actuator, where 0%
represents no braking
and 100% represents
full braking.
5706 Aftertreatment 1 Percentage of
Diesel Exhaust Fluid heating applied to
Pump Heater the aftertreatment 1
pump heater.
5743 After treatment Modules take 2,4,5
Selective Catalytic temperature sensor
Reduction inputs from the After
Temperature Sensor treatment Selective
Module Catalytic Reduction
Temperature Sensors
and multiplex the
sensor values to the
engine ECU via the
J1939 network.
5745 After treatment 1 After treatment DEF 3,5
Diesel Exhaust Fluid heater internal to
Dosing Unit Heater the After treatment
Dosing Unit.
5841 Diesel Exhaust Fluid Indicates that the 1
Quality Malfunction diagnostic system
has determined
that the engine has
been operated with
a diesel exhaust
fluid (reagent) quality
malfunction.
7461 Aftertreatment 1 Rotational speed of
Diesel Exhaust Fluid the motor driving
Pump 2 Motor Speed a pump for diesel
exhaust fluid used
in an aftertreatment
system.
a. Possible FMIs, for an explanation of the code see the table under the heading fault type
identifier.

Troubleshooting 10
10.5 Constant Speed Engine Fault Codes

(1) SPN and FMI Fault Codes For Constant Speed
Table 10.2 - SPN and FMI Descriptions
SPN FMI Description of Fault Corrective Action
000028 03 Throttle #3 Signal Out of Range High Check Sensor and Wiring
04 Throttle #3 Signal Out of Range Low Check Sensor and Wiring
000029 03 Throttle #2 Signal Out of Range High Check Sensor and Wiring
04 Throttle #2 Signal Out of Range Low Check Sensor and Wiring
000084 31 Vehicle Speed Signal Unreliable Contact Servicing Dealer
000091 03 Throttle #1 Signal Out of Range High Check Switch and Wiring
04 Throttle #1 Signal Out of Range Low Check Switch and Wiring
09 Throttle #1 Communication Signal Check Sensor and Wiring
Erratic
000094 03 Low Pressure Fuel Signal Out of Range Check Sensor and Wiring
High
04 Low Pressure Fuel Signal Out of Range Check Sensor and Wiring
Low
10 Low Pressure Fuel Rate of Change Contact Servicing Dealer
Abnormal
13 Low Pressure Fuel Out of Calibration Contact Servicing Dealer
17 High Pressure Fuel System- Pressure Contact Servicing Dealer
Slightly Low
000097 00 Water in Fuel Continuously Detected Contact Servicing Dealer
03 Water-in-Fuel Signal Out of Range High Check Sensor and Wiring
04 Water-in-Fuel Signal Out of Range Low Check Sensor and Wiring
16 Water in Fuel Detected Stop and Drain Water
Separator
000100 01 Engine Oil Pressure Signal Extremely Check Oil Level
Low
03 Engine Oil Pressure Signal Out of Check Sensor and Wiring
Range High
04 Engine Oil Pressure Signal Out of Check Sensor and Wiring
Range Low
18 Engine Oil Pressure Signal Moderately Check Oil Level
Low
000105 00 Intake Manifold Air Temperature Signal Check Air Cleaner,
Extremely High Aftercooler, or Room
Temperature
03 Intake Manifold Air Temperature Signal Check Sensor and Wiring
Out of Range High
04 Intake Manifold Air Temperature Signal Check Sensor and Wiring
Out of Range Low

10 Troubleshooting
SPN FMI Description Of Fault Corrective Action

16 Intake Manifold Air Temperature Signal Check Air Cleaner,
Moderately High Aftercooler, or Room
Temperature
000107 00 Air Filter Pressure Differential Extremely Check for plugged air
High filter
000110 00 Engine Coolant Temperature Signal Check Cooling System,
Extremely High Reduce Power
03 Engine Coolant Temperature Signal Check Sensor and Wiring
Out of Range High
04 Engine Coolant Temperature Signal Check Sensor and Wiring
Out of Range Low
15 Engine Coolant Temperature Signal Check Cooling System,
Slightly High Reduce Power
16 Engine Coolant Temperature Signal Check Cooling System,
Moderately High Reduce Power
000111 01 Engine Coolant Level Low Check Operator's
Manual, “Adding
Coolant”
000158 17 ECU Power Down Error (Internal ECU Contact Servicing Dealer
Problem)
000160 02 Axle Speed Signal Unreliable Contact Servicing Dealer
000174 00 Fuel Temperature Signal Extremely Add Fuel or Switch Fuel
High Tanks
000174 03 Fuel Temperature Signal Out of Range Check Sensor and Wiring
High
04 Fuel Temperature Signal Out of Range Check Sensor and Wiring
Low
16 Fuel Temperature Signal Moderately Add Fuel or Switch Fuel
High Tanks
000189 00 Engine Speed Derate Condition Exists Check Fault Codes or
Contact Servicing Dealer
000190 00 Engine Speed Extremely High Reduce Engine Speed
16 Engine Speed Moderately High Reduce Engine Speed
000611 03 Injector Shorted to Power Check Wiring
04 Injector Shorted to Ground Check Wiring
000620 03 Sensor Supply 2 Voltage High Check Wiring
04 Sensor Supply 2 Voltage Low Check Wiring
000627 01 All Injector Currents Are Low Check Battery Voltage
and Wiring
000629 13 ECU Programming Error Contact Service Dealer
000636 02 Engine Position Sensor Signal Check Sensor and Wiring
Unreliable
08 Engine Position Sensor Signal Missing Check Sensor and Wiring

Troubleshooting 10

10 Engine Position Sensor Signal Rate of Check Sensor and Wiring
Change Abnormal
000637 02 Engine Timing Sensor Signal Unreliable Check Sensor and Wiring
07 Engine Timing and Position Sensors Check Sensor and Wiring
Out of Sync
08 Engine Timing Sensor Signal Missing Check Sensor and Wiring
10 Engine Timing Signal Rate of Change Check Sensor and Wiring
Abnormal
000639 13 CAN Bus Error (Communication Contact Servicing Dealer
network problem)
000651 05 Injector Number 1 Circuit Has High Check Injector Wiring or
Resistance Injector Solenoid
06 Injector Number 1 Circuit Has Low Check Injector Wiring or
07 Injector Number 1 Not Responding Injector Failed or Flow
Limiter Closed
Limiter Closed
Limiter Closed
Limiter Closed
Limiter Closed

10 Troubleshooting

Limiter Closed
000898 09 Vehicle Speed or Torque Message Contact Servicing Dealer
Unreliable
000970 31 External Shutdown Commanded Not Engine Fault. Check
Other Shutdown Devices
000971 31 External Fuel Derate Switch Active Not Engine Fault. Check
Other Shutdown Devices
001069 09 Tire Size Invalid Contact Servicing Dealer
31 Tire Size Error Contact Servicing Dealer
001079 03 Sensor Supply 1 Voltage High Check Wiring
04 Sensor Supply 1 Voltage Low Check Wiring
001080 03 Fuel Rail Pressure Sensor Supply Check Wiring
Voltage High
04 Fuel Rail Pressure Sensor Supply Check Wiring
Voltage Low
001109 31 Engine Protection Shutdown Warning Shut Down Engine,
Check Fault Codes
001110 31 Engine Protection Shutdown Shut Down Engine,
Check Fault Codes
001347 03 High Pressure Fuel Pump Control Valve Contact Servicing Dealer
Signal Out of Range High
05 High Pressure Fuel Pump Solenoid Check Pump Wiring
Number 1 Circuit Has High Resistance
07 High Pressure Fuel Pump Not Able to Check Fuel Filter and
Meet Required Rail Pressure Lines
001568 02 Requested Torque Curve Signal Contact Servicing Dealer
Unreliable
001569 31 Engine in Derate Condition Check Fault Codes
002000 13 Security Violation Contact Servicing Dealer

Troubleshooting 10
10.6 Machine Troubleshooting

(1) Accessing Active Alarms And Alarm History
NOTICE
The control panel screen will automatically display all active faults.
PROCEDURE

4. With the information screen displayed, press the alarm faults / alarm history button (Item 1,

10 Troubleshooting
5. Any active faults are shown on the fault screen. When, a fault has been rectified a red x is
displayed over the alarm symbol (Item 1, Reference; Figure 10.15).
Figure 10.15 - Active Alarm Fault Screen

6. To acknowledge the alarm and clear the fault when rectified, use the scroll button (Item
2, Reference; Figure 10.15) and highlight the fault. Press the scroll button to okay and
acknowledge the fault.
» The fault clears from the screen. Any active or uncleared alarms remain.
7. To access the alarm history log, press the alarm history button (Item 3, Reference; Figure
10.15).
Figure 10.16 - Alarm History Screen

8. On the alarm history screen, the left and right arrow buttons (Items 1 & 2, Reference; Figure
10.16) allow the operator to scroll through the alarm fault history.

Troubleshooting 10
(2) Machine Diagnostic Fault List

NO: Alarm Alarm Icon
1 Emergency Stop
2 Safe Output Monitor Fault
3 Umbilical Stop
4 Radio Stop Fault
5 Radio Signal Lost
7 Inhibit Tracking
9 Engine Fault Reported
10 Engine Stopped
11 Engine Maintenance Due

(Cat Engine Only)
12 Urea Low

10 Troubleshooting

13 Nox Failure
17 J1939 Engine
Communication Fault
19 Fuel Level Low
20 Controller Communication
Lost
21 Can Bus Error
22 Node 1 Error
33 Clutch Fault
34 Clutch Lockout
35 Clutch Communication Fault
38 Hydraulic Oil Low

Troubleshooting 10

39 Hydraulic Oil Temperature
Critical
40 High Hydraulic Oil

Temperature
41 Hyd Oil Temperature Sensor

Open Circuit
42 Hyd Oil Temperature Sensor

Short Circuit
43 Main Conveyor Underspeed
69 Coolant Level Low (Volvo

Only)
170 Impactor Hood Open
172 Apron Pressure Fault
173 Apron Pressure Sensor

Fault

10 Troubleshooting

174 Clutch Slippage Pause
175 Clutch Slippage Shutdown

Troubleshooting 10
10.7 Clutch Diagnostic Data

(1) Accessing The PT Tech Status Screen
PROCEDURE


10 Troubleshooting
5. On the engine information screen press the press the clutch diagnostic button (Item 1,

6. The PT Tech status is displayed at the bottom of the screen. If, a fault or error occurs the
LED below the icon illuminates to indicate the problem.
Figure 10.20 - PT Tech Status Screen

7. To scroll through the SPN and FMI fault codes use the up and down buttons (Items 1 & 2,

Troubleshooting 10
(2) PT Tech Clutch Symbols Explained

Table 10.3 - Clutch Symbol Descriptions
Symbol Description Explanation
Power LED Indicator The "Power LED" illuminates to notify the operator
that the controller is receiving switched power from
the engine ignition switch.
IMPORTANT: The engine ignition switch must be
sending power to the controller in all switched
positions except when the engine ignition switch
is in the off position. If the power supplied to the
controller is below 20 volts, the "Power LED"
flashes and the clutch cannot engage.
INPUT Speed Detected When the engine is running, the "INPUT SPEED
LED Indicator DETECTED LED" must be illuminated steady. It
indicates that the controller is receiving a good
input speed signal from either the J1939 CAN BUS
or the input speed pickup mounted on the HPTO
unit.
Pressure Transducer When the engine ignition switch in the ON
Detected LED Indicator position and the controller is powered on, the
"PRESSURE TRANSDUCER DETECTED LED"
must be illuminated steady. It indicates that
the controller is receiving a good signal from
the pressure transducer mounted in the HPTO
hydraulic manifold at the location stamped "PS/PT".
CAUTION: the illumination of the Pressure.
Transducer LED does NOT indicate that system
pressure is good.
SAE J1939 CAN BUS The "CAN LED" illuminates to notify the operator
Detected LED Indicator that the controller is connected to a J1939 CAN
BUS and is receiving error-free communication.
During, this time the controller uses the J1939
CAN engine speed signal for operation. If
communication with the J1939 CAN is lost, the
controller automatically looks for and uses an input
speed coming from a magnetic speed pickup.
During, this time the "SAE J1939 CAN LED"
flashes to indicate that the controller has lost J1939
CAN communications and is running off a magnetic
speed pickup for input speed.
Once the engine ignition is cycled off and then
back on, the controller attempts to re-establish
J1939 CAN communications. If the controller is not
connected to a J1939 CAN BUS, then the "SAE
J1939 CAN LED" is extinguished.

10 Troubleshooting

Clutch Engagement To engage the clutch, the "Engage/Disengage
signal" must be sent for 3 seconds. Once the
"CLUTCH ENGAGED LED" starts flashing. The
controller begins the engagement of the clutch and
perform a series of "bumps" to bring the impactor
up to engine speed.
During this time the "CLUTCH ENGAGED LED"
flashes to indicate that the clutch is in the process
of engaging. Once, the clutch is engaged the
"CLUTCH ENGAGED LED" illuminates steady. At
this point, engine speed is increased and normal
machine operation can take place.
FAULT – OIL The Oil Pressure Transducer sends a signal to the
PRESSURE Loss controller. The signal provides the controller with
the precise oil pressure in the clutch and manifold.
The controller monitors the clutch oil pressure with
the clutch both engaged and disengaged.
WARNING: DO NOT run the engine while a
pressure fault is occurring. A pressure fault could
starve the clutch of necessary lubrication oil. Shut
down the system and locate the cause of the
pressure fault to avoid possible damage to vital
HPTO components.
If, there is a pressure loss while the clutch is
disengaged the "OIL PRESSURE LED" illuminates
steady. The controller stops the clutch becoming
engaged. When oil pressure returns to normal, the
LED turns off.
If there is a pressure loss while the clutch is
engaged, the controller disengages the clutch and
the "OIL PRESSURE LED" flashes to indicate that
there was a pressure loss while the clutch was
engaged.
SAFETY SWITCH The Equipment Safety Switch (customer supplied)
must be a normally closed switch (opens when
safety hazard exists).
The controller can be wired to a switch on the
equipment that, when open, prevents the clutch
from engaging. This switch could be attached to a
tub cover, mill box, and so on. When attempting to
engage the clutch, the "SAFETY SWITCH LED"
illuminates and prevent the clutch from engaging.
Correct the safety hazard and the light turns off.
WARNING: Once the clutch is engaged, if this
switch opens, the fault is displayed but the clutch
wont, disengage. This feature only prevents the
clutch from engaging.

Troubleshooting 10

TIMED LOCKOUT The controller allows 3 failed clutch startup attempts
in a row. After the third failed clutch startup attempt,
the controller will prevent the clutch from being
engaged for 5 minutes. While the clutch is in
lockout, the "TIMED LOCKOUT LED" illuminates to
indicate that the clutch is in lockout and cannot be
engaged. Once the lockout timer has expired, the
LED turns off and the clutch can be engaged.
CLUTCH OVERLOAD This clutch does not have an output speed sensor
(NOT AVAILABLE) and therefore this functionality is not utilized for
this controller.
RPM Too High LED The engine rpm must be below 1200 rpm to allow
while attempting to the clutch to disengage. If the engine speed is
disengage above this limit while attempting to disengage the
clutch, the "RPM TOO HIGH LED" illuminates
steady. Reduce engine speed below 1200
rpm and the LED turns off. Reattempt clutch
disengagement.
RPM Too High LED If, while the clutch is engaged, the speed of the
while fully engaged engine drops below 500 rpm. The controller
attempts to disengage the clutch before the
engine comes to a complete stall. If, it occurs the
"RPM TOO HIGH LED" flashes and the clutch
disengages. The purpose of this functionality is to
attempt to prevent the engine from stalling when
the clutch sees a sudden shock load. A shock
possibly caused by a locked or jammed rotor in
the equipment. The lockout timer is activated for 5
minutes when this condition occurs.
ATTENTION: Once the lockout timer has expired,
shut off the engine and clear any jammed object
from the rotor before attempting to re-engage the
clutch.

10 Troubleshooting
(3) PT Tech SPN and FMI Fault Codes

SPN FMI Parameters FMI Parameter Ad- Ad- Adv- Ba- Ba-
Description Description v4 v3 2R sic 2 sic R
525100 4 Low Voltage at Voltage Below Machine battery
Clutch Controller Normal, or Shorted voltage is below
to Low Source 20 volts while X X X X X
attempting to
engage clutch.
521501 5 Machine Ignition Current Below Input Speed
Voltage Missing Normal or Open detected but no
at Clutch Circuit voltage received X X X X X
Controller from engine
ignition switch.
521502 11 Input Speed Root Cause Not Input Speed
Missing Known missing while
attempting to X X X X X
engage the
clutch.
521503 4 Pressure Voltage Below Pressure
Transducer Fault Normal, or Shorted Transducer
to Low Source offset is returning X X X
a voltage below
0.9 volts.
521503 3 Pressure Voltage Above Pressure
Transducer Fault Normal, or Shorted Transducer
too High Source offset is returning X X X
a voltage above
1.2 volts.
521504 18 Clutch Oil Data Valid but Clutch oil
Pressure Fault Below Normal pressure is low. X X X X X
Operating Range
521505 18 Clutch Oil Data Valid but Clutch
Pressure Fault Below Normal disengaged due
while Engaged Operating Range to a pressure X X X X X
fault while it was
engaged.
521506 16 Clutch Oil Data Valid but Clutch oil
Temperature Above Normal temperature is X X X
Fault Operating Range too high.
521507 16 Clutch Oil Data Valid but Clutch
Temperature Above Normal disengaged after
Fault while Operating Range 15 minutes of a X X X
Engaged temperature fault
being reported.
521508 16 Clutch Oil Filter Data Valid but Filter is clogged
Clog Above Normal and must be X X X
Operating Range replaced.
521509 16 Clutch Oil Filter Data Valid but Clutch
Clog while Above Normal disengaged after
Engaged Operating Range 15 minutes of a X X X
filter clog being
reported.
521510 0 PWM Coil Fault - Data Valid but PWM wiring or
Maximum PWM Above Normal coil itself can
value reached Operating Range be defective,
low controller
X X X
input voltage, or
extreme high
temperature
operation.
521510 5 PWM Coil Fault Current Below PWM Coil can
Normal or Open be defective with
Circuit too high of a X X X
resistance or a
wire can be cut.

Troubleshooting 10
521510 6 PWM Coil Fault Current Above PWM Coil can
Normal or be defective
Grounded Circuit with too low of
X X X
a resistance or
a wire can be
grounded.
521511 5 ON/OFF Coil Current Below ON/OFF Coil
Fault Normal or Open can be defective
Circuit with too high of X X X X X
a resistance or a
wire can be cut.
521511 6 ON/OFF Coil Current Above ON/OFF Coil
Fault Normal or can be defective
Grounded Circuit with too low of
X X X X X
a resistance or
a wire can be
grounded.
521512 5 Equipment Current Below Switch not
Safety Normal or Open returning voltage
Fault while Circuit to the controller. X X X X
Disengaged Clutch cannot be
engaged
521513 5 Equipment Current Below Switch not
Safety Fault Normal or Open returning voltage
while Engaged Circuit to the controller.
Clutch wont X X X X
automatically
disengage due
to this fault.
521514 16 Engagement Data Valid but Clutch doesn't X X X X X
Prevented Above Normal engage when
because of Operating Range the engine speed
Engine Speed is above 1100
RPM.
521515 18 Engine Stalled Data Valid but Engine speed X X X X X
while Attempting Below Normal went to zero or
Engagement Operating Range was lost while
attempting to
engage the
clutch.
521516 16 Disengagement Data Valid but Clutch will not X X X X X
Prevented Above Normal disengage if the
because of Operating Range engine speed
Engine Speed is above 1200
RPM.
521517 1 Clutch Shock Data Valid but While, clutch X X X X X
load with Lockout Below Normal was engaged the
Operating Range engine speed
dropped below
500 RPM most
likely due to a
shock load at
the mill. Clutch
automatically
disengaged.
521518 0 Clutch Overload Data Valid but While attempting X X X
Above Normal to engage,
Operating Range the clutch
overload had
not completely
dissipated.

10 Troubleshooting
521519 0 Clutch Overload Data Valid but While attempting X X X
with Lockout Above Normal to engage the
Operating Range clutch. Or while
the clutch was
already engaged
too great a
difference
between clutch
input speed and
output speed
was detected
(slippage).
Clutch
automatically
disengaged.
521520 11 Clutch in Lockout Root Cause Not Clutch can go X X X X X
- Due to Other Known into lockout after
Reason 3 consecutive
attempts at any
of the following:
while attempting
engagement the
engine speed
goes to zero,
the operator
attempts to in-
crease engine
speed while the
clutch is engag-
ing, the operator
pushes the en-
gage/disengage
button while the
clutch is in the
process of en-
gaging.
521521 2 Lost Output Data Erratic, Output speed X
Speed Signal Intermittent, or signal present
Incorrect and then
NOT present
while engaged
or NEVER
present upon
engagement
attempt.
Possible
output speed
adjustment error
or transducer
failure causing
erratic output
speed signals.
521521 10 Noisy Output Abnormal Rate of Possible X
Speed Signal Change output speed
adjustment error
or transducer
failure causing
erratic output
speed signals.

Troubleshooting 10
521522 0 Brake NOT Data Valid but Pressure reading X
released before Above Normal NOT dropping
engagement Operating Range to zero before
attempt engagement
attempt.
Engagement
attempt aborted
because Brake
does NOT
appear to be
released.
521523 16 Engagement Data Valid but Clutch will not X X
Prevented Above Normal engage if the
because Output Operating Range output speed is
Speed is greater greater than the
than Engine engine speed.
Speed

10 Troubleshooting
10.8 Vee Belt Troubleshooting

Small Cracks on Vee belt side and Base
Caused by shortage of belt tension but excessive heat and/or chemical fumes can also give
same failure.
Vee Belt Swelling or Softening
Caused by excessive contamination by oil, certain cutting fluids, or rubber solvent.
Whipping During Running
Caused by incorrect tensioning, principally on long center drives. If, a slightly higher [or lower]
tension does not cure the problem there can be a critical vibration frequency in the system which
requires rectification. Consult your local Terex dealer or Terex Technical Support department.

Storage 11
Table of Content
11 Storage ...................................................................................................... 11-1
11.1 Storage......................................................................................................... 11-2

11 Storage
11 Storage
11.1 Storage
On receipt of the machine and the separate lubrication and hydraulic equipment and carry
out a careful inspection and immediately report any component damage or loss. Conduct
a careful visual check of the machine and check all the separate loose items against the
equipment delivery note.
The equipment should be stored in a dry, well-ventilated area free of excessive dust. All
openings should be sealed to prevent the ingress of dirt or moisture.
For machines that are kept in storage, start the engine, and run all machine functions for at
least a few minutes every 8 weeks.
Running all machine functions ensures that all moving parts have been activated. Activating
all moving parts prevents bearing corrosion and other potential problems that occur due to a
lack of use.
If the machinery cannot be stored indoors it must be sheeted over and made thoroughly
weatherproof to avoid deterioration.
Contact Terex for advice on any situation wherever storage or inactivity is in excess of that
reasonably to be expected or where a possibly hostile environment exists, as the defects
liability warranty may be affected.

Glossary Of Terms 12
Table of Content
12 Glossary Of Terms....................................................................................12-1
12.1 Glossary Of Terms ....................................................................................... 12-2

12 Glossary Of Terms
12.1 Glossary Of Terms
Assemblies
Individual sections of the platform made up of different components parts.
Auxiliary Control Valve
A bank of hydraulic valves which carry out various movement functions throughout the platform.
Belt Scraper
A device fixed or flexible mounted across the width of a belt of a conveyor for removing
adherent material.
Centre Roller
A roller, which supports the loaded belt.
Control Panel
A panel that is situated on the machine which is used to start the engine and view the various
warning lights.
Controller
An electromechanical device or assembly of devices for starting, stopping, accelerating, or
decelerating a drive, or serving, to govern in some predetermined manner the power delivered
to the drive.
Conveyor
A horizontal, inclined, or vertical device for moving or transporting bulk material, packages,
or objects, in a path determined by the design of the device, and having points of adding
and discharge, fixed or selective.
Conveyor belt
A belt used to carry materials and transmit the power required to move the load being conveyed.
Conveyor, extendable
A conveyor that may be lengthened or shortened to suit operating needs.
Control Valve
A hydraulic valve, which carries out a movement function on the machine.
CSS (Closed Side Setting)
The region between the blow bars and the Aprons where the crushing takes place.
Depressurized
To release the pressure from a vessel i.e. a tire, hydraulic system.
Discharge Area
The area where material is dumped from the machine.
Discharge Conveyor
Conveyor used to move the material from the hopper to the screen unit.
Drive
An assembly of the necessary structural, mechanical, and electrical parts provide the motive
power to change direction.
Drive Drum
The drum that drives the conveyor belt sometimes called the head drum.

Non Drive Drum

The drum that is non-driven in the conveyor belt sometimes called the tail drum.
Feed Conveyor
Conveyor used to move the material from the hopper to the main conveyor.
Feedboot
An extended metal surround located at the bottom of the main, tail & side conveyors.
Feeder Unit
Conveyor which feeds the material onto the incline conveyor at an even rate.
Filler Cap
A cap used to seal a tank and is removed in order to fill the tank.
Fines Material
Material that is screened through the VGF/Prescreen and is discharged on to the tail conveyor.
Four Bank
A bank of hydraulic control valves used to control functions of the machine.
Flywheel
A half moon shaped counter weight, which is mounted on the screen unit shaft for the purpose
of counter acting the weight of the eccentric of the screen shaft.
Gate
A device or structure by means of which the flow of material may be stopped or regulated; also
a section of a machine equipped with a hinge mechanism for movable service often called a
hinge section.
Grid Aperture
The spacing between the grid bars (typically 100mm) which determines the material size that
enters the feed hopper.
Guard
A covering, barricade, grating, fence, or other form of barrier used to prevent inadvertent
physical contact with operating components such as gears, sprockets, chains, and belts.
Hopper
A box having a funnel shaped bottom, or a bottom reduced in size, narrowed, or necked to
receive material and direct it to a conveyor, feeder, or chute.
Hydraulic Components
A part used in the hydraulic system of the machine i.e. valve, motor etc.
Jacking legs
Hydraulic adjustable legs which raise or lower the back of the machine for the purpose of
coupling to the tractor unit.
Landing Leg
A support leg which lowers from the machine and is used to stabilise it whilst in the working
position.
LHS
Left Hand Side, used with reference to the side conveyors.
Lockout

Procedure to be carried out to ensure the machine is safe for maintenance or repairs.
Machine Stop
A stop arising from a sudden and unexpected need, and not as a part of the normal operation.
Nip Point
A point at which a machine element moving in line meets a rotating element in such a manner
that it is possible to nip, pinch, squeeze, or entrap a person or objects coming into contact
with one or two of the members.
Congealed lumps in the product usually due to an excessive percentage of fines in the feed.
Platform
A working space for persons, elevated above the surrounding floor or ground for the operation
of machinery and equipment.
Power unit
An inclosed unit situated under the main conveyor which houses the component parts which
together drive the machine.
Prevent
When used in a context such as prevent access or prevent physical contact, means to impede
or block; when used in a context such as prevent injury, means to reduce the chances of, but
does not imply that an injury cannot occur.
P.S.I
Pounds per square inch. Unit of Pressure. Conversion 1 Bar = 14.5 P.S.I
Rated speed
The speed, as established by the manufacture or a qualified person, at which safe and
satisfactory service can be expected.
Recommissioning
To prepare the machine for use.
Remote control
Any system of controls in which the actuator is situated in a remote location.
Retract
Withdraw or fold up conveyor.
Return Roller
A roller, which is used to support the unladened belt on the underside of the conveyor.
RHS
Right Hand Side, used with reference to the side conveyors.
Safety device
A mechanism or an arrangement placed in use for the specific purposes of preventing an
unsafe condition, preventing the continuation of an unsafe condition, warning of an unsafe
condition, or limiting or eliminating the unsafe effects of a possible condition.
Scraper
A device fixed or flexibly mounted across the width of a belt of a conveyor for removing
adherent material.
Vibratory unit used to separate by size raw materials.
Should

As used in the context of a provision of this manual, indicates a recommendation, the

advisability of which depends on the facts in a particular situation.
Bypass Conveyor
Conveyor used to collect the material from the screen unit and move it to the discharge area at
90 degrees to the main machine.
Side Roller
Roller used to create arc on the belt to reduce spillage.
Spillage
Material that spills over the edge of a conveyor etc.
Sprocket
A toothed wheel arranged to fit into the links of a chain.
Strut
Rigid support used to hold an assembly in place.
Take-up
The assembly of the necessary structural and mechanical parts that provides the means to
adjust the length of belts, cables, chains, etc. to compensate for stretch, shrinkage, and wear.
Telescopic Head Section
A section of a conveyor which extends out telescopically into transport position.
Tracks
The beams, shapes, or formed section on which trolleys, rollers, shoes, or wheels roll or slide
while propelled.
Transport Bracket
A bracket used to hold an assembly in place whilst in transport.
Transport Position
The position of the machine when conveyors are folded.
Underpan Feeder
Vibrating unit which feeds the discharge conveyor.
Variable Speed Flow Control
A device which is used to hydraulically vary the speed of the conveyor belt.
Caused by excessive contamination by oil, certain cutting fluids or rubber solvent.
Drive belts Whipping During Running — Usually caused by incorrect tensioning, principally
on long centre drives.
If a slightly higher [or lower] tension does not cure the problem there may be a critical vibration
frequency in the system which requires rectification.
Viewing Apertures
Opening holes to view the conveyor belt.
Vulcanized Belt
A conveyor belt that has been joined seamlessly using a special treatment.
Wearing parts — Components subject to wear from the stone being crushed. Mainly the
blow bars.


Declaration Of Conformity A
Appendix A Declaration Of Conformity

A.1 Declaration Of Conformity
This machine is in conformity with the provisions of the EC Machinery Directive 2006/42/EC
together with appropriate EN Harmonized Standards and National BS Standards and
Specifications.
A Declaration of Conformity certificate is applicable to each machine. The original copy of
the certificate is sent out with the machine.
The following example page shows the Declaration of Conformity certificate and the information
which must be included in it.
Each item of information on the example is numbered and the list of explanations refer to the
corresponding numbered items on the example.
1 Full name and address of the manufacturer of the machine.
2 The name of the person authorised to compile the technical file.
3 The address of the person authorised to compile the technical file.
4 The function of the machine.
5 The model or type of the machine.
6 Serial number or pin number of the machine.
7 Commercial name of the machine.
8 Manufacturers declaration of conformity to the Machinery Directive 2006/42/EC.
9 Manufacturers declaration of conformity to the EMC Directive 2004/108/EC.
10 The place where the machine was issued from.
11 The date on which the machine was issued.
12 Identification of the person empowered to sign on behalf of the manufacturer.

Cobra 290 and 290R Page A-1
A Declaration Of Conformity
Figure A.1 - Declaration of Conformity Example

Page A-2 Cobra 290 and 290R
Warranty B
Appendix B Warranty
B.1 Non-USA Sales Warranty
Terex GB Ltd. and Terex USA, LLC (hereafter referred to collectively as “Seller”) warrants its
new Equipment, to be free of defects in material or workmanship for a period of (i) 12 months
from the date the Equipment is first placed into service, whether such Equipment is sold,
rented or leased or (ii) 2,000 hours of use, whichever first occurs, provided that in no event
shall this warranty extend beyond a period of 24 months from the date of shipment from the
factory; provided that (1) the Buyer or the end-user sends Seller written notice of the defect
within sixty (60) days of its discovery and establishes to the Seller's satisfaction that: (i) the
Equipment has been maintained and operated within the limits of rated and normal usage, and
that there have been no alterations to it; and (ii) the defect did not result in any manner from the
intentional or negligent action or inaction by Buyer or the end-user or any of their respective
agents or employees or any person using it and (2) a new machine registration certificate or the
commissioning documents have been completed, signed and delivered to Seller within thirty
(30) days of the equipment’s “in-service” date. If requested by Seller, Buyer must return the
defective equipment to Seller’s manufacturing facility, or other location designated by Seller, for
inspection, and if Buyer cannot establish that conditions (1) (i) and (1) (ii) above have been met,
then this warranty shall not cover the alleged defect.
Subject to the Buyer establishing that conditions (1)(i) and 1(ii) above have been met, Seller
warrants all Critical Components (as defined herein) to be free, under normal use and service,
of any defects in manufacture or materials for a period of: (1) twenty four (24) months from
the date of commissioning, (2) 4000 hours of use (except for Bison 35, Bison 100, Bison 120
and Harrier 220, for which 2500 hours shall apply), or (3) Thirty Six (36) months the date of
shipment from the factory, whichever occurs first. For the purposes of this warranty, Critical
Components shall mean:
• Jaw Machines :- Mainframe including Cross Beam, Eccentric Shaft, Jaw Stock, Toggle
Beam, Flywheels, Main Adjustment Cylinders on HA & HR Machines Only
• Impactor Machines (vertical and horizontal shaft):- Rotor, Main shaft, Crusher Body and
Drive Pulley
• Screen Boxes;- Screen Box Welded Assembly, Screen Box Sub frame, Main Shaft
Seller’s obligation and liability under this warranty is expressly limited to, at Seller’s sole
option, repairing or replacing, with new or remanufactured parts or components, any part,
which appears to Seller upon inspection to have been defective in material or workmanship.
Such parts shall be provided at no cost to the owner. If requested by Seller, components or
parts for which a warranty claim is made shall be returned to Seller at a location designated
by Seller. All components and parts replaced under this limited product warranty become
the property of Seller.
This warranty shall be null and void if parts (including wear parts) other than genuine OEM
Seller parts are used in the equipment.
Seller makes no other warranty, express or implied, and makes no warranty of merchantability
or fitness for any particular purpose.
No employee or representative is authorized to modify this warranty unless such modification is
made in writing and signed by an authorized officer of Seller.
Seller’s obligation under this warranty shall not include duty, taxes, environmental fees, including
without limitation, disposal or handling of tires, batteries, petrochemical items, or any other
charges whatsoever, or any liability for direct, indirect, incidental, or consequential damages.
Improper maintenance, improper use, abuse, improper storage, operation beyond rated
capacity, operation after discovery of defective or worn parts, accident, sabotage or alteration or
repair of the equipment by persons not authorized by Seller shall render this warranty null and
void. Seller reserves the right to inspect the installation of the product and review maintenance
procedures to determine if the failure was due to improper maintenance, improper use, abuse,

Cobra 290 and 290R Page B-1
B Warranty
improper storage, operation beyond rated capacity, operation after discovery of defective or
worn parts, or alteration or repair of the equipment by persons not authorized by Seller.
Parts Warranty: Seller warrants the parts ordered from the Seller’s parts department to be
free of defect in material or workmanship for either (1) a period of 12 months after date of
shipment from the factory or (2) 2000 hrs of use or (3) the balance of the remaining new
equipment warranty, whichever occurs first. With respect to parts ordered from the Seller’s
parts department for Equipment that is no longer covered under this limited product warranty
due to lapse of time or usage in excess of 4,000 hours of Critical Components, Seller warrants
such parts to be free of defect in material or workmanship for a period of either 12 months after
date of shipment from the factory or 2000 hrs of use, whichever occurs first.
Telematics. If a telematics system is included with the Equipment, the telematics system is
administered by a third party (Teleservices Provider) and collects a range of operational data
about the Equipment including, but not limited to, usage, performance and reliability. Buyer
consents to Seller’s obtaining such data from the Teleservices Provider for warranty, product
improvement and customer support purposes. Buyer understands that the Equipment warranty
is conditioned on the proper operation of the telematics system and Buyer shall not disable,
tamper or interfere with the telematics system. NO TRANSFERABILITY OF WARRANTY: This
warranty is limited to the original purchaser or original end-user if sold to a distributor, and is not
assignable or otherwise transferable without the written agreement of Seller. Please contact
your local distributor for additional details if needed.
NO TRANSFERABILITY OF WARRANTY: This warranty is limited to the original purchaser
or original end-user if sold to a distributor, and is not assignable or otherwise transferable
without the written agreement of Seller. Please contact your local distributor for additional
details if needed.
ITEMS NOT COVERED BY SELLER WARRANTY
The following items are NOT covered under the Seller Warranty (the following list is not
exhaustive):
1 Items sold by any individual, corporation, partnership or any other organization or legal
entity that is not an authorized Seller distributor.
2 Components which are not manufactured by Seller are not covered by Seller’s warranty.
Such components are covered only by the warranty that is provided by the manufacturer
of such components. Such components may include, but are not limited to, chassis,
air compressors, batteries, tires, engines, engine components, and customer supplied
products.
3 Replacement of assemblies: Seller has the option to repair or replace any defective part or
assembly. It is Seller’s policy to refuse claims for the replacement of a complete assembly
that is field repairable by the replacement or repair of defective part(s) within the assembly.
4 Normal Operational Maintenance Services and Wear Parts: Maintenance services and
wear parts are excluded from warranty claims. Maintenance services and wear parts not
covered include, but are not limited to, such items as: seals, gaskets, hoses, friction plates,
glass, clutch and brake linings, filters, wire rope, exterior coatings, proper tightening of
bolts, nuts and pipe fittings, adding or replacing of fluids, filters, belts, screening media,
rubber skirting, chute linings and paint, services supplies such as hand cleaners, towels
and lubricants, and inspections, diagnostic time and travel time.
5 Transportation cost and/ or damage: Any damage caused by carrier handling is a
transportation claim and should be filed immediately with the respective carrier.
6 Deterioration: Repairs, work required or parts exposed as the result of age, storage,
weathering, lack of use, demonstration use, or use for transportation of corrosive chemicals.
7 Secondary Failures: Should the owner or operator continue to operate a machine after it
has been noted that a failure has occurred, Seller will not be responsible under the warranty
for resultant damage to other parts due to that continued operation.

Page B-2 Cobra 290 and 290R
Warranty B
8 Workmanship of Others: Seller does not accept responsibility for improper installation or
labor costs or costs of any kind from personnel other than authorized Seller distributor
personnel.
9 Stop and Go Warranty: Seller does not recognize “Stop and Go” warranties.
10 INCIDENTAL OR CONSEQUENTIAL DAMAGE: SELLER SHALL NOT BE LIABLE FOR
ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND, INCLUDING,
BUT NOT LIMITED TO, LOST PROFITS, LOSS OF PRODUCTION, INCREASED
OVERHEAD, LOSS OF BUSINESS OPPORTUNITY, DELAYS IN PRODUCTION, COSTS
OF REPLACEMENT COMPONENTS AND INCREASED COSTS OF OPERATION THAT
MAY ARISE FROM THE BREACH OF THIS WARRANTY. CUSTOMER’S SOLE REMEDY
SHALL BE LIMITED TO (AT SELLER’S SOLE OPTION) REPAIR OR REPLACEMENT
OF THE DEFECTIVE PART.
THIS WARRANTY IS EXPRESSLY IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES,
EXPRESS OR IMPLIED (INCLUDING THE WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE) AND ALL OTHER OBLIGATIONS OR LIABILITY
ON SELLER'S PART. THERE ARE NO WARRANTIES THAT EXTEND BEYOND THE
LIMITED WARRANTY CONTAINED HEREIN.
Seller neither assumes nor authorizes any other person to assume for Seller any other liability
in connection with the sale of Seller’s equipment. This warranty shall not apply to any of Seller's
equipment or any part thereof which has been subject to misuse, alteration, abuse, negligence,
accident, acts of God or sabotage. No action by any party shall operate to extend or revive this
limited warranty without the prior written consent of Seller. In the event that any provision of
this warranty is held unenforceable for any reason, the remaining provisions shall remain in
full force and effect.
IN THE EVENT OF ANY BREACH OF THE WARRANTY BY SELLER, SELLER'S LIABILITY
SHALL BE LIMITED EXCLUSIVELY TO THE REMEDIES (AT SELLER’S SOLE OPTION)
OF REPAIR OR REPLACEMENT OF ANY DEFECTIVE EQUIPMENT COVERED BY THE
WARRANTY. IN NO EVENT SHALL SELLER, OR ANY AFFILIATE, SUBSIDIARY OR
DIVISION THEREOF BE LIABLE FOR ANY A) LOST PROFITS AND/OR BUSINESS
INTERRUPTION (WHETHER DIRECT OR INDIRECT); AND (B) INDIRECT, INCIDENTAL,
CONSEQUENTIAL (WHETHER DIRECT OR INDIRECT) OR OTHER DAMAGES OR
LOSSES OF ANY KIND, RESULTING FROM A BREACH OF WARRANTY INCLUDING,
WITHOUT LIMITATION, LABOR COSTS, LOSS OF USE OF OTHER EQUIPMENT, THIRD
PARTY REPAIRS, LOST PROFITS, LOST TIME, TOWING OR HAULING OF EQUIPMENT,
RENTAL COSTS, PERSONAL INJURY, EMOTIONAL OR MENTAL DISTRESS, IMPROPER
PERFORMANCE OR WORK, PENALTIES OF ANY KIND, LOSS OF SERVICE OF
PERSONNEL, OR FAILURE OF EQUIPMENT TO COMPLY WITH APPLICABLE LAWS.
THE SELLER’S LIABILITY TO THE BUYER SHALL NOT IN ANY EVENT EXCEED THE
PURCHASE PRICE OF THE EQUIPMENT, PROVIDED THAT NOTHING CONTAINED IN
THIS LIMITED PRODUCT WARRANTY SHALL OPERATE TO EXCLUDE THE SELLER’S
LIABILITY FOR DEATH OR PERSONAL INJURY.

B Warranty
B.2 USA Sales Warranty

Terex GB Ltd. and Terex USA, LLC (hereafter referred to collectively as “Seller”) warrants its
new Equipment, to be free of defects in material or workmanship for a period of (i) 12 months
from the date the Equipment is first placed into service, whether such Equipment is sold,
rented or leased or (ii) 2,000 hours of use, whichever first occurs, provided that in no event
shall this warranty extend beyond a period of 24 months from the date of shipment from the
factory; provided that (1) the Buyer or the end-user sends Seller written notice of the defect
within sixty (60) days of its discovery and establishes to the Seller's satisfaction that: (i) the
Equipment has been maintained and operated within the limits of rated and normal usage, and
that there have been no alterations to it; and (ii) the defect did not result in any manner from the
intentional or negligent action or inaction by Buyer or the end-user or any of their respective
agents or employees or any person using it and (2) a new machine registration certificate or the
commissioning documents have been completed, signed and delivered to Seller within thirty
(30) days of the equipment’s “in-service” date. If requested by Seller, Buyer must return the
defective equipment to Seller’s manufacturing facility, or other location designated by Seller, for
inspection, and if Buyer cannot establish that conditions (1) (i) and (1) (ii) above have been met,
then this warranty shall not cover the alleged defect.
Subject to the Buyer establishing that conditions (1)(i) and 1(ii) above have been met, Seller
warrants all Critical Components (as defined herein) to be free, under normal use and service,
of any defects in manufacture or materials for a period of: (1) twenty four (24) months from
the date of commissioning, (2) 4000 hours of use (except for Bison 35, Bison 100, Bison 120
and Harrier 220, for which 2500 hours shall apply), or (3) Thirty Six (36) months the date of
shipment from the factory, whichever occurs first. For the purposes of this warranty, Critical
Components shall mean:
• Jaw Machines :- Mainframe including Cross Beam, Eccentric Shaft, Jaw Stock, Toggle
Beam, Flywheels, Main Adjustment Cylinders on HA & HR Machines Only
• Impactor Machines (vertical and horizontal shaft):- Rotor, Main shaft, Crusher Body and
Drive Pulley
• Screen Boxes;- Screen Box Welded Assembly, Screen Box Sub frame, Main Shaft
Seller’s obligation and liability under this warranty is expressly limited to, at Seller’s sole
option, repairing or replacing, with new or remanufactured parts or components, any part,
which appears to Seller upon inspection to have been defective in material or workmanship.
Such parts shall be provided at no cost to the owner. If requested by Seller, components or
parts for which a warranty claim is made shall be returned to Seller at a location designated
by Seller. All components and parts replaced under this limited product warranty become
the property of Seller.
This warranty shall be null and void if parts (including wear parts) other than genuine OEM
Seller parts are used in the equipment.
Seller makes no other warranty, express or implied, and makes no warranty of merchantability
or fitness for any particular purpose.
No employee or representative is authorized to modify this warranty unless such modification is
made in writing and signed by an authorized officer of Seller.
Seller’s obligation under this warranty shall not include duty, taxes, environmental fees, including
without limitation, disposal or handling of tires, batteries, petrochemical items, or any other
charges whatsoever, or any liability for direct, indirect, incidental, or consequential damages.
Improper maintenance, improper use, abuse, improper storage, operation beyond rated
capacity, operation after discovery of defective or worn parts, accident, sabotage or alteration or
repair of the equipment by persons not authorized by Seller shall render this warranty null and
void. Seller reserves the right to inspect the installation of the product and review maintenance
procedures to determine if the failure was due to improper maintenance, improper use, abuse,
improper storage, operation beyond rated capacity, operation after discovery of defective or
worn parts, or alteration or repair of the equipment by persons not authorized by Seller.

Warranty B
Parts Warranty: Seller warrants the parts ordered from the Seller’s parts department to be
free of defect in material or workmanship for either (1) a period of 12 months after date of
shipment from the factory or (2) 2000 hrs of use or (3) the balance of the remaining new
equipment warranty, whichever occurs first. With respect to parts ordered from the Seller’s
parts department for Equipment that is no longer covered under this limited product warranty
due to lapse of time or usage in excess of 4,000 hours of Critical Components, Seller warrants
such parts to be free of defect in material or workmanship for a period of either 12 months after
date of shipment from the factory or 2000 hrs of use, whichever occurs first.
Telematics. If a telematics system is included with the Equipment, the telematics system is
administered by a third party (Teleservices Provider) and collects a range of operational data
about the Equipment including, but not limited to, usage, performance and reliability. Buyer
consents to Seller’s obtaining such data from the Teleservices Provider for warranty, product
improvement and customer support purposes. Buyer understands that the Equipment warranty
is conditioned on the proper operation of the telematics system and Buyer shall not disable,
tamper or interfere with the telematics system. NO TRANSFERABILITY OF WARRANTY: This
warranty is limited to the original purchaser or original end-user if sold to a distributor, and is not
assignable or otherwise transferable without the written agreement of Seller. Please contact
your local distributor for additional details if needed.
NO TRANSFERABILITY OF WARRANTY: This warranty is limited to the original purchaser
or original end-user if sold to a distributor, and is not assignable or otherwise transferable
without the written agreement of Seller. Please contact your local distributor for additional
details if needed.
ITEMS NOT COVERED BY SELLER WARRANTY
The following items are NOT covered under the Seller Warranty (the following list is not
exhaustive):
1 Items sold by any individual, corporation, partnership or any other organization or legal
entity that is not an authorized Seller distributor.
2 Components which are not manufactured by Seller are not covered by Seller’s warranty.
Such components are covered only by the warranty that is provided by the manufacturer
of such components. Such components may include, but are not limited to, chassis,
air compressors, batteries, tires, engines, engine components, and customer supplied
products.
3 Replacement of assemblies: Seller has the option to repair or replace any defective part or
assembly. It is Seller’s policy to refuse claims for the replacement of a complete assembly
that is field repairable by the replacement or repair of defective part(s) within the assembly.
4 Normal Operational Maintenance Services and Wear Parts: Maintenance services and
wear parts are excluded from warranty claims. Maintenance services and wear parts not
covered include, but are not limited to, such items as: seals, gaskets, hoses, friction plates,
glass, clutch and brake linings, filters, wire rope, exterior coatings, proper tightening of
bolts, nuts and pipe fittings, adding or replacing of fluids, filters, belts, screening media,
rubber skirting, chute linings and paint, services supplies such as hand cleaners, towels
and lubricants, and inspections, diagnostic time and travel time.
5 Transportation cost and/ or damage: Any damage caused by carrier handling is a
transportation claim and should be filed immediately with the respective carrier.
6 Deterioration: Repairs, work required or parts exposed as the result of age, storage,
weathering, lack of use, demonstration use, or use for transportation of corrosive chemicals.
7 Secondary Failures: Should the owner or operator continue to operate a machine after it
has been noted that a failure has occurred, Seller will not be responsible under the warranty
for resultant damage to other parts due to that continued operation.
8 Workmanship of Others: Seller does not accept responsibility for improper installation or
labor costs or costs of any kind from personnel other than authorized Seller distributor
personnel.

B Warranty
9 Stop and Go Warranty: Seller does not recognize “Stop and Go” warranties.
10 INCIDENTAL OR CONSEQUENTIAL DAMAGE: SELLER SHALL NOT BE LIABLE FOR
ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND, INCLUDING,
BUT NOT LIMITED TO, LOST PROFITS, LOSS OF PRODUCTION, INCREASED
OVERHEAD, LOSS OF BUSINESS OPPORTUNITY, DELAYS IN PRODUCTION, COSTS
OF REPLACEMENT COMPONENTS AND INCREASED COSTS OF OPERATION THAT
MAY ARISE FROM THE BREACH OF THIS WARRANTY. CUSTOMER’S SOLE REMEDY
SHALL BE LIMITED TO (AT SELLER’S SOLE OPTION) REPAIR OR REPLACEMENT
OF THE DEFECTIVE PART.
THIS WARRANTY IS EXPRESSLY IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES,
EXPRESS OR IMPLIED (INCLUDING THE WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE) AND ALL OTHER OBLIGATIONS OR LIABILITY
ON SELLER'S PART. THERE ARE NO WARRANTIES THAT EXTEND BEYOND THE
LIMITED WARRANTY CONTAINED HEREIN.
Seller neither assumes nor authorizes any other person to assume for Seller any other liability
in connection with the sale of Seller’s equipment. This warranty shall not apply to any of Seller's
equipment or any part thereof which has been subject to misuse, alteration, abuse, negligence,
accident, acts of God or sabotage. No action by any party shall operate to extend or revive this
limited warranty without the prior written consent of Seller. In the event that any provision of
this warranty is held unenforceable for any reason, the remaining provisions shall remain in
full force and effect.
IN THE EVENT OF ANY BREACH OF THE WARRANTY BY SELLER, SELLER'S LIABILITY
SHALL BE LIMITED EXCLUSIVELY TO THE REMEDIES (AT SELLER’S SOLE OPTION)
OF REPAIR OR REPLACEMENT OF ANY DEFECTIVE EQUIPMENT COVERED BY THE
WARRANTY. IN NO EVENT SHALL SELLER, OR ANY AFFILIATE, SUBSIDIARY OR
DIVISION THEREOF BE LIABLE FOR ANY A) LOST PROFITS AND/OR BUSINESS
INTERRUPTION (WHETHER DIRECT OR INDIRECT); AND (B) INDIRECT, INCIDENTAL,
CONSEQUENTIAL (WHETHER DIRECT OR INDIRECT) OR OTHER DAMAGES OR
LOSSES OF ANY KIND, RESULTING FROM A BREACH OF WARRANTY INCLUDING,
WITHOUT LIMITATION, LABOR COSTS, LOSS OF USE OF OTHER EQUIPMENT, THIRD
PARTY REPAIRS, LOST PROFITS, LOST TIME, TOWING OR HAULING OF EQUIPMENT,
RENTAL COSTS, PERSONAL INJURY, EMOTIONAL OR MENTAL DISTRESS, IMPROPER
PERFORMANCE OR WORK, PENALTIES OF ANY KIND, LOSS OF SERVICE OF
PERSONNEL, OR FAILURE OF EQUIPMENT TO COMPLY WITH ANY FEDERAL, STATE
OR LOCAL LAWS. THE SELLER’S LIABILITY TO THE BUYER SHALL NOT IN ANY EVENT
EXCEED THE PURCHASE PRICE OF THE EQUIPMENT

Warranty B
B.3 Machine Warranty Registration

To, register the warranty of this machine visit: https://mp-warranty.terex.com
B.4 Engine Warranty Registration
Depending, on the engine fitted to your machine you must also register the engine of your
product via:
John Deere
https://www.johndeere.com/enginewarranty
Volvo
http://www.volvopenta.com/brand/en-en/contact/dealers.html

B Warranty

Schematics C
Appendix C Schematics

Cobra 290 and 290R Page C-1
1 2 3 4 5 6 7 8 9
A A
B B
Project Name: COBRA ELECTRICAL SYSTEM REV5
C C
Company / Customer TEREX

Project Description COBRA
D Drawing Number MPESD_3109 D
For this document and the object represented in that we reserve all rights according to DIN 34.
Duplication announcement onto third party or utilization of his contents are without forbidden to our.
E E
Date Created 14/07/2016 By AC

Date Modified 01/05/2019 By DS Number of Sheets 42
F F
Changing Date Name Type COBRA Description: COBRA

drawing M.-Nr.: ELECTRICAL SCHEMATIC
User 14/07/2016 AC
only in Drawing number Sheet 1
5 24789 SEE REV5 CHANGE DOC 01/05/2019 DS
the E3! MPESD_3109 No. 42 Sh.
REV ECO Revision text Date Name
1 2 3 4 5 6 7 8 9
D
C
E
F
A
BATTERY ISOLATOR
SWITCH
+WB2
12V
12V
+WB3 +WB1 +WB4
-TB2A
1
-TB1A -TB4B
1
-TB3A 70mm-B 70mm-B 70mm-R 70mm-R
B- BL + +
-TB3B -TB2B -TB4A
-TB1B
0
1/1 6.0-GY +WB3 +WB2 +WB4
0 +WB1
+LH
-LHT1
=PCB+PCB/5.F1
=LH+LH-SPL0A:1
+JDH
-TJDH5
M10 STUD POSITIVE BUS BAR

M10 STUD NEGATIVE BUS BAR
6.0-GY
2
2
0 =JDH+JDH-SPL+:1
6.0-BU
=JDH+JDH/3.D4
0
+
2.5-GY + -TJDH7
0
+VOH +JDH
-TVOH1
=VOH+VOH/4.E3
=JDH+JDH/3.E1
=VOH+VOH-SPL0:1
=JDH+JDH-SPL0B:1
DC PUMP -TB5A
+WB6 +WB5 +WB5
3
-TB6B
3
-TB5B
M
35mm-B 35mm-R
0 +
Changing
drawing
the E3!
only in
-TB6A
+WB6
/2.F7 /2.B7
REV
0 +
5
ECO
24789
-TJDB1A
Revision text
SEE REV5 CHANGE DOC
+WJDB2
-TJDB2B =JDB+WJDB1-TJDB1B:1 +WJDB1
70mm-B 70mm-R
0 =JDH+JDH/3.D1 =JDH+JDH/3.A1 + +
4
4
=JDB+WJDB2-TJDB2A:1
=VOB+WVOB1-TVOB1B:1
70mm-B 70mm-R
0 =VOH+VOH/4.E1 =VOH+VOH/4.B1 + +
+WVOB2 0 =VOB+WVOB2-TVOB2A:1 -TVOB1A
+
-TVOB2B +WVOB1
=JDH+JDH/3.A2
Date
01/05/2019
5
5
Name
DS
Proved
User
14/07/2016 AC
Date
6
6
Name
7
7
BATTERY BUS BAR
P.-Nr.:
Type COBRA
-FWP
OPTIONAL
+WPH +WPH +WPH
30A
WATER PUMP -TWPH3

-TWPH6 -TWPH1
1/1
M
4.0-GY 4.0-BU 4.0-BU 4.0-BU

/2.F3 0 0 310 309 + /2.A3
2
-TWPH2 1/1 +
WPS
-TWPH4 -TWPH5
+WPH +WPH +WPH
1/2
-SKTWPS
2/2
Description: COBRA
ELECTRICAL SCHEMATIC
8
8
E7
0
1.0-GY
1.0-BU
Drawing number
MPESD_3109
=LH+LH-SPL0A:1
=PCB+PCB/16.E8 0 =PCB+PCB/16.D8
E7 =LH+LH-SKTL:17
9
9
Assignment =BCK
No.
Location +BCK
Sheet
42 Sh.
2
C
E
F
A
F
A
E
B
+WJDB1
1
1
=JDB+WJDB2-TJDB2B:1 -TJDB1B
=BCK+BCK/2.E2
-TJDH5:1
70mm-B 70mm-R
M
=BCK+BCK/2.E4 0 0 + =BCK+BCK/2.B4
+ =JDB+WJDB1-TJDB1A:1
-TJDB2A
+WJDB2
-TJDH4
0
-TJDH2
0
4.0-BU 4.0-BU
301 300
-TJDH3
6.0-GY
=BCK+BCK/2.A4
-SPL0B
1/2
2/2
+
1.0-GY
-SKTSMR
0
2
2
-SKTENG:P f7 1.0-BU
/3.E5 f7
+WJDB6
-TJDB6A
+WJDB5 +WJDB4
+WJDB5 -TJDB5A +WJDB6
-TJDB5B -TJDB4B
25mm-R 25mm-R -TJDB6B 25mm-R
2
1
303 302 +
AIR HEATER -TJDB4A
100A
JOHN DEERE ENGINE

F1
+WJDB4
-TJDH6
3 4.0-BU
2
1
3
1/2
2/2
B/3 300
-SKTAHR
1.0-BU -TJDH1
303
30A
F2
A/3
+WJDB3
only in
1.0-BU
the E3!
drawing
Changing
-SKTAH
306 -TJDB3B
AIR HEATER
25mm-R
2
1
C+
REV
5
ENGINE CONNECTOR
-TJDB3A
1.0-GY
100A
F3
ALTERNATOR +WJDB3
0
ECO
24789
-SKTENG
B/21 2.5-BU
-SPL+ 6.0-BU 1
=PCB+PCB/5.A1 =BCK+BCK/2.A2
2
1
+ + + + -TJDH7:1
25A
ENGINE FUSE BOX
F4
4
Revision text
4
G/21 2.5-BU 2
=PCB+PCB/5.A1
2
1
+ +
25A
F5
SEE REV5 CHANGE DOC

D/21 2.5-BU 3
=PCB+PCB/5.A1
2
1
+ +
25A
F6
f7 P/21 1.0-BU f7 2.5-BU 4

=PCB+PCB/8.C6 /3.B2
2
1
f7 304 4/4
-SKTSMR:1
25A
F7
E/21
Date
2.5-GY
=PCB+PCB/6.F1 0 0
01/05/2019
-SKTECU
5
5
1.0-GY
/3.C8
-SPL305
0 0 -SKTCL:B 1.5-BU
DS
BATTERY +
Name
304 13/54
1.5-BU
BATTERY +
304 14/54
1.5-BU
BATTERY +
304 23/54
User
1.5-BU BATTERY +
Proved
304 24/54
-SPL0A
Date
2.5-GY 1.5-GY
BATTERY -
0 0 27/54
6
6
1.0-GY 1.5-GY
BATTERY -
0 B/3 0 43/54
14/07/2016 AC
-SKTENG
Name
209 K/21 1.0-BU 1.0-BU
ENGINE
1.5-GY BATTERY -
-SKTAU
=PCB+PCB/5.D3
AUXILIARY
209 209 C/3 0 44/54
CONNECTOR
106 L/21 1.0-BU
=PCB+PCB/6.D1 106
206 J/21 1.0-BU 1.0-BU
=PCB+PCB/5.D3 KEY SWITCH
206 206 7/54
W/21 -SPL26
BRN BRN 1.0-BU
=PCB+PCB/7.B1 CAN HI
26 26 26 26 2/54
V/21 -SPL25
WHT WHT 1.0-BU
=PCB+PCB/7.C1 CAN LOW
25 25 25 25 1/54
7
7
0
0
0
T/21 -R23
SCRN SCRN
=PCB+PCB/7.C1 0 0 0
120 Ohm
14X1 H/21 1.0-BU 1.0-BU RATED
=PCB+PCB/8.C7 14X1 14X1 SPEED
9/54
P.-Nr.:
M/21 1.0-BU 1.0-BU
=PCB+PCB/8.B8 +5V SUPPLY
350 350 350 28/54
Type COBRA
351 C/21 1.0-BU 1.0-BU 1500/1800
=PCB+PCB/8.B8 351 351 RPM SELECT
JD ENG WIRING
53/54
1.0-BU AIR FILTER
307 RESTRICTION
41/54
1.0-BU COOLANT LEVEL
8
8
308 SWITCH
22/54
/3.E5
-SPL0B:1
Description: COBRA
1.0-GY
307
308
0
106
MPESD_3109
Drawing number
1.0-BU 2/2
1/2
-SKTAF
1.0-BU C/3
1.0-GY B/3
1.0-BU A/3
-SKTCL
9
9
LEVEL
SWITCH
No.
COOLANT
AIR FILTER
Sheet
RESTRICTION
3
Location +JDH
42 Sh.
Assignment =JDH
F
A
E
B
D
D
C
E
F
A
1
1
VOLVO ENGINE
+WVOB1
=VOB+WVOB2-TVOB2B:1 -TVOB1B
70mm-B 70mm-R
M
=BCK+BCK/2.E4 0 0 + =BCK+BCK/2.B4
+ =VOB+WVOB1-TVOB1A:1
-TVOB2A -TVOH2 6.0-BU
+WVOB2 +
=BCK+BCK/2.F2
2
2
0 -TVOH1:1
0
2.5-GY
3
3
Changing
drawing
the E3!
only in
REV
5
-SPL+
ECO
-SKTENG
24789
B/21 2.5-BU 6.0-BU

=PCB+PCB/5.A1 + + +
Revision text
SEE REV5 CHANGE DOC
G/21 2.5-BU
=PCB+PCB/5.A1 + +
4
4
=WVOEST -SKTVOEST
D/21 2.5-BU +WVOEST
=PCB+PCB/5.A1 +WVOEST
(NOT PART OF ENGINE HARNESS)
+ +
-PLGVOEST
-SPL0
=WVOEST
4/6 B B
VOLVO ENGINE SERVICE
BACKBONE 2 (H)
E/21 404 404 4/6
2.5-GY
=PCB+PCB/6.F1 0
TOOL EXTENTION
0 6/6 W W
BACKBONE 2 (L)
406 406 6/6
5/6 1.0-BU 1.0-BU
POWERTRAIN CAN (H)
Date
01/05/2019
405 405 5/6

2/6 1.0-BU 1.0-BU
POWERTRAIN CAN (L)
402 402 2/6
5
5
0
1.0-GY
1/6 1.0-BU 1.0-BU

Name
DS
BATT +
401 401 1/6
3/6 1.0-GY 1.0-GY
BATT -
403 403 3/6
Proved
User
-SKTENG -SKTECU
14/07/2016 AC
Date
206 J/21 2.5-BU 2.5-BU

=PCB+PCB/5.D3 206 206 5/8
KEY SWITCH
W/21
6
BRN BRN
6
=PCB+PCB/7.B1 26 26 26 1/8 CAN HI
Name
V/21 WHT WHT

=PCB+PCB/7.C1 25 25 25 2/8
CAN LOW
0
T/21 SCRN SCRN

=PCB+PCB/7.C1 0 0 0
106 L/21 1.0-BU

=PCB+PCB/6.D1 106
N/21 1.0-BU
=PCB+PCB/17.D5 14X3 14X3
7
7
P.-Nr.:
VOLVO ENGINE WIRING
Description: COBRA Type COBRA

8
8
14X3
106
0
1.0-BU
1.0-GY
1.0-BU
Drawing number
MPESD_3109
-SKTCL
C/3
B/3
A/3
LEVEL
COOLANT
9
9
Assignment =VOH
No.
Location +VOH
Sheet
42 Sh.
4
C
E
F
A
1 2 3 4 5 6 7 8 9
+ -PLGENG
=JDH+JDH/3.F4
D/21 62
+
/6.A1
+
=VOH+VOH/4.F4
+ -PLGENG
=JDH+JDH/3.F4
G/21
+ + +
A =VOH+VOH/4.F4 A
+ -PLGENG
=JDH+JDH/3.F4
B/21
+ + +
+
+
+
+
=VOH+VOH/4.F4
1 1 1 1 1 1 1 1 1 1
-F1 -F2 -F3 -F4 -F5 -F6 -F7 -F8 -F9 -F10
15A 5A 5A 5A 15A 5A 5A 25A 5A 1A
2 2 2 2 2 2 2 2 2 2
B B
204
213
215
214
207
13
-K2
/6.F9 14
211
202
207
21/47
4/47
-PLGL
-PLGL
36/47
-PLGL
61
62
90
205
/8.B2
4/47
21/47
36/47
3 3 3 3 3
+LH
+LH
+LH
/8.F5 /8.F6 /8.F7 /8.F6 /8.F9
-SKTL
-SKTL
-SKTL
210
-K5A -K4A -K4B -K5B -K1
5 4 5 4 5 4 5 4 5 4
1.0-BU
1.0-BU
215
214
C C
1.0-BU
+LH
213
-R1 -R2 -R3 -R4 -R5 -SPL214
1K 1K 1K 1K 1K
BRN
203
206
209
212
213
215
214
-H1 -H2 -H3 -H4 -H5

1.0-BU
214
J/21
22/47
-PLGL
-PLGENG
-PLGENG
-PLGR
34/47
-PLGL
34/47
-PLGL
1/47
K/21
/9.A1
/12.F6
/12.C7
D D
=LH+LH-SKTB:1
=LH+LH-SKTOP:1
1/47
=LH+LH-SKTTU:24
22/47
34/47
206
206
209
+LH
+LH
+RH
+LH
-SKTRC
+/2
-SKTL
-SKTL
-SKTR
1.0-BU
210
1.0-BU
1.0-BU
90
210
203
90
A/2
+LH
-SKTOC
=JDH+JDH/3.F7
=JDH+JDH/3.F6
=VOH+VOH/4.F6
/6.A6
E E
=RH+RH-SKTCLH:1
=LH+LH-SKT1:1
OIL COOLER
RADIO CHARGE SUPPLY
+LH +LH +LH

RESERVED FOR AUX HYD OIL COOLER
=CLU+CLU/18.C3
-SPL0A#1 -SPL0B#1 -SPL0C#1
0 0 0
B/2
-LHT1:1, -SKTOC:B, -DCP2:1, -SKTWPS:2, -SKTRLL:2, -SPL0C:1, -SKTPL:2 -SPL0C:1, -SKTWL:2, -SPL0E:1, -SKT21:2, -SKTOP:9, -SKTOP:19, -SKTRC:-, -SKTEST:4 -SPL0A:1, -SPL0B:1, -SKTSC:2, -SPL0D:1
-/2
+LH
Grey,Grey,Grey,Grey,Grey,Grey,Grey Grey,Grey,Grey,Grey,Grey,Grey,Grey,Grey Grey,Grey,Grey,Grey
+LH
LH71, LH72, LH54, LH55, LH56, LH45, LH82 LH46, LH49, LH50, LH51, LH52, LH53, LH44, LH86 LH45, LH46, LH47, LH48
-SKTOC
-SKTRC
6.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,2.50 mm²,1.00 mm² 1.50 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm² 2.50 mm²,1.50 mm²,1.00 mm²,1.50 mm²
1.0-GY
1.0-GY
+LH +LH +LH
0
0
-SPL0A -SPL0B -SPL0C 1.0-GY

0 /9.F3
F 0 =LH+LH-SKTOP:9 F
=LH+LH-LHT1:1 0 6.0-GY 0
=BCK+BCK/2.E1 0 /11.F1
Changing Date Name Type COBRA Description: COBRA Assignment =PCB

drawing P.-Nr.: ELECTRICAL SCHEMATIC Location +PCB
User 14/07/2016 AC
the E3! Proved FUSES MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9
D
C
E
F
A
=VOH+VOH/4.F4
/5.A9
=JDH+JDH/3.F5
=JDH+JDH/3.F6 -PLGENG
106 L/21
106
=VOH+VOH/4.F7
1
106
1
-SPL106
62
-F11
+LH
5A
-PLGL
0
1.0-BU 46/47
/9.F3 106 106 106 106
1
0
46/47
-SKTL
E/21
-PLGENG
+LH
/7.A2 106
-F12
2
2
5A
-PLGR
=RH+RH-SPL64A:1 14/47
1.0-BU
/13.A4 64 64 64
1
14/47
-SKTR
+RH
-F13
10A
-K2
/6.F9
/7.A2 107 107 65
1
24
23
-PLGR
=RH+RH-SKTCLH:2 5/47
1.0-BU
=CLU+CLU/18.A3
3
107 107
3
-R6
5/47
1K
-SKTR
Changing
-F14
drawing
the E3!
only in
-A2
10A
/8.E2
-K2
+RH
-H6
/6.F9
Address:
Comment:
/8.A1
REV
108 108 66
1
34
33
5
ECO
24789
AI_ANA_06
Input
E-STOP
108
-F15
2
10A
-K2
Revision text
SEE REV5 CHANGE DOC
/6.F9
/8.E1 109 109 67
1
44
43
4
4
-PLGL
5/47
109
-F16
Date
01/05/2019
5A
-PLGL
=LH+LH-SKTOP:29 20/47
1.0-BU
/11.A1 114 114 114 114
1
20/47
5
5
-SKTL
Name
DS
+LH
-K3A
/13.F4
-PLGL
=LH+LH-SPL116:1 35/47
1.0-BU
/11.B7 116 116 116
44
43
35/47
-SKTL
Proved
User
+LH
-K3B
/13.F2
-PLGR
14/07/2016 AC
Date
=RH+RH-SPL116:1 8/47
1.0-BU
/11.B8 116 116
44
43
8/47
=LH+LH-SKTL:22
-SKTR
6
6
+RH
Name
/5.E9
MIDDLE LEFT E-STOP FRONT LEFT E-STOP
+W2 +W2 +LH +W1 +W1 +LH

-ES2 -ES1
-PLG2 -SKT2 -PLG1 -SKT1
2/2 1.0-BU 2 1 1.0-BU 1/2 1.0-BU 2/2 1.0-BU 2 1 1.0-BU 1/2 1.0-BU
90
2/2 92 91 1/2 91 2/2 91 90 1/2 90
DT06-2S
-SKT2 2 1 -PLG2 -SKT1 2 1 -PLG1
+LH +W2 +LH +W1
+RH
7
-PLGL -SKTR
1.0-BU 13/47 6/47 1.0-BU
FUSES / E-STOPS
P.-Nr.:
Type COBRA
92 13/47 6/47 92
-PLGR
REAR RIGHT E-STOP FRONT RIGHT E-STOP
+W4 +W4 +RH +W3 +W3 +RH

-ES4 -ES3
-PLG4 -SKT4 -PLG3 -SKT3
2/2 1.0-BU 2 1 1.0-BU 1/2 1.0-BU 2/2 1.0-BU 2 1 1.0-BU 1/2
2/2 94 93 1/2 93 2/2 93 92 1/2
-SKT4 -PLG4 -SKT3 -PLG3
Description: COBRA
2 1 2 1
8
+RH +W4 +RH +W3

Drawing number
MPESD_3109
1.0-BU
94
-K2
+RH
/6.F9
62
52
33
23
13
43
-SKTR
11/47
-K2
/6.E9
0 94 94
0
11/47
0
-PLGR
14
34
44
51
61
24
9
9
/6.B3
/6.B3
/5.B3
/6.B4
Assignment =PCB
No.
Location +PCB
Sheet
/7.F1
42 Sh.
6
C
E
F
A
1 2 3 4 5 6 7 8 9
106 106
/6.C2 +LH /8.A1
-PLGL -SKTL
107 43/47 43/47 BRN 14
/6.C3 14 /9.F3
-PLGL =LH+LH-SPL14:1
44/47 44/47 WHT 32
32 /9.F3
-PLGENG -PLGL =LH+LH-SPL32:1
0
A A/21 6/47 6/47
A
0
14
/9.F3
-PLGENG +RH
F/21 -PLGR -SKTR
32 40/47 40/47 W
-PLGENG 14
14 14 /13.A1
S/21 -PLGR =RH+RH-SKTRAD:5
0 13/47 13/47 N 32
32 32 /13.A1
-PLGENG -PLGR =RH+RH-SKTRAD:4
X/21 2/47
26 0
-PLGENG
U/21 26
25
/8.A1
-A2:3
B B
25
/8.A1
+LH -A2:2
26 -PLGENG -PLGL -SKTL
=JDH+JDH/3.F7
W/21 28/47 28/47 BRN 26
26 26 26 /9.A3
26 -PLGL =LH+LH-SPL26:1
=VOH+VOH/4.F6
25 -PLGENG 16/47 16/47 WHT 25
=JDH+JDH/3.F7 25 25 /9.A3
V/21 -PLGL =LH+LH-SPL25:1
0
25 25 8/47 8/47 0
=VOH+VOH/4.F6 0
/9.A3
0 -PLGENG
=JDH+JDH/3.F7 +RH
T/21 -PLGR -SKTR
0 0 39/47 39/47 BRN 26
=VOH+VOH/4.F6 =CLU+CLU/18.A7
-R10
120 Ohm
C 26 26
-PLGR =RH+RH-SKTCLH:5 C
25/47 25/47 WHT 25
25 25 =CLU+CLU/18.A7
-PLGR =RH+RH-SKTCLH:4
0
7/47 7/47 0
0
=CLU+CLU/18.A8
=RH+RH-SKTCLH:6
0
0
26
25
32
14
106
106
107
107
2
4
2
4
6
1
1
3
3
5
N
D D
GND
VBBs
GND
VBB1
VBB2
CAN2_L
VBBs
CAN2_H
CAN1_L
CAN1_H
ifm
CR0403
E E
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
VBBs
VBBs
VBBs
VBBs
GND
GND
VBBs
VBBs
-A1
OUT3
UNDERPAN
OUT2
RIGHT TRACK PWM
WATER PUMP
OUT0
FEEDER/AUX PWM
MAIN CONV SPEED

RS ENABLE
FAST TRACK IN
UMBILICAL TRACK ENABLE
OUT1
LEFT TRACK PWM
OUT7
RT FOR / TOP APRON CLOSE
APRON PRESSURE
LT FOR / TOP APRON OPEN
LT REV / BOT APRON OPEN
RT REV / BOT APRON CLOSE
OUT11
CRANK OUTPUT
IN2
IN3
OUT10
SIDE CONVEYOR
IN6
IN7
IN9
IN8
IN10
IN11
OUT6
FEEDER/AUX POWER
OUT9
ENGINE ENABLE
OUT4
DC PUMP
OUT8
MAIN CONV RUN
OUT5
HYD OIL COOLER
SPARE
HYD OIL TEMP

IN5
IGNITION KEY ON
IN0
IN4
IN1
2
6
2
4
4
3
1
6
1
3
2
5
8
4
5
7
8
6
7
7
5
1
2
4
6
1
8
5
3
7
8
5
2
4
6
2
4
6
8
8
3
7
1
3
7
A
C
D
B
E
F
/8.A6
/8.B5
/8.A5
/8.D8
/15.A1
/15.B1
/15.B6
/16.A6
/16.A7
/15.B5
/15.A9
/16.A7
/13.E7
/15.B3
/17.F8
/13.E7
/13.E3
/14.F3
/13.E6
/13.E9
/13.E5
/14.F6
/17.F3
/14.E2
F 0 0 F
/6.F9 /8.F1

User 14/07/2016 AC
the E3! Proved CONTROLLER MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9
D
C
E
F
A
/6.C3
/7.B9
/7.B9
/7.A9
/7.F9
/6.C4 WURTH ELEKTRONIK
109
ICCS 48P
108
106
X1
25
26
1
1
0
-A2
KL_30_1 1
108
CAN_L 2
25
CAN_H 3
DI_01 26
SPARE 4 /17.F5
DI_02
AUTO START/STOP 5 /10.F1
DI_03
FEEDER START/STOP 6 /10.F7
DI_KL15 7
X3 KL_30_2 8
106A
106
106
JUMPER LINK
I/O_16
1 KL_30_5 TOP APRON CLOSE 9 /16.A1
109 AI_ANA_06 I/O_15
/6.E3 2 10 /16.B2
2
E-STOP TOP APRON OPEN
2
AI_ANA_07 I/O_14
/13.E4 3 UMBILICAL STOP BOTTOM APRON CLOSE 11 /16.A3
AI_ANA_08 I/O_13
/10.F2 4 TRACK SWITCH BOTTOM APRON OPEN 12 /16.A3 /5.B4
AI_ANA_09 PWM_OUT_08 207
/9.F1 5 CRANK INPUT RUN DOWN HOLD SIGNAL 13 /8.E8
AI_ANA_10 PWM_OUT_07
/10.F3 6 SET UP SWITCH JD RATED SPEED 14 /8.B6
PWM_OUT_06
7 VDD5V SIREN/BEACON 15 /17.A1
PWM_OUT_05
8 KL_30_6 JD 1500/1800 RPM SELECT 16 /8.A7
109 I/O_24
/14.F2 9 FUEL LEVEL
I/O_23
/14.A8 10
/14.A9 11
RS SLEW LEFT
I/O_22
RS SLEW RIGHT
X2
I/O_21
/17.A8 12 SPARE KL_30_3 1
I/O_20 AI_ANA_01 108
/13.E2 13 RADIO TRACK ENABLE SPARE 2 /17.F7
3
3
I/O_19 AI_ANA_02
/17.F5 14 COOLANT LEVEL SPARE 3 /17.F8
-PLGR
Changing
drawing
I/O_18 AI_ANA_03
the E3!
only in
/15.A2 15 LEFT TRACK POWER HYD OIL LEVEL 4 /14.E4

I/O_17 AI_ANA_04
/15.A4 16 RIGHT TRACK POWER CHAMBER INTERLOCK 5 /14.F5
1/47
AI_ANA_05
6 /17.F6
REV
SPARE
GROUND 7
5
0
KL_30_4 8
1/47
-SKTR
+RH
108
ECO
24789
DOM_OUT_04
CHAMBER CLOSE 9 /16.A4
DOM_OUT_03
CHAMBER OPEN 10 /16.A5
0
DOM_OUT_02
1.5-GY 0
RECIRC 11 /15.A7
Revision text
SEE REV5 CHANGE DOC
DOM_DOUT_01
SCREENS/FINES 12 /15.B7
I/O_12
FEEDER LAMP 13 /10.F6
4
4
I/O_11
SPARE 14 /17.A6
DOM_OUT_10
FAST TRACK 15 /15.A5
DOM_OUT_09
DELAYED TRACK ENABLE 16 /14.A7
/11.F8
=RH+RH-SPL0A:1
-A1
/7.F7
Address:
Comment:
0 0
-K5A
Date
01/05/2019
/8.F5
HYD OIL COOLER

5
4
Output
-K5A
OUT5
5
5
/8.F5
0 E3 E3
1
2
Name
DS
3
-A1
/7.F8
3 /5.C2
Address:
Comment:
-K5B
/8.F6
CRANK OUTPUT
-PLGENG
5
4
=JDH+JDH/3.F5
Output
Proved
User
f7
OUT11
P/21
-K5B
/8.F5
0 E3 f7
1
2
7
14/07/2016 AC
Date
-A1
/7.F8
3 /5.C5
Address:
Comment:
6
6
-K4A
Name
/8.F6
ENGINE ENABLE
5
4
Output
-K4A
OUT9
/8.F6
0 F3 F3
1
2
3
-A2
/8.B2
3 /5.C3
Address:
Comment:
-K4B
/8.F7
JD RATED SPEED
-PLGENG
PWM_OUT_07
5
4
=JDH+JDH/3.F7
Output
14X1 H/21
-K4B
/8.F7
0 F3 14X1
1
2
-PLGL
14
7
7
-A2
/8.B3
-R9
9/47
3 /5.C4
1K
-PLGR
Address:
Comment:
SLAVE I/O
P.-Nr.:
Type COBRA
20/47
-H9
-K6
JD 1500/1800 RPM SELECT

/8.F8
PWM_OUT_05
5
4
Output
/8.F7
-K6
0 16X1 16X1
1
2
-PLGL
16
-A2
-A1
/8.B2
/7.F4
18/47
3 /8.C8
Address:
Comment:
Address:
Comment:
-K6
/8.F8
RUN DOWN HOLD SIGNAL
Description: COBRA
4
8
=JDH+JDH/3.F7
8
IGNITION KEY ON
350
PWM_OUT_08
Output
Input
5
3
350 M/21
2
2
1
1
IN5
13X1 B3 -PLGENG
13
3
-D4
-D3
Drawing number
MPESD_3109
351
=JDH+JDH/3.F8
351 C/21
-PLGENG
-K1
/8.F9
106
106
+LH
-SKTL
5
4
42/47 1.0-BU
2
1
/8.F9
-K1
0 216A 216 216 216 /9.E1

1
2
42/47 216 =LH+LH-SKTOP:2

0
9
-D5
-PLGL
/12.C5
/13.A1
-D1:1
3 /5.C7
Assignment =PCB
No.
Location +PCB
Sheet
/13.F1
8
42 Sh.
C
E
F
A
F
A
E
B
+OPH +OPH +LH
-PLGOP -SKTKS -SKTKS -SKTOP
-SPL213
+OPH
ON
=LH+LH-SKTL:42 2/47 +OPH 1/6 1/47

1.0-BU WHT BRN 1.0-BU 1.0-BU
/8.A9 /5.D6
1
216
1
216 2/47 216 4/6 213 213 1/47 213

=LH+LH-SKTL:21
-SKTOP -PLGOP
+LH +OPH
/8.E2
-A2
START
Address:
213
Comment:
+LH 2/6
BRN
+OPH
-SKTL -PLGOP
27/47 1.0-BU 3/47 BLU
IGNITION SWITCH
3X5 3X5 3X5

Input
5
27/47 3/47
AI_ANA_09
CRANK INPUT
-PLGL -SKTOP
+LH
2
2
=LH+LH-SKTL:8
=LH+LH-SKTL:16
=LH+LH-SKTL:28
/7.C9
/7.C9
/7.B9
0
25
26
=LH+LH-SKTL:6
=LH+LH-SKTL:43
=LH+LH-SKTL:44
0
25
26
/7.A9
/7.A9
/7.A9
/5.F9
/6.E1
=LH+LH-SPL0B:1
BRN
WHT
SCRN
3
3
=OPH+OPH-SPT1:4(4) A3I
/10.E5 +OPH
0
14
32
106
0
-SKTPDM1 0
only in 1_Supply I/O 5_CAN2
BRN
the E3!
drawing 1/5
Changing
0
14
32
SHIELD 1
A3I
213 1 10-32V DC (KI.30)

BRN
GRY
WHT
0
REV
SCRN
5
WHT 2/5 APRON DUMP
2 VBBc 2
1.0-GY
0 +OPH A3I INPUT

+OPH 0
ECO
24789
-SPLA3I
25
26
-PLGOP
CR1080
9/47 BLU 3/5

WHT
3 0 CAN2_GND 3
9/47 0
-PLGOP +LH
-SKTOP +OPH
AUTO START/STOP +OPH +OPH -SKTOP
-SPLA3O
BRN -SPL26
4
+LH
Revision text
+LH
4
BLK 4/5 -PLGPDM5 BLK 18/47 1.0-BU

4 LAMP CAN2_H 4
A3O 4/5 26 18/47 26
+OPH OUTPUT
-SKTOP
-PLGOP
SEE REV5 CHANGE DOC

+LH
1.0-BU 8/47 GRY 5/5 GRY 17/47 1.0-BU
5 10-32V DC (KI.15) CAN2_L 5
106 106 25 25
-SPL25
+LH
8/47 5/5 17/47

A3O
2_CAN1 6_CAN3/4
42/47 1.0-BU
CAN3_H
0
=OPH+OPH-SPT1:2(1)
1 SHIELD 1 25
42/47
GRY/PNK
/10.D4 A3O
SCRN
44/47
Date
1.0-BU
2 VBBc CAN3_L 2
1
0 44/47 26
01/05/2019
5
5
120 Ohm
+OPH
-R21
14
32
DS
3 0 CAN3/4_GND 3
Name
+LH
WHT
-PLGOP -PLGPDM2
-SKTOP +OPH
+OPH
14 11/47 BLK 4/5
4 CAN1_H CAN4_H 4
1.0-BU 14
BRN -SPL14
+LH
11/47
10/47 5/5
User
32 GRY
Proved
5 CAN1_L CAN4_L 5
-SPL32
+LH
1.0-BU 10/47 32
Date
3_USB 7_NA1
1 +5 V DC 1
6
6
14/07/2016 AC
Name
2 - DATA 2
1.0-BU 106
106 /10.E5
=LH+LH-SKTOP:7
3 + DATA 3
4 ID 4
7
7
5 0 5
+WETH
-PLGETH
-SKTETH 4_Ethernet 8_NA2
1/8 +WETH
1 TxD + 1
1/4
P.-Nr.:
3/8
2 RxD + 2
Type COBRA
2/4
2/8
OPERATOR PANEL
+WETH
3 TxD - 3
3/4
-SKTETH_BULK
8
8
6/8
14
32
106
106
4 RxD - 4
4/4
1.0-BU
NG ETHERNET PROGRAMMING PORT
14
32
25
26
1.0-BU,1.0-BU
1.0-BU,1.0-BU
1.0-BU,1.0-BU
106
106
5
Description: COBRA
MPESD_3109
Drawing number
/12.A1
/12.A1
/17.A1
/12.A1
/12.A1
/12.A1
=LH+LH-SKTAP:A
9
9
No.
Sheet
=LH+LH-SKTEST:3, =LH+LH-SKTTU:4
9
=LH+LH-SKTOP:21, =LH+LH-SKTOP:46
=LH+LH-SKTOP:20, =LH+LH-SKTOP:45
Location +PCB
42 Sh.
Assignment =PCB
F
A
E
B
D
1 2 3 4 5 6 7 8 9
A +OPH
A
-SPT1
EBC014
CHANNEL 3 CHANNEL 4
SETUP SWITCH NOT USED
=PBCK+PBCK/21.E6 TRACK SWITCH APRON DUMP PB =PBCK+PBCK/21.E7
1/5 1/5
1 L+ L+ 1
+WS1-3 | 0 || 2/5
2 IN/OUT IN/OUT 2
-S1-3 +WS1-4
3 L- L- 3 -S1-4
B 4/5
4 IN/OUT IN/OUT 4
4/5 B
+WS1-3 5 Shell Shell 5 +WS1-4
-PLGS1-3 -PLGS1-4
CHANNEL 1 CHANNEL 2
AUTO START/STOP LAMP FEEDER LAMP
=PBCK+PBCK/21.F6 AUTO START/STOP PB FEEDER START/STOP =PBCK+PBCK/21.F7
1/5 1/5
1 L+ L+ 1
2/5 2/5
+WS1-1 2 IN/OUT IN/OUT 2 +WS1-2
-S1-1 3/5 3/5
3 L- L- 3 -S1-2
4/5 4/5
4 IN/OUT IN/OUT 4
5 Shell Shell 5 +WS1-2

+WS1-1
-PLGS1-2
-PLGS1-1
C C
GREEN/YELLOW
BROWN/GREEN
WHITE/GREEN
GREY/PINK
RED/BLUE
YELLOW
BROWN
GREEN
WHITE
GREY
BLUE
3(1-4)
5(1-4)
1(1-4)
4(1)
2(1)
4(3)
2(3)
2(4)
4(4)
2(2)
4(2)
WHT/GRN
GRY/PNK
RED/BLU
WHT
D D
GRN
GRY
BRN
BLU
YEL
-SKTOP -PLGOP
5X1
6X1
A3I
A3O
4X3
6X3
106
13X2
+OPH
33/47
15/47
16/47
19/47
12/47
A3O
6/47
7/47
=OPH+OPH-SPLA3O:1
/9.E5
+LH
6/47
1.0-BU 15/47
16/47
7/47
19/47
33/47
12/47
A3I
1.0-BU
5X1
1.0-BU
6X1
1.0-BU 1.0-BU
6X3
4X3 13X2
=OPH+OPH-SPLA3I:1
/9.E3
1.0-BU
1.0-GY
E E
1.0-BU
1.0-BU
1.0-BU
40/47 1.0-BU
1.0-BU
106
0
-SKTL
-SKTL
-SKTL
-SKTL
-SKTL
5X1
6X1
4X3
6X3
13X2
106
0
+LH
+LH
+LH
+LH
+LH
39/47
15/47
14/47
11/47
5X1 39/47
-PLGL
4X3 15/47
-PLGL
6X3 14/47
-PLGL
40/47
-PLGL
6X1 11/47
-PLGL
/11.E1
=LH+LH-SPL106:1
=LH+LH-SPL0B:1
/9.E6
13X2
5 4 6 13 6
DI_02 AI_ANA_08 AI_ANA_10 I/O_12 DI_03
F Address: Address: Address: Address: Address: F
/8.B2 /8.E2 /8.E2 /8.B4 /8.B2
AUTO START/STOP TRACK SWITCH SET UP SWITCH FEEDER LAMP FEEDER START/STOP
-A2 Comment:
-A2 Comment:
-A2 Comment:
-A2 Comment: -A2 Comment:
Input Input Input Output Input
User 14/07/2016 AC
the E3! Proved PANEL SWITCHES MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9
F
A
E
B
=LH+LH-SKTL:20
/6.E5
/5.F9
1
1
114
0
114
1.0-GY
0 /10.E5
0 =LH+LH-SKTOP:19
1.0-BU
0
+LH
29/47
-SPL0D#1
2
2
-SPL0D
+LH
29/47
Grey,Grey,Grey,Grey,Grey,Blue
LH57, LH48, LH59, LH60, LH58, BLU
114
BRN
1.00 mm²,1.50 mm²,1.00 mm²,1.00 mm²,1.00 mm²,0.34 mm²

-SKTFLL:2, -SPL0C:1, -SKTS:B, -SKTBEC:2, -SKTAV:8, -SKTB:3
-SLS
+WLS
3
3
LIGHT SWITCH
+OPH +WLS
| ||
-PLGOP -PLGWLS +OPH

30/47 4/5 -SKTLS
only in
1.0-BU BLK BRN
the E3!
drawing 4/5
Changing 72 30/47 72 1/5 1/5 114
-SKTLS
-SKTOP +OPH
REV
-PLGWLS
5
+LH +WLS
1.0-BU
ECO
72
24789
+W21 +LH
-L21
-PLG21 -SKT21
+LH
-SPL71
1.0-GY 2/2 =CHK +W21 -W21 U =CHK +W21 -W21 N 1/2 1.0-BU
1
0 72
4
Revision text
0 72 1/2
4
2/2
-SKT21 OPERATOR PANEL LAMP -PLG21
+LH +W21
SEE REV5 CHANGE DOC

+WLH
-SKTWL1
1/2
Date
U N
TOWER
0 72
2/2
01/05/2019
-SKTWL1
5
5
+WLH
OPTIONAL LIGHTING
+WLH
DS
-SKTWL2
Name
U 1/2 N
0 72
2/2
-SKTWL2
+WLH +WLH +LH
+WLH
-PLGWL -SKTWL3 -SKTWL
-SPL71
1.0-GY 2/2 1.0-GY U 1/2 N 1.0-BU 1/2 1.0-BU

0 2/2 0 0 72 72 1/2 72
User
2/2
Proved
-SKTWL -SKTWL3 -PLGWL
Date
+LH +WLH +WLH
-SPL0
6
6
14/07/2016 AC
Name
+LH
-SKTPL
1.0-GY 1/2 1.0-BU
0 2/2 72
-SKTPL POWER UNIT LAMP
+LH
+LH
-SKTFLL
7
-SKTFLL
7
-SPL116
+LH
1.0-GY +LH 1/2 1.0-BU 1.0-BU

0 116 116 /6.E5
2/2 116 =LH+LH-SKTL:35
FRONT LEFT TRACK LAMP
P.-Nr.:
LIGHTS
+LH
-SKTRLL
-SKTRLL
Type COBRA
1.0-GY +LH 1/2 1.0-BU
0 2/2 116
REAR LEFT TRACK LAMP
/8.F4
8
8
+RH
-SKTFRL
-SKTFRL
-SPL116
+RH
1.0-GY +RH 1/2 1.0-BU 1.0-BU
0 116 116 /6.E6
2/2 116 =RH+RH-SKTR:8
FRONT RIGHT TRACK LAMP
Description: COBRA
+RH
-SKTRRL
MPESD_3109
-SKTRRL
Drawing number
0
+RH 1/2
1.0-GY 1.0-BU
0 2/2 116
REAR RIGHT TRACK LAMP
9
9
No.
Sheet
/12.F1
/13.F5
11
Location +PCB
42 Sh.
Assignment =PCB
F
A
E
B
D
1 2 3 4 5 6 7 8 9
=LH+LH-SPL26:1 26
/9.A8
=LH+LH-SPL25:1 25
/9.A8
=LH+LH-SPL106:1 106
A /9.F8 A
PT7000
=LH+LH-SPL14:1 14
/9.F8
TELEMETRY
=LH+LH-SPL32:1 32
/9.F8
MODULE
+LH
-SKTTU
1.0-BU 20/31 20 BLU/WHT 20
B (MTS)TX CONSOLE RS232 TX (OUTPUT) B
1.0-BU 21/31 21 PUR/WHT 21
1.0-BU
1.0-BU
1.0-BU
1.0-BU
1.0-BU
1.0-BU
1.0-BU
(MTS)RX CONSOLE RS232 RX (INPUT)

32
14
32
14
106
25
26
-PLGL -D2
47/47
1
2
33/47
-SKTOP
1.0-BU
1.0-BU
-PLGL +LH
-PLGTST
-D1
+LH
(MTS)TX
(MTS)RX
106
20/47
21/47
45/47
46/47
/8.A9 -SKTTU
2
1.0-BU 4/31 4 GRN 4
D_IN_1
+LH
106
CIRCUIT NO LONGER USED
4/6
5/6
+OPH
-PLGOP
=LH+LH-SKTL:36 1.0-BU 24/31 24 RED 24

20/47
21/47
45/47
46/47
/5.D6 POWER
C 215
C
1.0-GY 23/31 23 BLK 23
TELEMETRY SERVICE 0 GND
1 TOOL CONNECTION
+OPH 1.0-GY 19/31 19 GRN/WHT 19
POINT GND
-R22 0
120 Ohm 3/31 3
1.0-GY 3 YEL
2 0 GND
BLK
2
G/Y
+WJDEST -PLGJDEST 1.0-GY 2/31 2 ORN

GND
-SKTEST
32
14
0
-PLGJDESTA +WJDEST
POINT (JOHN DEERE)

+LH 1
TOOL CONNECTION
1/4 1.0-BU 1.0-GY 1.0-GY 1/31 1 BRN
ENGINE SERVICE
26 0 0 GND
1/4 C/9
+LH
2/4 1.0-BU
D -SPL0E D
2/4 25 D/9 7/31 7 GRY 7
1.0-BU
25
J1939-
TOOL CONNECTION
+OPH 3/4 1.0-BU

3/4 106 B/9 18/31 18 YEL/WHT 18
-SKTIFM 1.0-BU
IFM SERVICE
26
J1939+
4/5 4/4 1.0-GY
POINT
4/4 0 A/9 8/31 8 WHT 8

1.0-BU
ONLY USED ON JOHN AUXRX EXT RS232 (OUTPUT)
5/5
DEERE ENGINES 9
1.0-BU 9/31 9 PNK
AUXTX
EXT RS232 (INPUT)
BELT WEIGH MODULE

+LH
-SPLAUXRX
-SPLAUXTX
+LH
1.0-GY
E RS232 E
+LH GND
0
-SKTB
WHT
TXD
AUXRX 2/5
BLK
RXD
AUXTX 4/5
BLU
GND
0 3/5
=LH+LH-SPL214:1 BRN
/5.D8 214
VIN
1/5
1.0-GY
VIN
BLU
0
0
F F
0 0
/11.F9 /16.F1
User 14/07/2016 AC
the E3! Proved TELEMETRY MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
106 =RH+RH-SKTR:14 64 1.0-BU 64

/8.A9 /6.E2 64 /14.A1
+RH +RH
+RH -SPL64A +RH -SPL64B
-SPL64A#1 -SPL64B#1
A =RH+RH-SKTR:40 14 64 64
A
/7.A9
-SPL64C:1, -SKTR:14, -SPL64B:1, -SKTHOT:A, -SKTHOL:1 -SPL64A:1, -PLGRS:1, -SKT24:1, -SKT9:A, -SKTFL:D
29/47
-PLGR
1.0-BU
64
=RH+RH-SKTR:13 32 Blue,Blue,Blue,Blue,Blue Blue,Blue,Blue,Blue,Blue
/7.B9
RH4, RH5, RH6, RH7, RH9 RH6, RH8, RH10, RH11, RH65
1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm² 1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²
29/47
+RH
+RH
-SKTR
-SPL64C
N
B
32
14
106
1.0-BU
1.0-BU
1.0-BU
64
64
64
4/5
+RH
-SKTRAD
5/5
1/5
B B
4/17
+RH
-SKTU
+RH
-SKTU
7/17
+RH
-SKTU
3/17
RADIO UMBILICAL
OPTIONAL
6/17
2/17
5/17
8/17
9/17
1/17
13/17
12/17
+RH
+RH
+RH
+RH
+RH
+RH
+RH
+RH
2/5
3/5
-SKTU
-SKTU
-SKTU
-SKTU
-SKTU
-SKTU
-SKTU
-SKTU
+RH
-SKTRAD
C C
1.0-BU
1.0-BU
1.0-BU
1.0-BU
1.0-BU
1.0-BU
1.0-GY
1.0-BU
G/Y
U
B6
C2
C3
C6
C7
111
0
3X3
110
23 33 23 33
-K3B -K3B -K3A -K3A
/13.F2 /13.F2 /13.F4 /13.F4
21/47
43/47
+RH
-SKTR
+RH
-SKTR
3/47
+RH
-SKTR
+RH
-SKTR
+RH
-SKTR
31/47
+RH
-SKTR
+RH
-SKTR
30/47
+RH
-SKTR
+RH
-SKTR
32/47
24 34 24 34
19/47
18/47
17/47
3/47
21/47
43/47
31/47
30/47
32/47
19/47
18/47
17/47
-R7 -R8
1K 1K
-PLGR
-PLGR
-PLGR
-PLGR
-PLGR
-PLGR
-PLGR
-PLGR
-PLGR
D D
B7
B6
C2
C3
C6
C7
3X3
13X3
-H7 -H8
0 0
-K3B -K3A
13 3 3 7
/13.F2 1 /13.F4 1
I/O_20 AI_ANA_07 IN9 IN11
Address: Address: Address: Address:
/8.E3 RADIO TRACK ENABLE /8.E2 UMBILICAL STOP /7.F5 RT FOR / TOP APRON CLOSE /7.F5 RT REV / BOT APRON CLOSE
Comment: Comment: Comment: Comment:
-A2 -A2 -A1 -A1
E Input/Output Input Input Input E
7 2 6 6
IN7 IN8 IN10 IN6

/7.F5 UMBILICAL TRACK ENABLE /7.F5 LT FOR / TOP APRON OPEN /7.F5 LT REV / BOT APRON OPEN /7.F4 FAST TRACK IN
-A1 -A1 -A1 -A1
Input Input Input Input
0 0 0
/8.F9 /11.F9 /14.F1
-K3B -K3A
+RH +RH
/13.E2 /13.E4 +RH -SPL0A +RH -SPL0B
13 14 /14.B8 13 14 /14.B7 -SPL0A#1 -SPL0B#1
23 24 /13.D2 23 24 /13.D3
F 33 33 0 0 F
34 /13.D3 34 /13.D4
43 44 /6.B6 43 44 /6.B5 -SKTR:1, -SKTRSV:3, -SKTRSV:4, -SKTCLH:3, -SPL0B:1, -SPL0D:1 -SKTRRL:2, -SKTHOL:2, -SKTFT:2, -SKTMC:2, -SPL0A:1, -SPL0C:1
52 51 52 51 Grey,Grey,Grey,Grey,Grey,Grey Grey,Grey,Grey,Grey,Grey,Grey
62 61 62 61 RH12, RH25, RH26, RH27, RH28, RH29 RH14, RH16, RH23, RH24, RH28, RH30
1.50 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm² 1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²

User 14/07/2016 AC
the E3! Proved UMBILICAL / RADIO MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9
D
C
E
F
A
/13.A9
/13.F9
1
1
+RH
-SKTFL
-SKTFL
64
+RH
0
1.0-GY D/4 1.0-BU

0 A/4 64
+RH
FUEL LEVEL
-SKTR
0 TO 5V
44/47 1.0-BU
9X3 44/47 9X3 C/4
FUEL LEVEL
Input
-PLGR
9
I/O_24
9X3 26/47
-PLGL
-A1
2
Comment:
/7.F3
2
Address:
+RH
-SKTHOT
Address:
Comment:
-A2
/8.E3
A/3 1.0-BU
TA4115 -50 TO 150 DEG C

64
HYD OIL TEMP SENS

+RH
4 TO 20 mA
HYD OIL TEMP
-SKTR
Input
47/47 1.0-BU
IN1
A3 47/47 A3 B/3
3
-PLGR -SKTHOT
+RH
-A1
/7.F4
ON RS
ONLY USED
THIS CIRCUIT
Address:
Comment:
3
3
Changing
+RSDH +RH
drawing
+RH +WRS +WRS

the E3!
only in
-SKTR -SKTRS -PLGRSA -SKTRSA -PLGRS

RS ENABLE
Input
46/47 1.0-BU 2/6 1.0-BU 2/6 1.0-BU 1/6 1.0-BU 1/6 1.0-BU
IN3
REV
A7 46/47 A7 2/6 A7 2/6 64/A7 1/6 64 1/6 64

7
5
-PLGR -PLGRS -SKTRSA -PLGRSA -SKTRS

+RH +WRS +RSDH +WRS
ECO
24789
+RH
-SKTHOL
-SKTHOL
+RH
Revision text
SEE REV5 CHANGE DOC
1.0-GY 1/4 1.0-BU

0 64
-A2
/8.B3
2/4
OIL LEVEL
4
SWITCH
4
Address:
Comment:
+RH 3/4
HYD OIL LEVEL
-SKTR
AI_ANA_03
Input
23/47 1.0-BU
4X2 23/47 4X2
4
-PLGR
+RH +W25 +RH +W24 +RH
-PLG25 -PLG24
-SKTR -PLG25 -SKT25 -PLG24 -SKT24
-A2
+W25 +W24
/8.B3
Date
01/05/2019
37/47 1.0-BU B/3 A/3 1.0-BU 2/2 1/2 1.0-BU

5X2 5X2B 64
64
5X2 37/47 B/3 A/3 2/2 1/2
5X2B
=CHK +W25 -W25
Address:
Comment:
=CHK +W24 -W24

5X2
5X2B
-PLGR -SKT25 -SKT24

U
N
5
5
-SKT25A
-SKT24A
+RH +RH
Name
DS
CHAMBER INTERLOCK
+W25
+W24
CHAMBER HOOD
1/4
1/4
2/4
2/4
CONNECTOR
CONNECTOR
AI_ANA_04
Input
DOOR
5
1/4
+W25
1/4
+W24
-PLG25A
-PLG24A
2/4
2/4
Proved
User
1.0-BU 1.0-BU
5X2A 5X2C
14/07/2016 AC
Date
-A1
/7.F4
+W9 +W9
6
+RH
6
-SKT9 -SKT9A -SKT9A
Name
-PLG9 -SKT9
Address:
+W9
Comment:
=W9 +W9 -W9.

1.0-GY +RH C/3 BLU 3/5 BRN A/3 1.0-BU
0 C/3 0 1/5 64 A/3 64
+RH
MAIN CONV
MAIN CONV SPEED
-PLG9
-SKTR
SPEED
+W9
Input
33/47 1.0-BU B/3 BLK 4/5

IN2
A6 33/47 A6 B/3 A6
6
-PLGR
GREEN
PIN 1
PIN 2
RED
-A2
/8.B4
TRACK
VALVE
SAFE
Address:
Comment:
7
7
DELAYED TRACK ENABLE
+RH
-K3A
RIGHT HARN INPUTS
P.-Nr.:
Type COBRA
/13.F4
-SKTTSV -SKTTSV -PLGR

DOM_OUT_09
Output
1.0-GY +RH 1/4 1.0-BU 9/47

0 68 68 16X2
14
13
E/4 9/47
16
-PLGRS -SKTR
1.0-GY
+RH 5/6 1.0-GY 5/6 1.0-GY +RH
ON RS
ONLY USED
THIS CIRCUIT
-K3B
-A2
/8.E3
/13.F2
0 5/6 0 5/6 0
+WRS
-SKTRSA +RSDH
-SKTRS
Address:
Comment:
+WRS -PLGRSA
14
13
1.0-GY
0
Description: COBRA
+RH
+WRS
8
+RSDH -SKTRS
RS SLEW LEFT
-SKTRSA -PLGRS -PLGR

Output
-SKTSLL 3/6 +WRS 3/6 16/47

I/O_23
2 1/4 1 1.0-BU 1.0-BU

2/4
+RSDH
0 10X3 3/6 10X3 3/6 10X3 16/47 10X3

-SPL0
10
-SKTSLL
Drawing number
-PLGRSA -SKTR
MPESD_3109
+RSDH
+RSDH +RH
-A2
/8.E3
Address:
Comment:
+WRS +RH
0
-SKTRS
RS SLEW RIGHT
+RSDH -SKTRSA -PLGRS -PLGR

Output
-SKTSLR 4/6 +WRS 4/6 28/47

I/O_22
2 1/4 1 1.0-BU 1.0-BU

9
0 2/4 11X3 4/6 11X3 4/6 11X3 28/47 11X3

11
-SKTSLR
-PLGRSA -SKTR
/15.F1
+RSDH
Assignment =PCB
No.
Location +PCB
Sheet
+RSDH +RH
14
42 Sh.
C
E
F
A
1 2 3 4 5 6 7 8 9
Output Output Output Output Output Output

Comment: Comment: Comment: Comment: Comment: Comment:
-A1 -A2 -A2 -A2 -A2 -A1
A FEEDER/AUX POWER /8.E3 LEFT TRACK POWER RIGHT TRACK POWER FAST TRACK RECIRC UNDERPAN A
/7.F7 Address:
/8.E3 Address:
/8.B4 Address:
/8.B4 Address:
/7.F6 Address:
Address:
OUT6 I/O_18 I/O_17 DOM_OUT_10 DOM_OUT_02 OUT3
5 15 16 15 11 7
Output Output Output Output Output
Comment: Comment: Comment: Comment: Comment:
-A1 -A1 -A1 -A1 -A2
FEEDER/AUX PWM LEFT TRACK PWM RIGHT TRACK PWM MAIN CONV RUN SCREENS/FINES
/7.F6 Address:
/7.F6 Address:
/7.F6 Address:
/7.F8 Address:
/8.B4 Address:
OUT0 OUT1 OUT2 OUT8 DOM_DOUT_01
1 3 5 1 12
B B
D1
D3
D5
F1
E5
D7
-R12 -R14 -R16
15X3
16X3
15X2
11X2
12X2
1K 1K 1K
-R11 -R13 -R15
0
0
0
10 K 10 K 10 K
-C1 -C2 -C3
+
-
+
-
+
-
1 uF 1 uF 1 uF
D1A
D3A
D5A
27/47
41/47
45/47
22/47
24/47
-PLGR
-PLGR
-PLGR
-PLGR
36/47
-PLGR
-PLGR
35/47
-PLGR
-PLGR
-PLGR
-PLGR
-PLGR
38/47
15/47
10/47
12/47
C C
27/47
41/47
45/47
22/47
24/47
36/47
35/47
38/47
15/47
10/47
12/47
+RH
+RH
+RH
+RH
+RH
+RH
+RH
+RH
+RH
+RH
+RH
-SKTR
-SKTR
-SKTR
-SKTR
-SKTR
-SKTR
-SKTR
-SKTR
-SKTR
-SKTR
-SKTR
1.0-BU
1.0-BU
11X2
12X2
1.0-BU
1.0-BU
1.0-BU
1.0-BU
1.0-BU
1.0-BU
1.0-BU
1.0-BU
1.0-BU
2/4
+RH
-SKTRSV
+RH
-SKTRSV
1/4
F1
E5
D7
D1A
D3A
D5A
15X3
16X3
15X2
2/4
1/4
THIS CIRCUIT
ONLY USED
1
1
D ON RS D
+RSPH
+RSPH
11X2
12X2
-PLGRSV
-PLGRSV
2/4
2/4
2/4
+RH
-SKTFEE
+RH
-SKTLT
+RH
-SKTRT
+RH
-SKTFT
+RH
-SKTMC
+RSPH
-SKTREC
+RSPH
-SKTSF
1/4
1/4
1/4
1/4
+RH +RH +RH

-SKTFEE -SKTLT -SKTRT +UPN
1/4 1/4 1/4 -SKTUPN
2/4
PROPORTIONAL PROPORTIONAL PROPORTIONAL GREEN

2/4
2/4
2/4
2/4
E/4
PVEA VALVE PVEA VALVE PVEA VALVE
3/4
3/4
3/4
PIN 1
+RH
+RH
+RH
+RH
+RH
+UPN
PORT A FEEDER PORT A LEFT TRACK REV PORT A RIGHT TRACK REV
+RSPH
+RSPH
-SKTFT
-SKTSF
-SKTMC
PORT B CONTROL BANKS PORT B LEFT TRACK FOR PORT B RIGHT TRACK FOR
-SKTLT
-SKTRT
-SKTUPN
-SKTREC
E RED E
-SKTFEE
2
2
0
0
PIN 2
+RH +RH
-SPL0C#1 -SPL0D#1
0 0
4/4
-PLGRSV
3/4
-PLGRSV
+RSPH
+RSPH
-SKTFRL:2, -SKT9:C, -PLGRS:5, -SPL0B:1, -SKTFL:A -SKTU:2, -SKTTSV:E, -SKTFEE:3, -SKTLT:3, -SKTRT:3, -SPL0A:1, -SKTUPN:E
1.0-GY
1.0-GY
1.0-GY
1.0-GY
1.0-GY
0
0
0
0
0
Grey,Grey,Grey,Grey,Grey Grey,Grey,Grey,Grey,Grey,Grey,Grey
4/4
3/4
RH13, RH17, RH19, RH30, RH66 RH15, RH18, RH20, RH21, RH22, RH29, RH69
+RH
+RH
1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm² 1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²
+RH +RH
-SKTRSV
-SKTRSV
-SPL0C -SPL0D
1.0-GY
1.0-GY
0
0
F 0 0 F
/14.F9 =CLU+CLU/18.F3
=RH+RH-SKTCLH:3

User 14/07/2016 AC
the E3! Proved RIGHT HARN OUTPUTS MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9
D
C
E
F
A
/12.F9
-A2
/8.B2
1
1
Address:
Comment:
-SPL0
+AVH
TOP APRON CLOSE

+AVH +AVH +LH
0
-PLGL
Output
-PLGAV -SKTTAC 1/8 -SKTAV 19/47
I/O_16
1.0-GY 1.0-GY 2 1/4 1 1/8 1.0-BU
0 8/8 8/8 0 0 2/4 9X1 9X1 19/47 9X1
-PLGAV
9
-SKTAV -SKTTAC
+LH +AVH +AVH -SKTL
+LH
-A2
/8.B2
Address:
Comment:
2
2
TOP APRON OPEN
+AVH +LH -PLGL
Output
-SKTTAO 2/8 -SKTAV 7/47
I/O_15
2 1/4 1 2/8 1.0-BU
0 2/4 10X1 10X1 7/47 10X1
-PLGAV
10
-SKTTAO
+AVH +AVH -SKTL
+LH
-A2
/8.B2
Address:
Comment:
BOTTOM APRON CLOSE
+AVH +LH -PLGL
Output
-SKTBAC -SKTAV
3
3
3/8 2/47
I/O_14
2 1/4 1 3/8 1.0-BU
0 2/4 11X1 11X1 11X1
Changing
-PLGAV 2/47
11
drawing
the E3!
-SKTBAC
only in
+AVH +AVH -SKTL

+LH
-A2
/8.B2
REV
5
Address:
Comment:
ECO
24789
BOTTOM APRON OPEN

+AVH +LH -PLGL
Output
-SKTBAO -SKTAV
Revision text
SEE REV5 CHANGE DOC
4/8 3/47
I/O_13
2 1/4 1 4/8 1.0-BU
0 2/4 12X1 12X1 3/47 12X1
-PLGAV
12
-SKTBAO
+AVH -SKTL
4
+AVH
4
+LH
-A2
/8.B4
Address:
Comment:
CHAMBER CLOSE
+AVH +LH -PLGL
DOM_OUT_04
Output
-SKTCC 5/8 -SKTAV 38/47
2 1/4 1 5/8 1.0-BU
0 2/4 9X2 9X2 38/47 9X2
-PLGAV
9
-SKTCC
Date
01/05/2019
+AVH +AVH -SKTL

+LH
-A2
/8.B4
5
5
Name
DS
Address:
Comment:
CHAMBER OPEN
+AVH +LH -PLGL
DOM_OUT_03
Output
-SKTCO 6/8 -SKTAV 24/47
2 1/4 1 6/8 1.0-BU
0 2/4 10X2 10X2 24/47 10X2
-PLGAV
10
-SKTCO
Proved
User
+AVH +AVH -SKTL

+LH
14/07/2016 AC
Date
-A1
/7.F8
Address:
Comment:
6
6
Name
SIDE CONVEYOR
+LH -PLGL
Output
-SKTSC
OUT10
1.0-GY 1/4 1.0-BU 29/47

0 2/4 F5 29/47 F5
5
-SKTSC
+LH -SKTL
+LH
-A1
/7.F7
Address:
Comment:
+LH
-DCP1 -PLGL
7
7
Output
DC PUMP
1/1 45/47
OUT4
1.0-GY 1.0-BU
0 1/1 E1 45/47 E1
1
LEFT HARN OUTPUTS
P.-Nr.:
Type COBRA
-DCP2 -SKTL
+LH +LH
-A1
/7.F7
Address:
Comment:
-PLGL
WATER PUMP
Output
=LH+LH-SKTWPS:1 17/47
OUT7
1.0-GY 1.0-BU
0 =BCK+BCK/2.D8 =BCK+BCK/2.C8 E7 E7 E7
Description: COBRA
0 17/47
=LH+LH-SKTWPS:2
7
8
-SKTL
+LH
Drawing number
MPESD_3109
0
/17.F1
9
9
Assignment =PCB
No.
Location +PCB
Sheet
16
42 Sh.
C
E
F
A
1 2 3 4 5 6 7 8 9
=LH+LH-SPL106:1 106 1.0-BU

/9.F8 106
Input/Output Input/Output
Comment: Comment:
-A2 -A2
/8.B4 SPARE /8.E3 SPARE
Address: Address:
Output I/O_11 I/O_21

A Comment:
A
-A2
SIREN/BEACON 14 12
/8.B2 Address:
PWM_OUT_06
15
14X2
12X3
15X1
B B
CAVITY FOR PIN 4
TO BE EMPTY TO ALLOW
'KEY' INSERT FROM HARNESS
TO PLUG INTO
1.0-BU
106
-PLGL
30/47
4/47
25/47
26/47
41/47
42/47
-PLGENG
-PLGL
-PLGR
-PLGL
-PLGR
R/21
-PLGR
A/3
+LH
-SKTAP
30/47
+LH
-SKTL
C APRON PRESSURE SENS
1.0-BU
PT5701 0 TO 250 BAR
C
4 TO 20 mA
15X1
+LH
-SPL15X1
B/3
+LH
-SKTAP
1.0-BU
1.0-BU
1.0-BU
A2
15X1
15X1
+LH
4/47
28/47
32/47
13/47
14/47
+LH
+LH
+LH
=VOH+VOH/4.F7
-SKTOP
-SKTOP
D D
-SKTOP
-SKTOP
-SKTOP
A/3
+LH
-SKTS
+LH
-SKTBEC
1/2
1.0-BU +LH
1.0-BU
1.0-BU
1.0-BU
1.0-BU
B2
4X1
6X2
2X2
2X3
14X3
1/2
A/3
+LH
23/47
+LH
-SKTL
32/47
-SKTL
+LH
-SKTL
+LH
-SKTL
37/47
+LH
-SKTL
+LH
-SKTL
31/47
12/47
10/47
=CHK +WBEC -WBEC
+WS
N
-PLGS
+WBEC
15X1
-PLGBEC
N
+WS
N/21
23/47
32/47
37/47
31/47
15X1
12/47
10/47
1.50 mm²
-H1 1
+WBEC
-PLGL
-PLGL
-PLGL
-PLGL
-PLGL
-PLGL
-LH2
-H2
-PLGENG
=CHK +WS -WS

E
A2
B2
E
4X1
6X2
2X2
2X3
14X3
U
U
0
1.50 mm²
2 4 2 2
2/2
B/3
IN0 DI_01 AI_ANA_01 IN4
+WBEC
-PLGBEC
+WS
-PLGS
/7.F3 APRON PRESSURE /8.B1 SPARE /8.B3 SPARE /7.F4 SPARE
2/2
B/3
-A1 -A2 -A2 -A1
+LH
+LH
Input Input Input Input
-SKTS
1.0-GY
1.0-GY
14 6 3
-SKTBEC
0
0
F F
0 I/O_19 AI_ANA_05 AI_ANA_02
Address: Address: Address:
/16.F9
COOLANT LEVEL /8.E3 /8.B3 SPARE /8.B3 SPARE
Comment: Comment: Comment:
-A2 -A2 -A2
Input Input Input

User 14/07/2016 AC
the E3! Proved LEFT HARN INPUTS MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9
D
C
E
F
A
1
1
=PCB+PCB/15.F9
=PCB+PCB/5.E4
=PCB+PCB/6.E3
PT TECH HPTO 12TS2 400
2
2
=RH+RH-SKTR:34
=RH+RH-SPL0A:1
107 =RH+RH-SKTR:5
210
0
107
210
0
3
3
1.0-GY
1.0-BU
1.0-BU
Changing
drawing
the E3!
only in
-SKTCLH
-SKTCLH
-SKTCLH
+RH
+RH
+RH
REV
1/6
3/6
2/6
5
ECO
24789
1/6
3/6
-PLGCLH
-PLGCLH
-PLGCLH
2/6
Revision text
SEE REV5 CHANGE DOC
107
1.0-OR
4
4
-SPL0
0
1.0-BK
-SPL107
-SKTG -SKTG
1.0-BK 8/12 1.0-RD
0 210
7/12
PT_TECH CONTROLLER
PWM COIL
GREY CONNECTOR
-SKTPWM
1.0-BK 1/2 1.0-PU
0 604
2/2 9/12
Date
01/05/2019
-SKTPWM
-SKTCON
1/2
5
1.0-BK 1.0-GN
5
0 605
2/2 10/12
Name
DS
-SKTCON CLUTCH ON/OFF
-SKTCIS 0.75 mm²

INPUT SPEED SENSOR
1 1/3 -WCLH4 R
1/12 1.0-OR 1.0-OR
614 11/12
107 107
Proved
User
0.75 mm²
2 2/3 -WCLH4 B
4/12 1.0-OR 1.0-OR
615
14/07/2016 AC
Date
12/12
107 107
3 3/3 -WCLH4 SCRN

6
6
615
Name
+RH
-SKTB 0.75 mm² -PLGCLH -SKTCLH
7/12
OUTPUT SPEED SENSOR
-SKTCOS 0.75 mm² -WCLH1 G 4/6 WHT

-SKTB 25 =PCB+PCB/7.C9
1 1/3 -WCLH3 R 25 4/6 25 =RH+RH-SKTR:25
7
607 2/12 +RH

-PLGCLH -SKTCLH
PT_TECH CONTROLLER
CLUTCH
P.-Nr.:
Type COBRA
0.75 mm² 0.75 mm²

2 2/3 -WCLH3 B 8/12 -WCLH1 Y 5/6 BRN
BLACK CONNECTOR
608 26 26 =PCB+PCB/7.C9
3/12 5/6 26 =RH+RH-SKTR:39
+RH
3 3/3 -WCLH3 SCRN
608
-PLGCLH -SKTCLH
-WCLH1 SCRN 6/6 SCRN
0 0 =PCB+PCB/7.C9
6/6 0 =RH+RH-SKTR:7
Description: COBRA
-SKTCPS
PRESSURE SENSOR
8
0.75 mm²
2 2/4 -WCLH5 R
611 10/12
3
0.75 mm²
Drawing number
1/4
MPESD_3109
1 -WCLH5 B
612 11/12
0.75 mm²
4 4/4 -WCLH5 W
613 12/12
-SKTB
612
SCRN
-WCLH5
9
9
Assignment =CLU
No.
Location +CLU
Sheet
18
42 Sh.
C
E
F
A
1 2 3 4 5 6 7 8 9 10 11 12
+WBEC
-LH2#2
0 0 U
1 15X1 N
A +WBEC A
-PLGBEC#1 -LH2S
+WBEC SEE TABLE
+W1 FRONT LEFT -PLGBEC#2
-PLG1#1 E-STOP
1 15X1 N
1850 2 0 U +WBEC
-H2#1
-LH2#1
-PLGBEC_H
+WBEC
WBEC
AMBER
+W1 W1 BEACON
-PLG1#2 -PLG1_H
THIS CABLE MUST BE IN CONDUIT
1 90 -ES1:1 Blue 1W1 1.00 mm² -ES1
2 91 -ES1:2 Blue 2W1 1.00 mm² +W1 +W1
B -ES1#1 B
1 90 -PLG1:1 Blue 1W1 1.00 mm²
2 91 -PLG1:2 Blue 2W1 1.00 mm²
-H1#1
+WS +WS -PLGS_H SEE TABLE
MIDDLE LEFT
+W2 -PLGS#2 -PLGS#1 +WS
E-STOP
-PLG2#1 A 15X1 N -H1#2
C 200
U + 15X1 N
C
B 0
- 0 U
WS
W2 SOUNDER
+W2 -PLG2_H
-PLG2#2 THIS CABLE MUST BE IN CONDUIT
-ES2
1 91 -ES2:1 Blue 1W2 1.00 mm² +W2
-ES2#1 +W2
2 92 -ES2:2 Blue 2W2 1.00 mm²
1 91 -PLG2:1 Blue 1W2 1.00 mm²
2 92 -PLG2:2 Blue 2W2 1.00 mm²
+W21 -L21#1
-PLG21#1 2
+W21 *2/2 100 +W21
D -PLG21#2 -L21#2 D
1 72 N 1 72 N
2 0 U 2 0 U
-PLG21_H
W21
+W3 FRONT RIGHT
-PLG3#1 E-STOP CONTROL CABINET LAMP
2900 THIS CABLE MUST BE IN CONDUIT
1
W3
E +W3 -PLG3_H +W24 E
-PLG3#2 -ES3 -PLG24A#2
1 92 -ES3:1 Blue 3W1 1.00 mm² +W3 1 5X2C W24_1
-ES3#1 +W3
2 93 -ES3:2 Blue 3W2 1.00 mm² 2 5X2C W24_1
1 92 -PLG3:1 Blue 3W1 1.00 mm²
2 93 -PLG3:2 Blue 3W2 1.00 mm² +W24 -SKT24A#1
-PLG24#1 -SKT24A_H -PLG24A#1
1800 -PLG24A_H
-PLG24_H
+W24 W24
-PLG24#2
F +W4 REAR RIGHT N CHAMBER INSPECTION DOOR DISCONNECT +W24 F
1 64
-PLG4#1 E-STOP THIS CABLE MUST BE IN CONDUIT -SKT24A#2
2 5X2B U
1900 1 64 N
2 5X2B U
W4 +W25
+W4 -PLG4_H -PLG25A#2
-PLG4#2 -ES4
+W4 1 5X2A W25_1
1 93 -ES4:1 Blue 4W1 1.00 mm²
-ES4#1 +W4 2 5X2A W25_1
2 94 -ES4:2 Blue 4W2 1.00 mm²
1 93 -PLG4:1 Blue 4W1 1.00 mm² -SKT25A#1 -PLG25A#1
-SKT25A_H
2 94 -PLG4:2 Blue 4W2 1.00 mm² -PLG25_H 2250
G -PLG25A_H G
-PLG25#1
*3/3
+W25
-PLG25#2 W25
A 5X2B N
B 5X2 U CHAMBER HOOD DISCONNECT +W25
THIS CABLE MUST BE IN CONDUIT -SKT25A#2
1 5X2B N
NOTE: USE SCREW PROVIDED
2 5X2 U
WITH INOX HOODS TO FIX INSERT
+WETH
500 -SKTETH#1
H +WETH H
-PLGETH#1
WETH
-SKTETH_BULK#1
COBRA NG PROGRAMMING ETHERNET CABLE CABLE NUMBER LENGTH IN KIT TC042-10101_MK03 LENGTH IN KIT TC043-10101_MK04
WBEC 970 2550
WS 210 260
I ALL CABLES ON THIS SHEET SUPPLIED IN I

TC042-10101_MK03 COBRA 230 ELECTRICAL CHASSIS KIT (=CHK)
AND
TC043-10101_MK04 COBRA 290 ELECTRICAL CHASSIS KIT (=CHK) Changing Date Name Type COBRA Description: COBRA Assignment =CHK
drawing M.-Nr.: ELECTRICAL WIRING SCHEMATIC Location +CHK
User 14/07/2016 AC
only in 5
24789 SEE REV5 CHANGE DOC 01/05/2019 DS Drawing number Sheet 19
the E3! REV ECO Revision text Date Name Proved CHASSIS CABLES MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
A A
SUPPLIED AS A LONE CABLE UNDER TC04201-WVOEST COBRA ENGINE SERVICE TOOL VOLVO CABLE WVOEST (=WVOEST). LENGTH IS 7000
SUPPLIED AS A LONE CABLE UNDER TC04301-WVOEST COBRA 290 ENGINE SERVICE TOOL T4 VOLVO CABLE WVOEST (=WVOEST). LENGTH IS 5600
=WVOEST
=WVOEST +WVOEST
+WVOEST HEAT SHRINK APPLIED AT NECK =WVOEST
-SKTVOEST#1 +WVOEST
-SKTVOEST#2
-PLGVOEST#2
1 401 -PLGVOEST:1 Blue WVOEST3 1.00 mm² -SKTVOEST_H SEE ABOVE 1 401 -SKTVOEST:1 Blue WVOEST3 1.00 mm²
2 402 -PLGVOEST:2 Blue WVOEST2 1.00 mm²
2 402 -SKTVOEST:2 Blue WVOEST2 1.00 mm²
B 3 403 -PLGVOEST:3 Grey WVOEST4 1.00 mm² B
3 403 -SKTVOEST:3 Grey WVOEST4 1.00 mm²
4 404 -PLGVOEST:4 B -WVOCAN 0.75 mm²
WVOEST 4 404 -SKTVOEST:4 B -WVOCAN 0.75 mm²
5 405 -PLGVOEST:5 Blue WVOEST1 1.00 mm²
5 405 -SKTVOEST:5 Blue WVOEST1 1.00 mm²
6 406 -PLGVOEST:6 W -WVOCAN 0.75 mm² ENGINE SERVICE TOOL VOLVO CABLE 6 406 -SKTVOEST:6 W -WVOCAN 0.75 mm²
=WVOEST
+WVOEST
-PLGVOEST#1
C C
SUPPLIED AS A LONE CABLE UNDER TC04201-WJDEST COBRA ENGINE SERVICE TOOL JD CABLE WJDEST (=WJDEST)
+WJDEST -PLGJDESTA#1 -PLGJDEST#1 +WJDEST
-PLGJDESTA#2 -PLGJDEST_H -PLGJDEST#2

420
-PLGJDESTA_H
1 26 -PLGJDEST:C Blue JDEST1 1.00 mm² A 0 -PLGJDESTA:4 Grey JDEST4 1.00 mm²
2 25 -PLGJDEST:D Blue JDEST2 1.00 mm² B 106 -PLGJDESTA:3 Blue JDEST3 1.00 mm²
D 3 106 -PLGJDEST:B Blue JDEST3 1.00 mm² C 26 -PLGJDESTA:1 Blue JDEST1 1.00 mm²
D
4 0 -PLGJDEST:A Grey JDEST4 1.00 mm² WJDEST D 25 -PLGJDESTA:2 Blue JDEST2 1.00 mm²
ENGINE SERVICE TOOL JD CABLE
-PLGJDEST_C
E E
SUPPLIED AS A LONE CABLE UNDER TC04203-W9 COBRA 230 SPEED WHEEL CABLE (=W9). LENGTH IS 4000
F SUPPLIED AS A LONE CABLE UNDER TC04303-W9 COBRA 290 SPEED WHEEL CABLE (=W9). LENGTH IS 4700
F
=W9
+W9 =W9 =W9
+W9 -PLG9_H SEE ABOVE +W9
-PLG9#2
-PLG9#1 -SKT9A#1
A 64 BRN *3/3
B A6 BLK
C 0 BLU
W9
MAIN CONVEYOR SPEED CABLE
(CABLE TO BE IN CONDUIT)
G G
SUPPLIED AS A LONE CABLE UNDER TC04201-WRS COBRA 230 RS MTG FRAME CABLE WRS (=WRS). LENGTH IS 1350
=WRS SUPPLIED AS A LONE CABLE UNDER TC04301-WRS COBRA 290 RS MTG FRAME CABLE WRS (=WRS). LENGTH IS 1100
=WRS +WRS =WRS
+WRS -SKTRS#1 +WRS
-SKTRS#2 -SKTRSA_H -SKTRSA#2
H 1 64 -SKTRSA:1 Blue WRS4 1.00 mm² -SKTRS_H SEE ABOVE -SKTRSA_C 1 64 -SKTRS:1 Blue WRS4 1.00 mm² H
2 A7 -SKTRSA:2 Blue WRS5 1.00 mm² 2 A7 -SKTRS:2 Blue WRS5 1.00 mm²
3 10X3 -SKTRSA:3 Blue WRS1 1.00 mm² 3 10X3 -SKTRS:3 Blue WRS1 1.00 mm²
4 11X3 -SKTRSA:4 Blue WRS2 1.00 mm² WRS 4 11X3 -SKTRS:4 Blue WRS2 1.00 mm²
5 0 -SKTRSA:5 Grey WRS3 1.00 mm² 5 0 -SKTRS:5 Grey WRS3 1.00 mm²
RS MTG FRAME CABLE
-SKTRSA#1
I I
Changing Date Name Type COBRA Description: COBRA Assignment =CHK
drawing M.-Nr.: ELECTRICAL WIRING SCHEMATIC Location +CHK
User 14/07/2016 AC
only in 5 SEE REV5 CHANGE DOC Drawing number Sheet 20
24789 01/05/2019 DS
the E3! REV ECO Proved CHASSIS CABLES MPESD_3109 No. 42 Sh.
Revision text Date Name
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
A A
B B
SUPPLIED AS A LONE CABLE UNDER TC04201-WLS_MK03 COBRA LIGHT SWITCH CABLE WLS (=WLS)
200 +WLS
-PLGWLS#1
2-POS
WLS
-SLS#1
C C
D D
=PCB+PCB/10.B3
=PCB+PCB/10.B6
-SPT1
+OPH
=OPH
=OPH
+OPH
-SPT1
Master
Master
PIN 4
PIN 2
PIN 2
PIN 4
SUPPLIED AS A LONE CABLE UNDER TC04201-WS1-3_MK03 COBRA TRACK/RUN/SETUP SWITCH CABLE WS1-3 (=WS1-3)
L+ L+
1
1
E +WS1-3 +WS1-4 500 E
1000 -PLGS1-4#1
-PLGS1-3#1 IN/OUT IN/OUT WHITE
2
2
*5/5
L- L-
3-POS
3
3
NOT USED
TRACK SWITCH
SETUP SWITCH
WS1-4
CHANNEL 3
CHANNEL 4
APRON DUMP PB
WS1-3 IN/OUT IN/OUT
4
4
-S1-4#1
-S1-3#1
Shell Shell
5
5
F F
=PCB+PCB/10.B3
=PCB+PCB/10.B6
-SPT1
+OPH
=OPH
=OPH
+OPH
-SPT1
Master
Master
PIN 4
PIN 2
PIN 2
PIN 4
L+ L+
1
1
500 +WS1-1 +WS1-2 500

GREEN -PLGS1-1#1 -PLGS1-2#1 BLUE
G IN/OUT IN/OUT G
2
2
L- L-
3
3
FEEDER LAMP
CHANNEL 1
WS1-1 WS1-2
CHANNEL 2
IN/OUT IN/OUT
4
4
FEEDER START/STOP
AUTO START/STOP PB
-S1-1#1 AUTO START/STOP LAMP -S1-2#1
Shell Shell
5
5
H H
ALL CABLES ON THIS SHEET (EXCEPT FOR THOSE IN DOTTED BOXES)

I SUPPLIED IN TC042-10107_MK03 COBRA OPERATOR PANEL SWITCH KIT (=PBCK) I
Changing Date Name Type COBRA Description: COBRA Assignment =PBCK

drawing M.-Nr.: ELECTRICAL WIRING SCHEMATIC Location +PBCK
User 14/07/2016 AC
only in 5
the E3! REV ECO Revision text Date Name Proved DOOR SWITCH CABLES MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
POWER UNIT LAMP
-SKTPL#2
-SKTPL#1
1 72 -SPL71:1 Blue LH81 1.00 mm²

2 0 -SPL0A:1 Grey LH82 1.00 mm²
-SKTPL_H
-SKTOC#2
R
A 203 -SKTL:1 Blue LH1 1.00 mm² LE -LHT1#2
-S
OO -SKTWPS#2
LC
KT
B 0 -SPL0A:1 Grey LH72 1.00 mm² OI 1 0 -SPL0A:1 Grey LH71 6.00 mm²
A 1 E7 -SKTL:17 Blue LH34 1.00 mm² A
OC
2 0 -SPL0A:1 Grey LH55 1.00 mm²

#1
WATER PUMP SOLENOID

GROUND TERMINAL
M10 TC042-10102_MK04 COBRA 230 LEFT HARNESS
-LHT1#1
1750
T/Y PIECES & CONDUIT MUST BE SUITABLY SIZED BY THE HARNESS MANUFACTURER
-SKTWPS#1
SEALING PLUGS MUST BE USED ON ALL UNUSED PINS FOR ALL CONNECTORS
90
0
DIMENSIONS BETWEEN T/Y PIECES ARE ON CENTERS

SPLICES ARE TO BE 50MM AWAY FROM NEAREST CONNECTOR / T/Y PIECE
80
120
-DCP1#2
1 E1 -SKTL:45 Blue LH33 1.00 mm²
700
-SKTAP#2
-DCP1#1 A 106 -SPL106:1 Blue LH66 1.00 mm²
1/1
B A2 -SKTL:32 Blue LH38 1.00 mm²
B 60 B
130 190 650 APRON PRESSURE
DC PUMP SOLENOID -SKTFLL#2 -SKTAP#1
1 116 -SPL116:1 Blue LH61 1.00 mm²
-DCP2#1
60 1/1 2 0 -SPL0D:1 Grey LH57 1.00 mm²
-SKTRLL_C
-SKTS#2
-SKTFLL_C
-SKTRLL#2
SIDE CONVEYOR -DCP2#2 A 15X1 -SPL15X1:1 Blue LH35 1.00 mm²
1 116 -SPL116:1 Blue LH62 1.00 mm²
-SKTSC#1 1 0 -SPL0A:1 Grey LH54 1.00 mm² B 0 -SPL0D:1 Grey LH59 1.00 mm²
2 0 -SPL0A:1 Grey LH56 1.00 mm²
-SKTSC#2 SOUNDER
-SKTRLL#1
-SKTAP_H
*2/2
1 F5 -SKTL:29 Blue LH32 1.00 mm² -SKTS#1

REAR LEFT TRACK LAMP
2 0 -SPL0C:1 Grey LH47 1.00 mm²
-SKTFLL#1
350
-SKTB#2
-SPL0A#3 1 214 -SPL214:1 BRN -WB. 0.34 mm²
-SKTRLL_H
0 2 AUXRX -SPLAUXRX:1 WHT -WB. 0.34 mm²

-LHT1:1, -SKTOC:B, -DCP2:1, -SKTWPS:2, -SKTRLL:2, -SPL0C:1, -SKTPL:2 3 0 -SPL0D:1 BLU -WB. 0.34 mm²
Grey,Grey,Grey,Grey,Grey,Grey,Grey 4 AUXTX -SPLAUXTX:1 BLK -WB. 0.34 mm²
-SKTS_H
-SKTFLL_H
C -SKTB_C C
LH71, LH72, LH54, LH55, LH56, LH45, LH82
-SPL0A#2 -SPL106#2 BELT WEIGHER
6.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,2.50 mm²,1.00 mm²
106 -SKTB#1
-SKTL:46, -SKTOP:8, -SKTTU:4, -SKTAP:A, -SKTOP:7, -SKTEST:3
400
100
Blue,Blue,Blue,Blue,Blue,Blue
LH68, LH67, LH64, LH66, LH65, LH85
1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²
170
-SKTL_H -SPL0C#3 -SPL0D#3 -SPL15X1#2
-SPL106#1
0 0 15X1
-SPL0A:1, -SPL0B:1, -SKTSC:2, -SPL0D:1 -SKTFLL:2, -SPL0C:1, -SKTS:B, -SKTBEC:2, -SKTAV:8, -SKTB:3 -SKTL:30, -SKTS:A, -SKTBEC:1
410
-SKTL#1
100
-SKTL#2 400 710 1600 850
Grey,Grey,Grey,Grey Grey,Grey,Grey,Grey,Grey,Blue Blue,Blue,Blue
LH45, LH46, LH47, LH48 LH57, LH48, LH59, LH60, LH58, BLU LH37, LH35, LH36
180
2.50 mm²,1.50 mm²,1.00 mm²,1.50 mm² 1.00 mm²,1.50 mm²,1.00 mm²,1.00 mm²,1.00 mm²,0.34 mm² 1.00 mm²,1.00 mm²,1.00 mm²
-SPL116#1
-SPL0C#2 -SPL0D#2 -SPL15X1#1 -SKTBEC#1
CONTROL BOX -SPL116#2
116 -SKTBEC_H
1650 195 350 505 215 170
-SKTL#3 -SKTL#3 -SKTFLL:1, -SKTRLL:1, -SKTL:35
1 203 -SKTOC:A Blue LH1 1.00 mm² 24 10X2 -SKTAV:6 Blue LH31 1.00 mm² Blue,Blue,Blue
2 11X1 -SKTAV:3 Blue LH28 1.00 mm² 27 3X5 -SKTOP:3 Blue LH6 1.00 mm² LH61, LH62, LH63 -SPL25#2 AUXTX -SPLAUXRX#1 -SPL214#1 -SPL214#2
D 3 12X1 -SKTAV:4 Blue LH29 1.00 mm² 28 26 -SPL26:1 BRN -WLHJ1939 1.00 mm²,1.00 mm²,1.00 mm² 25 -SPLAUXTX#1 -SKTB:4, -SKTTU:9 214 BEACON D
-SPLAUXRX#2 -SKTBEC#2
4 214 -SPL214:1 Blue LH70 1.00 mm² 29 F5 -SKTSC:1 Blue LH32 1.00 mm² -SKTL:16, -SKTOP:17, -SKTOP:42, -SKTTU:7, -SKTEST:2 -SPL25#1 -SPLAUXTX#2 Black,Blue -SKTL:4, -SKTB:1, -SKTRC:+
AUXRX 1 15X1 -SPL15X1:1 Blue LH36 1.00 mm²
6 0 SCRN -WLHCAN 30 15X1 -SPL15X1:1 Blue LH37 1.00 mm² White,Blue,Blue,Blue,Blue BLK, LH73 Blue,Brown,Blue
-SKTB:2, -SKTTU:8 2 0 -SPL0D:1 Grey LH60 1.00 mm²
7 10X1 -SKTAV:2 Blue LH27 1.00 mm² 31 B2 -SKTOP:4 Blue LH4 1.00 mm² WHT, LH21, LH76, LH20, LH84 0.34 mm²,1.00 mm² LH70, BRN, LH69
-SPL26#2 White,Blue
200
8 0 SCRN -WLHJ1939 32 A2 -SKTAP:B Blue LH38 1.00 mm² 1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm² -SPL26#1 1.00 mm²,0.34 mm²,1.00 mm² -SKTTU#2
85
26 WHT, LH74
10 6X2 -SKTOP:32 Blue LH75 1.00 mm² 35 116 -SPL116:1 Blue LH63 1.00 mm² 1 0 -SPL0E:1 Grey LH91 1.00 mm²
-SKTL:28, -SKTOP:18, -SKTOP:44, -SKTTU:18, -SKTEST:1 0.34 mm²,1.00 mm²
11 6X1 -SKTOP:12 Blue LH13 1.00 mm² 36 215 -SKTTU:24 Blue LH24 1.00 mm² -SPL0B#2 2 0 -SPL0E:1 Grey LH90 1.00 mm²
Brown,Blue,Blue,Blue,Blue
12 4X1 -SKTOP:28 Blue LH25 1.00 mm² 37 2X2 -SKTOP:13 Blue LH14 1.00 mm² -SKTTU#1 -SKTTU_C 3 0 -SPL0E:1 Grey LH89 1.00 mm²
-SPL0B#3 BRN, LH19, LH77, LH18, LH83 -SKTTU_H
13 92 -SKT2:2 Blue LH40 1.00 mm² 38 9X2 -SKTAV:5 Blue LH30 1.00 mm² 4 106 -SPL106:1 Blue LH64 1.00 mm²
0 1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm² -SKTAV#2
14 6X3 -SKTOP:16 Blue LH17 1.00 mm² 39 5X1 -SKTOP:6 Blue LH3 1.00 mm² 7 25 -SPL25:1 Blue LH20 1.00 mm²
-SPL0C:1, -SKTWL:2, -SPL0E:1, -SKT21:2, -SKTOP:9, -SKTOP:19, -SKTRC:-, -SKTEST:4 1 9X1 -SKTL:19 Blue LH26 1.00 mm²
-SKTAV_H
15 4X3 -SKTOP:15 Blue LH16 1.00 mm² 40 13X2 -SKTOP:33 Blue LH5 1.00 mm² 250 8 AUXRX -SPLAUXRX:1 Blue LH74 1.00 mm²
Grey,Grey,Grey,Grey,Grey,Grey,Grey,Grey 2 10X1 -SKTL:7 Blue LH27 1.00 mm²
16 25 -SPL25:1 WHT -WLHJ1939 42 216 -SKTOP:2 Blue LH8 1.00 mm² 9 AUXTX -SPLAUXTX:1 Blue LH73 1.00 mm²
LH46, LH49, LH50, LH51, LH52, LH53, LH44, LH86 3 11X1 -SKTL:2 Blue LH28 1.00 mm²
17 E7 -SKTWPS:1 Blue LH34 1.00 mm² 43 14 -SPL14:1 BRN -WLHCAN 18 26 -SPL26:1 Blue LH18 1.00 mm²
1.50 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm² 4 12X1 -SKTL:3 Blue LH29 1.00 mm²
-SPL0E#1
19 9X1 -SKTAV:1 Blue LH26 1.00 mm² 44 32 -SPL32:1 WHT -WLHCAN 19 0 -SPL0E:1 Grey LH88 1.00 mm²
5 9X2 -SKTL:38 Blue LH30 1.00 mm²
20 114 -SKTOP:29 Blue LH41 1.00 mm² 45 E1 -DCP1:1 Blue LH33 1.00 mm² 20 (MTS)TX -PLGTST:4 Blue LH22 1.00 mm²
-SPL0E#2 TELEMETRY UNIT 6 10X2 -SKTL:24 Blue LH31 1.00 mm²
21 213 -SKTOP:1 Blue LH7 1.00 mm² 46 106 -SPL106:1 Blue LH68 1.00 mm² 21 (MTS)RX -PLGTST:5 Blue LH23 1.00 mm²
0 8 0 -SPL0D:1 Grey LH58 1.00 mm²
22 90 -SKT1:1 Blue LH2 1.00 mm² 23 0 -SPL0E:1 Grey LH87 1.00 mm²
-SPL0B:1, -SKTTU:23, -SKTTU:19, -SKTTU:3, -SKTTU:2, -SKTTU:1
E 23 2X3 -SKTOP:14 Blue LH15 1.00 mm² 24 215 -SKTL:36 Blue LH24 1.00 mm² E
950
Grey,Grey,Grey,Grey,Grey,Grey -SKTAV#1
LH50, LH87, LH88, LH89, LH90, LH91
1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²
-SKT1#1
-SKT1_H
550
450
-SPL71#2
72
-SKTOP:30, -SKT21:1, -SKTWL:1, -SKTPL:1 FRONT LEFT E-STOP
Blue,Blue,Blue,Blue -SPL71#1
-SKT1#2
LH42, LH43, LH80, LH81
420
1 90 -SKTL:22 Blue LH2 1.00 mm²
150
1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²
2 91 -SKT2:1 Blue LH39 1.00 mm²
-SKT21#1
-SKTEST#2
-SKT21#2 -SKT21_H 1 26 -SPL26:1 Blue LH83 1.00 mm²
100
1 72 -SPL71:1 Blue LH43 1.00 mm² 2 25 -SPL25:1 Blue LH84 1.00 mm²
-SKTWL_H
2 0 -SPL0B:1 Grey LH51 1.00 mm² 3 106 -SPL106:1 Blue LH85 1.00 mm²
4 0 -SPL0B:1 Grey LH86 1.00 mm²
OPERATOR PANEL LAMP
F -SKTEST#1 F
430
-SKTEST_C
260 -SKTWL#2
-SKTOP#3 -SKTOP#3
1 72 -SPL71:1 Blue LH80 1.00 mm²
1 213 -SKTL:21 Blue LH7 1.00 mm² 17 25 -SPL25:1 Blue LH21 1.00 mm²
2 0 -SPL0B:1 Grey LH49 1.00 mm²
-SKTEST_H
3 3X5 -SKTL:27 Blue LH6 1.00 mm² 19 0 -SPL0B:1 Grey LH53 1.00 mm² ENGINE SERVICE TOOL -SKTWL#1
70
4 B2 -SKTL:31 Blue LH4 1.00 mm² 20 32 -SPL32:1 Blue LH11 1.00 mm² -SKTOP_H WORK LIGHTS
6 5X1 -SKTL:39 Blue LH3 1.00 mm² 21 14 -SPL14:1 Blue LH9 1.00 mm²
-SKTWL_C
-SKTOP#1
7 106 -SPL106:1 Blue LH65 1.00 mm² 28 4X1 -SKTL:12 Blue LH25 1.00 mm²
-SKTOP#2 350
8 106 -SPL106:1 Blue LH67 1.00 mm² 29 114 -SKTL:20 Blue LH41 1.00 mm²
9 0 -SPL0B:1 Grey LH52 1.00 mm² 30 72 -SPL71:1 Blue LH42 1.00 mm²
11 14 -SPL14:1 Blue LH10 1.00 mm² 33 13X2 -SKTL:40 Blue LH5 1.00 mm² HEAT SHRINK APPLIED AT NECK
12 6X1 -SKTL:11 Blue LH13 1.00 mm² 42 25 -SPL25:1 Blue LH76 1.00 mm² OPERATOR PANEL -SPL14#1 -SPL32#1 TELEMETRY SERVICE TOOL
13 2X2 -SKTL:37 Blue LH14 1.00 mm² 44 26 -SPL26:1 Blue LH77 1.00 mm² -SPL14#2 -SPL32#2 -PLGTST#1
70
14 2X3 -SKTL:23 Blue LH15 1.00 mm² 45 32 -SPL32:1 Blue LH78 1.00 mm² 14 32
15 4X3 -SKTL:15 Blue LH16 1.00 mm² 46 14 -SPL14:1 Blue LH79 1.00 mm² -SKTL:43, -SKTOP:21, -SKTOP:46, -SKTOP:11 -SKTL:44, -SKTOP:20, -SKTOP:45, -SKTOP:10
-PLGTST#2
G 16 6X3 -SKTL:14 Blue LH17 1.00 mm² Brown,Blue,Blue,Blue White,Blue,Blue,Blue
250
G
4 (MTS)TX -SKTTU:20 Blue LH22 1.00 mm²
BRN, LH9, LH79, LH10 WHT, LH11, LH78, LH12
5 (MTS)RX -SKTTU:21 Blue LH23 1.00 mm²
1.00 mm²,1.00 mm²,1.00 mm² 1.00 mm²,1.00 mm²,1.00 mm²
70
-SKTRC#1
DUST CAP REQ
250
RADIO CHARGE SOCKET
-SKTRC#2
+ 214 -SPL214:1 Blue LH69 1.00 mm²
200
- 0 -SPL0B:1 Grey LH44 1.00 mm²
H H
-SKT2_H
-SKT2#2
-SKT2#1
1 91 -SKT1:2 Blue LH39 1.00 mm²
2 92 -SKTL:13 Blue LH40 1.00 mm²
Changing Date Name Type COBRA Description: COBRA Assignment =LH
drawing M.-Nr.: ELECTRICAL SCHEMATIC Location +LH
User 14/07/2016 AC
MIDDLE LEFT E-STOP 5 24789 SEE REV5 CHANGE DOC 01/05/2019 DS
the E3! Proved LEFT HARNESS MPESD_3109 No. 42 Sh.
1
1 2 3 4 5 6 7 8 9 10 11 12
1/1
GROUND TERMINAL
-LHT1#4 M10
1 0 -SPL0A:1 Grey LH71 6.00 mm² TC043-10102_MK04 COBRA 290 LEFT HARNESS (=LH)
E R -SKTOC#4
-LHT1#3 O OL -SKTL:1 Blue LH1 1.00 mm²
A 203
LC
OI B 0 -SPL0A:1 Grey LH72 1.00 mm² T/Y PIECES & CONDUIT MUST BE SUITABLY SIZED BY THE HARNESS MANUFACTURER
C #3
230
TO DIMENSIONS BETWEEN T/Y PIECES ARE ON CENTERS
- SK
A 0 -SKTPL#3 SPLICES ARE TO BE 50MM AWAY FROM NEAREST CONNECTOR / T/Y PIECE A
85
-SKTPL_H#1 -SKTPL#4
830 1100 -SPL71:1 Blue LH81 1.00 mm²
-SKTFLL_C#1
1 72
2 0 -SPL0A:1 Grey LH82 1.00 mm²
-SKTFLL#3
POWER UNIT LAMP -SKTFLL#4 -SKTAV#4
-SKTAV#3
2 0 -SPL0D:1 Grey LH57 1.00 mm² 2 10X1 -SKTL:7 Blue LH27 1.00 mm²
3 11X1 -SKTL:2 Blue LH28 1.00 mm²
4 12X1 -SKTL:3 Blue LH29 1.00 mm²
480
-SKTWPS#4
5 9X2 -SKTL:38 Blue LH30 1.00 mm²
1 E7 -SKTL:17 Blue LH34 1.00 mm²
6 10X2 -SKTL:24 Blue LH31 1.00 mm²
2 0 -SPL0A:1 Grey LH55 1.00 mm² -SPL0A#5
8 0 -SPL0D:1 Grey LH58 1.00 mm²
-SKTAV_H#1
0
-SKTWPS#3 -LHT1:1, -SKTOC:B, -DCP2:1, -SKTWPS:2, -SKTRLL:2, -SPL0C:1, -SKTPL:2
-SKTFLL_H#1
130 -SKTB#4
Grey,Grey,Grey,Grey,Grey,Grey,Grey
1 214 -SPL214:1 BRN -WB. 0.34 mm²
LH71, LH72, LH54, LH55, LH56, LH45, LH82
2 AUXRX -SPLAUXRX:1 WHT -WB. 0.34 mm²
WATER PUMP SOLENOID 6.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,2.50 mm²,1.00 mm²
B 3 0 -SPL0D:1 BLU -WB. 0.34 mm² B
-SPL0A#4 4 AUXTX -SPLAUXTX:1 BLK -WB. 0.34 mm²
-DCP2#4
1 0 -SPL0A:1 Grey LH54 1.00 mm² -SKTSC#4
1 F5 -SKTL:29 Blue LH32 1.00 mm²
-DCP1#4 -SPL0C:1 Grey LH47 1.00 mm²
-SKTRLL_C#1
2 0
REAR LEFT TRACK LAMP -SKTB_C#1
1 E1 -SKTL:45 Blue LH33 1.00 mm² SIDE CONVEYOR
*2/2
BELT WEIGHER
-DCP1#3
-DCP2#3
1/1
1/1
-SKTSC#3
-SKTB#3
-SKTRLL#4
-SKTRLL#3
1 116 -SPL116:1 Blue LH62 1.00 mm²
450
2 0 -SPL0A:1 Grey LH56 1.00 mm²
110
DC PUMP SOLENOID
535
50
50
-SKTRLL_H#1
C C
-SPL106#4 -SPLAUXRX#4 -SPL0D#5 -SPL15X1#4
106 -SPLAUXTX#4 AUXRX 0 15X1
-SKTL:46, -SKTOP:8, -SKTTU:4, -SKTAP:A, -SKTOP:7, -SKTEST:3 AUXTX -SKTB:2, -SKTTU:8 -SKTFLL:2, -SPL0C:1, -SKTS:B, -SKTBEC:2, -SKTAV:8, -SKTB:3 -SKTL:30, -SKTS:A, -SKTBEC:1
200
430
200
Blue,Blue,Blue,Blue,Blue,Blue -SKTB:4, -SKTTU:9 White,Blue Grey,Grey,Grey,Grey,Grey,Blue Blue,Blue,Blue
330
LH68, LH67, LH64, LH66, LH65, LH85 Black,Blue WHT, LH74 LH57, LH48, LH59, LH60, LH58, BLU LH37, LH35, LH36
1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm² BLK, LH73 0.34 mm²,1.00 mm² 1.00 mm²,1.50 mm²,1.00 mm²,1.00 mm²,1.00 mm²,0.34 mm² 1.00 mm²,1.00 mm²,1.00 mm²
-SKTL_H#1 0.34 mm²,1.00 mm² -SPLAUXRX#3
-SPL106#3 -SPL0D#4 -SPL15X1#3
-SPLAUXTX#3 -SKTS_H#1
-SKTL#5 360 100 1310 1360 470 580 275 310 150
-SKTS#3
-SKTL#4
SOUNDER
2100
-SPL116#3 -SPL25#4
-SPL0C#5 -SPL0C#4 -SPL214#3
25
CONTROL BOX -SPL116#4 0 -SPL214#4 -SKTS#4
-SKTL:16, -SKTOP:17, -SKTOP:42, -SKTTU:7, -SKTEST:2
116 -SPL0A:1, -SPL0B:1, -SKTSC:2, -SPL0D:1 214 A 15X1 -SPL15X1:1 Blue LH35 1.00 mm²
White,Blue,Blue,Blue,Blue -SPL25#3
-SKTFLL:1, -SKTRLL:1, -SKTL:35 Grey,Grey,Grey,Grey -SKTL:4, -SKTB:1, -SKTRC:+ B 0 -SPL0D:1 Grey LH59 1.00 mm²
-SKTL#6 -SKTL#6 WHT, LH21, LH76, LH20, LH84
Blue,Blue,Blue LH45, LH46, LH47, LH48 Blue,Brown,Blue
1 203 -SKTOC:A Blue LH1 1.00 mm² 24 10X2 -SKTAV:6 Blue LH31 1.00 mm² 1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²
LH61, LH62, LH63 2.50 mm²,1.50 mm²,1.00 mm²,1.50 mm² LH70, BRN, LH69
300
D 2 11X1 -SKTAV:3 Blue LH28 1.00 mm² 27 3X5 -SKTOP:3 Blue LH6 1.00 mm² -SKTTU#4 D
1.00 mm²,1.00 mm²,1.00 mm² 1.00 mm²,0.34 mm²,1.00 mm²
3 12X1 -SKTAV:4 Blue LH29 1.00 mm² 28 26 -SPL26:1 BRN -WLHJ1939 -SPL0E#4 1 0 -SPL0E:1 Grey LH91 1.00 mm²
4 214 -SPL214:1 Blue LH70 1.00 mm² 29 F5 -SKTSC:1 Blue LH32 1.00 mm² -SPL26#4 0 2 0 -SPL0E:1 Grey LH90 1.00 mm²
620
6 0 SCRN -WLHCAN 30 15X1 -SPL15X1:1 Blue LH37 1.00 mm² 26 -SPL0B:1, -SKTTU:23, -SKTTU:19, -SKTTU:3, -SKTTU:2, -SKTTU:1 3 0 -SPL0E:1 Grey LH89 1.00 mm²
7 10X1 -SKTAV:2 Blue LH27 1.00 mm² 31 B2 -SKTOP:4 Blue LH4 1.00 mm² -SKTL:28, -SKTOP:18, -SKTOP:44, -SKTTU:18, -SKTEST:1 Grey,Grey,Grey,Grey,Grey,Grey -SKTTU_H#1 -SKTTU#3 -SKTTU_C#1 4 106 -SPL106:1 Blue LH64 1.00 mm²
8 0 SCRN -WLHJ1939 32 A2 -SKTAP:B Blue LH38 1.00 mm² Brown,Blue,Blue,Blue,Blue LH50, LH87, LH88, LH89, LH90, LH91 -SPL0E#3 7 25 -SPL25:1 Blue LH20 1.00 mm²
-SPL26#3
10 6X2 -SKTOP:32 Blue LH75 1.00 mm² 35 116 -SPL116:1 Blue LH63 1.00 mm² BRN, LH19, LH77, LH18, LH83 1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm² 8 AUXRX -SPLAUXRX:1 Blue LH74 1.00 mm²
11 6X1 -SKTOP:12 Blue LH13 1.00 mm² 36 215 -SKTTU:24 Blue LH24 1.00 mm² 1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm² 9 AUXTX -SPLAUXTX:1 Blue LH73 1.00 mm²
12 4X1 -SKTOP:28 Blue LH25 1.00 mm² 37 2X2 -SKTOP:13 Blue LH14 1.00 mm² 18 26 -SPL26:1 Blue LH18 1.00 mm²
13 92 -SKT2:2 Blue LH40 1.00 mm² 38 9X2 -SKTAV:5 Blue LH30 1.00 mm² 230 19 0 -SPL0E:1 Grey LH88 1.00 mm²
14 6X3 -SKTOP:16 Blue LH17 1.00 mm² 39 5X1 -SKTOP:6 Blue LH3 1.00 mm² -SKTBEC#3 -SPL0B#5 20 (MTS)TX -PLGTST:4 Blue LH22 1.00 mm²
700
15 4X3 -SKTOP:15 Blue LH16 1.00 mm² 40 13X2 -SKTOP:33 Blue LH5 1.00 mm² 0 TELEMETRY UNIT 21 (MTS)RX -PLGTST:5 Blue LH23 1.00 mm²
-SKTBEC#4 -SKTBEC_H#1
16 25 -SPL25:1 WHT -WLHJ1939 42 216 -SKTOP:2 Blue LH8 1.00 mm² 100 -SPL0C:1, -SKTWL:2, -SPL0E:1, -SKT21:2, -SKTOP:9, -SKTOP:19, -SKTRC:-, -SKTEST:4 23 0 -SPL0E:1 Grey LH87 1.00 mm²
1 15X1 -SPL15X1:1 Blue LH36 1.00 mm²
17 E7 -SKTWPS:1 Blue LH34 1.00 mm² 43 14 -SPL14:1 BRN -WLHCAN Grey,Grey,Grey,Grey,Grey,Grey,Grey,Grey 24 215 -SKTL:36 Blue LH24 1.00 mm²
2 0 -SPL0D:1 Grey LH60 1.00 mm²
19 9X1 -SKTAV:1 Blue LH26 1.00 mm² 44 32 -SPL32:1 WHT -WLHCAN LH46, LH49, LH50, LH51, LH52, LH53, LH44, LH86
20 114 -SKTOP:29 Blue LH41 1.00 mm² 45 E1 -DCP1:1 Blue LH33 1.00 mm² BEACON 1.50 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²
55
21 213 -SKTOP:1 Blue LH7 1.00 mm² 46 106 -SPL106:1 Blue LH68 1.00 mm² -SPL0B#4
-SKTWL_C#1 -SKTWL#4
22 90 -SKT1:1 Blue LH2 1.00 mm² 100 1 72 -SPL71:1 Blue LH80 1.00 mm²
-SKTAP_H#1
E 23 2X3 -SKTOP:14 Blue LH15 1.00 mm² 2 0 -SPL0B:1 Grey LH49 1.00 mm² E
-SKTWL_H#1
-SKTWL#3
WORK LIGHTS
-SKT1#3
630
-SPL71#4
-SKT1_H#1
72 1000 -SKT1#4
-SKTOP:30, -SKT21:1, -SKTWL:1, -SKTPL:1 1 90 -SKTL:22 Blue LH2 1.00 mm² APRON PRESSURE
Blue,Blue,Blue,Blue 2 91 -SKT2:1 Blue LH39 1.00 mm² -SKTAP#3
LH42, LH43, LH80, LH81 -SPL71#3 FRONT LEFT E-STOP -SKTAP#4
400
-SKT21#3 1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm² A 106 -SPL106:1 Blue LH66 1.00 mm²
B A2 -SKTL:32 Blue LH38 1.00 mm²
-SKT21#4 -SKT21_H#1
100
1 72 -SPL71:1 Blue LH43 1.00 mm²
2 0 -SPL0B:1 Grey LH51 1.00 mm²
OPERATOR PANEL LAMP

-SKTEST#3
430
-SKTEST_H#1 -SKTEST_C#1 -SKTEST#4
260
F 1 26 -SPL26:1 Blue LH83 1.00 mm² F
2 25 -SPL25:1 Blue LH84 1.00 mm²
-SKTOP#6 -SKTOP#6 3 106 -SPL106:1 Blue LH85 1.00 mm²
1 213 -SKTL:21 Blue LH7 1.00 mm² 17 25 -SPL25:1 Blue LH21 1.00 mm² ENGINE SERVICE TOOL 4 0 -SPL0B:1 Grey LH86 1.00 mm²
-SKTOP_H#1
70
3 3X5 -SKTL:27 Blue LH6 1.00 mm² 19 0 -SPL0B:1 Grey LH53 1.00 mm²
4 B2 -SKTL:31 Blue LH4 1.00 mm² 20 32 -SPL32:1 Blue LH11 1.00 mm²
6 5X1 -SKTL:39 Blue LH3 1.00 mm² 21 14 -SPL14:1 Blue LH9 1.00 mm² -SKTOP#5 350
8 106 -SPL106:1 Blue LH67 1.00 mm² 29 114 -SKTL:20 Blue LH41 1.00 mm²
-SKTOP#4
9 0 -SPL0B:1 Grey LH52 1.00 mm² 30 72 -SPL71:1 Blue LH42 1.00 mm² HEAT SHRINK APPLIED AT NECK
-SPL14:1 Blue LH10 1.00 mm² -SKTL:40 Blue LH5 1.00 mm² OPERATOR PANEL -SPL14#3 -SPL32#3
11 14 33 13X2 TELEMETRY SERVICE TOOL
-SPL14#4 -SPL32#4
-SKTL:11 Blue LH13 1.00 mm² -SPL25:1 Blue LH76 1.00 mm² -PLGTST#3
70
12 6X1 42 25
14 32
13 2X2 -SKTL:37 Blue LH14 1.00 mm² 44 26 -SPL26:1 Blue LH77 1.00 mm²
-SKTL:43, -SKTOP:21, -SKTOP:46, -SKTOP:11 -SKTL:44, -SKTOP:20, -SKTOP:45, -SKTOP:10
14 2X3 -SKTL:23 Blue LH15 1.00 mm² 45 32 -SPL32:1 Blue LH78 1.00 mm² -PLGTST#4
Brown,Blue,Blue,Blue White,Blue,Blue,Blue
15 4X3 -SKTL:15 Blue LH16 1.00 mm² 46 14 -SPL14:1 Blue LH79 1.00 mm² 250 4 (MTS)TX -SKTTU:20 Blue LH22 1.00 mm²
BRN, LH9, LH79, LH10 WHT, LH11, LH78, LH12
16 6X3 -SKTL:14 Blue LH17 1.00 mm² 5 (MTS)RX -SKTTU:21 Blue LH23 1.00 mm²
1.00 mm²,1.00 mm²,1.00 mm² 1.00 mm²,1.00 mm²,1.00 mm²
G G
70
-SKTRC#3
DUST CAP REQ
250
RADIO CHARGE SOCKET

-SKTRC#4
+ 214 -SPL214:1 Blue LH69 1.00 mm²
200
- 0 -SPL0B:1 Grey LH44 1.00 mm²
H H
-SKT2_H#1
-SKT2#4
1 91 -SKT1:2 Blue LH39 1.00 mm²
2 92 -SKTL:13 Blue LH40 1.00 mm²
-SKT2#3
MIDDLE LEFT E-STOP Description: COBRA Assignment =LH

Changing Date Name Type COBRA
drawing M.-Nr.: ELECTRICAL SCHEMATIC Location +LH
User 14/07/2016 AC
the E3! Proved LEFT HARNESS MPESD_3109 No. 42 Sh.
1
1 2 3 4 5 6 7 8 9 10 11 12
TC042-10104_MK01 COBRA 230 RIGHT HARNESS (=RH+RH)
A A
-SKTRSV#2 SEALING PLUGS MUST BE USED ON ALL UNUSED PINS FOR ALL CONNECTORS
1 11X2 -SKTR:22 Blue RH51 1.00 mm²
2 12X2 -SKTR:24 Blue RH52 1.00 mm² DIMENSIONS BETWEEN T/Y PIECES ARE ON CENTERS
3 0 -SPL0A:1 Grey RH25 1.00 mm² SPLICES ARE TO BE 50MM AWAY FROM NEAREST CONNECTOR / T/Y PIECE
4 0 -SPL0A:1 Grey RH26 1.00 mm²
-SKTRT#2
1 D5A -SKTR:35 Blue RH48 1.00 mm²
-SKTRSV_C
2 16X3 -SKTR:41 Blue RH45 1.00 mm²

3 0 -SPL0D:1 Grey RH22 1.00 mm²
RIGHT TRACK
-SKTRT#1
-SKTRSV#1
-SKTLT#2
-SKTFT#2
RS VALVES 1 D3A -SKTR:36 Blue RH47 1.00 mm²
1 15X2 -SKTR:12 Blue RH49 1.00 mm² TRACK DIVERT
LEFT TRACK 2 15X3 -SKTR:27 Blue RH44 1.00 mm²
-SKTTSV#2
-SKTTSV#1
2 0 -SPL0B:1 Grey RH23 1.00 mm²
-SKTLT#1 3 0 -SPL0D:1 Grey RH21 1.00 mm²
FAST TRACK 1 68 -SKTR:9 Blue RH61 1.00 mm²
B E 0 -SPL0D:1 Grey RH18 1.00 mm²
B
-SKTFT#1
-SKTRAD#2
-SKTRSV_H
*4/4
1 106 -SKTR:29 B -SKTRAD 1.00 mm²

FEEDER/CONTROL BANKS
2 110 -SKTR:3 U -SKTRAD 1.00 mm²
-SKTFEE#1
PIN 3 NEAR GLAND

3 0 -SKTR:19 G/Y -SKTRAD 1.00 mm²
4 32 -SKTR:13 N -SKTRAD 1.00 mm²
5 14 -SKTR:40 W -SKTRAD 1.00 mm²
-SKTRAD_C 300
300 -SKT4#2
-SKTU#2
1 93 -SKT3:2 Blue RH58 1.00 mm²
-SKTFEE#2 1 B6 -SKTR:32 Blue RH37 1.00 mm²
200 2 94 -SKTR:11 Blue RH59 1.00 mm²
-SKTMC#2 1 D1A -SKTR:10 Blue RH46 1.00 mm² 2 0 -SPL0D:1 Grey RH15 1.00 mm²
REAR RIGHT E-STOP
1 F1 -SKTR:45 Blue RH50 1.00 mm² 2 E5 -SKTR:15 Blue RH43 1.00 mm² 3 64 -SPL64C:1 Blue RH1 1.00 mm²
2 0 -SPL0B:1 Grey RH24 1.00 mm² 3 0 -SPL0D:1 Grey RH20 1.00 mm² 4 64 -SPL64C:1 Blue RH3 1.00 mm²
-SKTRAD#1
-SKT4#1
MAIN CONVEYOR 5 C2 -SKTR:31 Blue RH33 1.00 mm²
300 6 C3 -SKTR:18 Blue RH34 1.00 mm²
-SKTMC#1
RADIO 7 64 -SPL64C:1 Blue RH2 1.00 mm²

C 8 C6 -SKTR:30 Blue RH35 1.00 mm² C
TE CONNECTIVITY DR-25-3/8-0 9 C7 -SKTR:17 Blue RH36 1.00 mm²
-SKT4_H
HEAT SHRINK FOR ALL THESE BRANCHES 12 3X3 -SKTR:43 Blue RH32 1.00 mm²
310
310
13 111 -SKTR:21 Blue RH31 1.00 mm²
-SKTU#1
UMBILICAL
-SPL0D#3 -SPL64C#2
570
0 64
1100
-SKTU:2, -SKTTSV:E, -SKTFEE:3, -SKTLT:3, -SKTRT:3, -SPL0A:1, -SKTU:3, -SKTU:7, -SKTU:4, -SPL64A:1 -SKTU_H
250
350
Grey,Grey,Grey,Grey,Grey, Blue,Blue,Blue,Blue
RH15, RH18, RH20, RH21, RH22, RH29, RH1, RH2, RH3, RH4
1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm², 1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²
-SKTR#2 -SKTR_H
-SPL0D#2 -SPL64C#1
-SKTR#1
300 100 450 1450 215 135 1540 1150

D D
250
-SPL0A#2 FRONT RIGHT E-STOP
-SPL0A#3 -SKT3#2
-SKT3#1
CONTROL BOX 0 1 92 -SKTR:6 Blue RH57 1.00 mm²
-SKTR:1, -SKTRSV:3, -SKTRSV:4, -SKTCLH:3, -SPL0B:1, -SPL0D:1 2 93 -SKT4:1 Blue RH58 1.00 mm²
Grey,Grey,Grey,Grey,Grey,Grey -SPL0B#2
-SKTR#3 -SKTR#3 -SPL0B#3
180
RH12, RH25, RH26, RH27, RH28, RH29

1 0 -SPL0A:1 Grey RH12 1.50 mm² 24 12X2 -SKTRSV:2 Blue RH52 1.00 mm² 0 -SKT9#2
1.50 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²
3 110 -SKTRAD:2 U -SKTRAD 1.00 mm² 25 25 -SKTCLH:4 WHT -WRHJ1939 -SKTRRL:2, -SKTHOL:2, -SKTFT:2, -SKTMC:2, -SPL0A:1, -SPL0C:1 -SPL64A#2 A 64 -SPL64B:1 Blue RH11 1.00 mm²
-SKT3_H
PIN 4 TO HOLD KEY PIN 0413-216-2005 27 15X3 -SKTLT:2 Blue RH44 1.00 mm² Grey,Grey,Grey,Grey,Grey,Grey B A6 -SKTR:33 Blue RH60 1.00 mm²
5 107 -SKTCLH:2 Blue RH56 1.00 mm² 28 11X3 -PLGRS:4 Blue RH54 1.00 mm² RH14, RH16, RH23, RH24, RH28, RH30 -SPL64A#3 C 0 -SPL0C:1 Grey RH17 1.00 mm²
6 92 -SKT3:1 Blue RH57 1.00 mm² 29 106 -SKTRAD:1 B -SKTRAD 1.00 mm² 1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm² 64
7 0 -SKTCLH:6 SCRN -WRHJ1939 30 C6 -SKTU:8 Blue RH35 1.00 mm² -SPL64C:1, -SKTR:14, -SPL64B:1, -SKTHOT:A, -SKTHOL:1
-SKT9#1
8 116 -SPL116:1 Blue RH64 1.00 mm² 31 C2 -SKTU:5 Blue RH33 1.00 mm² Blue,Blue,Blue,Blue,Blue
-SKTCLH_H
*3/3
MAIN CONVEYOR
9 68 -SKTTSV:1 Blue RH61 1.00 mm² 32 B6 -SKTU:1 Blue RH37 1.00 mm² RH4, RH5, RH6, RH7, RH9
340
SPEED WHEEL CABLE
10 D1A -SKTFEE:1 Blue RH46 1.00 mm² 33 A6 -SKT9:B Blue RH60 1.00 mm² 1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²
400
11 94 -SKT4:2 Blue RH59 1.00 mm² 34 210 -SKTCLH:1 Blue RH55 1.00 mm²
12 15X2 -SKTFT:1 Blue RH49 1.00 mm² 35 D5A -SKTRT:1 Blue RH48 1.00 mm²
E 13 32 -SKTRAD:4 N -SKTRAD 1.00 mm² 36 D3A -SKTLT:1 Blue RH47 1.00 mm² E
-SKT9_H
14 64 -SPL64A:1 Blue RH5 1.00 mm² 37 5X2 -SKT25:B Blue RH42 1.00 mm²
15 E5 -SKTFEE:2 Blue RH43 1.00 mm² 39 26 -SKTCLH:5 BRN -WRHJ1939 CLUTCH -SKTFL#2 -SKTFL#1
16 10X3 -PLGRS:3 Blue RH53 1.00 mm² 40 14 -SKTRAD:5 W -SKTRAD 1.00 mm² A 0 -SPL0C:1 Grey RH66 1.00 mm² 1250 -SPL64B#3
17 C7 -SKTU:9 Blue RH36 1.00 mm² 41 16X3 -SKTRT:2 Blue RH45 1.00 mm² C 9X3 -SKTR:44 Blue RH67 1.00 mm² 64
18 C3 -SKTU:6 Blue RH34 1.00 mm² 43 3X3 -SKTU:12 Blue RH32 1.00 mm² D 64 -SPL64B:1 Blue RH65 1.00 mm² -SPL64A:1, -PLGRS:1, -SKT24:1, -SKT9:A, -SKTFL:D
FUEL LEVEL -SKTFRL#2
19 0 -SKTRAD:3 G/Y -SKTRAD 1.00 mm² 44 9X3 -SKTFL:C Blue RH67 1.00 mm² Blue,Blue,Blue,Blue,Blue
1 116 -SPL116:1 Blue RH63 1.00 mm²
21 111 -SKTU:13 Blue RH31 1.00 mm² 45 F1 -SKTMC:1 Blue RH50 1.00 mm² -SKTCLH#1 RH6, RH8, RH10, RH11, RH65
-SKTCLH#2 2 0 -SPL0C:1 Grey RH13 1.00 mm²
740
140
22 11X2 -SKTRSV:1 Blue RH51 1.00 mm² 46 A7 -PLGRS:2 Blue RH39 1.00 mm² 1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²
1 210 -SKTR:34 Blue RH55 1.00 mm²
23 4X2 -SKTHOL:3 Blue RH40 1.00 mm² 47 A3 -SKTHOT:B Blue RH38 1.00 mm² -SPL64B#2 -SKTFRL#1
2 107 -SKTR:5 Blue RH56 1.00 mm²
3 0 -SPL0A:1 Grey RH27 1.00 mm² -SKTFRL_H -SKTFRL_C
4 25 -SKTR:25 WHT -WRHJ1939 690 2410 1740 550 70
80
5 26 -SKTR:39 BRN -WRHJ1939
6 0 -SKTR:7 SCRN -WRHJ1939
-SPL116#1 FRONT LEFT TRACK LAMP
-SPL116#2 -SPL0C#2
116 -SPL0C#3
F F
-SKTFRL:1, -SKTRRL:1, -SKTR:8 0
Blue,Blue,Blue -SKTFRL:2, -SKT9:C, -PLGRS:5, -SPL0B:1, -SKTFL:A
100
RH63, RH62, RH64 Grey,Grey,Grey,Grey,Grey
200
110
1.00 mm²,1.00 mm²,1.00 mm² RH13, RH17, RH19, RH30, RH66 -PLGRS#2
790
1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm² 1 64 -SPL64B:1 Blue RH8 1.00 mm²
2 A7 -SKTR:46 Blue RH39 1.00 mm²
3 10X3 -SKTR:16 Blue RH53 1.00 mm²
HEAT SHRINK APPLIED AT NECK 4 11X3 -SKTR:28 Blue RH54 1.00 mm²
-SKTRRL_H
5 0 -SPL0C:1 Grey RH19 1.00 mm²
-SKTHOT#1 150
-SKTRRL#2 RS SECTION
-SKTRRL#1
1 116 -SPL116:1 Blue RH62 1.00 mm² -PLGRS#1
HYD OIL TEMP -SKTHOT_H 2 0 -SPL0B:1 Grey RH14 1.00 mm²
-SKTHOT#2
70
-SKTRS_C#1
A 64 -SPL64A:1 Blue RH7 1.00 mm²
G G
70
B A3 -SKTR:47 Blue RH38 1.00 mm²
-SKTRRL_C
370
_H
-SKTRS_CH
25
KT
-S
-SKT24_H
-SKTHOL#1
-SKT25#1
HOOD
-SKT25#2
-SKT24#1
HYD OIL LEVEL A 5X2B -SKT24:2 Blue RH41 1.00 mm²
-SKTHOL#2 B 5X2 -SKTR:37 Blue RH42 1.00 mm²
1 64 -SPL64A:1 Blue RH9 1.00 mm²
H 2 0 -SPL0B:1 Grey RH16 1.00 mm² ATTACH 150MM LONG WIRE H
SIDE INSPECTION DOOR
3 4X2 -SKTR:23 Blue RH40 1.00 mm² ROPE TO THIS HOOD
-SKT24#2
1 64 -SPL64B:1 Blue RH10 1.00 mm²
2 5X2B -SKT25:A Blue RH41 1.00 mm²
Changing Date Name Type COBRA Description: COBRA Assignment =RH
drawing M.-Nr.: ELECTRICAL SCHEMATIC Location +RH
User 14/07/2016 AC
the E3! Proved RIGHT HARNESS MPESD_3109 No. 42 Sh.
1
1 2 3 4 5 6 7 8 9 10 11 12
HYD OIL LEVEL
-SKTHOL#4
1 64 -SPL64A:1 Blue RH9 1.00 mm²
TC043-10104_MK04 COBRA 290 RIGHT HARNESS (=RH+RH+UPN) 2 0 -SPL0B:1 Grey RH16 1.00 mm² -SKTRT#4
-SKTHOL#3
3 4X2 -SKTR:23 Blue RH40 1.00 mm² 1 D5A -SKTR:35 Blue RH48 1.00 mm²
2 16X3 -SKTR:41 Blue RH45 1.00 mm²
3 0 -SPL0D:1 Grey RH22 1.00 mm²
T/Y PIECES & CONDUIT MUST BE SUITABLY SIZED BY THE HARNESS MANUFACTURER RIGHT TRACK
A SEALING PLUGS MUST BE USED ON ALL UNUSED PINS FOR ALL CONNECTORS -SKTRT#3 A
550
SPLICES ARE TO BE 50MM AWAY FROM NEAREST CONNECTOR / T/Y PIECE -SKTLT#4
1 D3A -SKTR:36 Blue RH47 1.00 mm²
TRACK DIVERT -SKTR:27 Blue RH44 1.00 mm²
LEFT TRACK 2 15X3
-SKTHOT#4 -SKTTSV#4
-SKTLT#3 3 0 -SPL0D:1 Grey RH21 1.00 mm²
A 64 -SPL64A:1 Blue RH7 1.00 mm² 1 68 -SKTR:9 Blue RH61 1.00 mm²
B A3 -SKTR:47 Blue RH38 1.00 mm² E 0 -SPL0D:1 Grey RH18 1.00 mm²
-SKTTSV#3
-SKTHOT#3 350
FEEDER/CONTROL BANKS
-SKTFEE#3
HYD OIL TEMP

-SKTHOT_H#1
300
300
PIN 3 NEAR GLAND

B B
-SKTRSV#4 -SKTFEE#4
1 11X2 -SKTR:22 Blue RH51 1.00 mm² 1 D1A -SKTR:10 Blue RH46 1.00 mm² 200
2 12X2 -SKTR:24 Blue RH52 1.00 mm² 2 E5 -SKTR:15 Blue RH43 1.00 mm² TE CONNECTIVITY DR-25-3/8-0
3 0 -SPL0A:1 Grey RH25 1.00 mm² 3 0 -SPL0D:1 Grey RH20 1.00 mm²
HEAT SHRINK FOR ALL THESE BRANCHES
4 0 -SPL0A:1 Grey RH26 1.00 mm²
250
+UPN -SKT4#4
250 -SKTU#4
-SKTUPN#1 1 93 -SKT3:2 Blue RH58 1.00 mm²
-SKTRSV_C#1
1 B6 -SKTR:32 Blue RH37 1.00 mm²
-SKTRSV#3 2 94 -SKTR:11 Blue RH59 1.00 mm²
2 0 -SPL0D:1 Grey RH15 1.00 mm²
-SKTRAD#4 REAR RIGHT E-STOP
3 64 -SPL64C:1 Blue RH1 1.00 mm²
1 106 -SKTR:29 B -SKTRAD 1.00 mm² PIN 3 NEAR GLAND
RS VALVES 4 64 -SPL64C:1 Blue RH3 1.00 mm²
2 110 -SKTR:3 U -SKTRAD 1.00 mm² +UPN
UNDERPAN 5 C2 -SKTR:31 Blue RH33 1.00 mm²
370
-S 3 0 -SKTR:19 G/Y -SKTRAD 1.00 mm² -SKTUPN#2
KT
RA 6 C3 -SKTR:18 Blue RH34 1.00 mm²
4 32 -SKTR:13 N -SKTRAD 1.00 mm² 2 D7 -SKTR:38 Blue RH68 1.00 mm²
-SKT4#3
D_
C# 7 64 -SPL64C:1 Blue RH2 1.00 mm²
1 5 14 -SKTR:40 W -SKTRAD 1.00 mm² E 0 -SPL0D:1 Grey RH69 1.00 mm²
C 8 C6 -SKTR:30 Blue RH35 1.00 mm² C
RA 9 C7 -SKTR:17 Blue RH36 1.00 mm²
DI
O 12 3X3 -SKTR:43 Blue RH32 1.00 mm²
13 111 -SKTR:21 Blue RH31 1.00 mm²
-SKT4_H#1
-S
-SKTRSV_H#1
KT
550
RA -SKTU#3
D#
3
UMBILICAL
-SPL0A#5 -SPL0D#5 -SPL64C#4
0 0 64
32 -SKTR:1, -SKTRSV:3, -SKTRSV:4, -SKTCLH:3, -SPL0B:1, -SPL0D:1 -SKTU:2, -SKTTSV:E, -SKTFEE:3, -SKTLT:3, -SKTRT:3, -SPL0A:1, -SKTUPN:E -SKTU:3, -SKTU:7, -SKTU:4, -SPL64A:1 -SKTU_H#1
0
220
600
Grey,Grey,Grey,Grey,Grey,Grey Grey,Grey,Grey,Grey,Grey,Grey,Grey Blue,Blue,Blue,Blue

RH12, RH25, RH26, RH27, RH28, RH29 RH15, RH18, RH20, RH21, RH22, RH29, RH69 RH1, RH2, RH3, RH4
1.50 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm² 1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm² 1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²
CLUTCH -SPL0A#4 -SPL0D#4 -SPL64C#3

170 180 115 950 90 540 900 1000
D D
350
-SKTCLH#3
-SKTCLH_H#1 -SKTFL#4
-SKTCLH#4 -SKT3#4
P A 0 -SPL0C:1 Grey RH66 1.00 mm²
1 210 -SKTR:34 Blue RH55 1.00 mm² 1 92 -SKTR:6 Blue RH57 1.00 mm² TO
S C 9X3 -SKTR:44 Blue RH67 1.00 mm²
T E-
2 107 -SKTR:5 Blue RH56 1.00 mm² 2 93 -SKT4:1 Blue RH58 1.00 mm²
I GH D 64 -SPL64B:1 Blue RH65 1.00 mm²
3 0 -SPL0A:1 Grey RH27 1.00 mm² N TR
O
4 25 -SKTR:25 WHT -WRHJ1939 FR
400
-
5 26 -SKTR:39 BRN -WRHJ1939 -SPL0B#4 SK
T -SKT9#4
6 0 -SKTR:7 SCRN -WRHJ1939 -SPL0B#5 -SPL64A#4 A 64 -SPL64B:1 Blue RH11 1.00 mm²
3#
-SKTFL#3
0 B A6 -SKTR:33 Blue RH60 1.00 mm²

FUEL LEVEL
-SKTRRL:2, -SKTHOL:2, -SKTFT:2, -SKTMC:2, -SPL0A:1, -SPL0C:1 -SPL64A#5 C 0 -SPL0C:1 Grey RH17 1.00 mm²
-S
Grey,Grey,Grey,Grey,Grey,Grey 64
KT
RH14, RH16, RH23, RH24, RH28, RH30 -SPL64C:1, -SKTR:14, -SPL64B:1, -SKTHOT:A, -SKTHOL:1
3
-SKT9#3
1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm² Blue,Blue,Blue,Blue,Blue
_H
*3/3
MAIN CONVEYOR
#1
RH4, RH5, RH6, RH7, RH9

SPEED WHEEL CABLE
1470
1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²
*4/4
E E
-SKTFT#3
55
0
200
FAST TRACK
-SPL64B#5
-SKTFT#4 -PLGRS#4
64
1 15X2 -SKTR:12 Blue RH49 1.00 mm²
-SKT9_H#1
1 64 -SPL64B:1 Blue RH8 1.00 mm²

-SPL64A:1, -PLGRS:1, -SKT24:1, -SKT9:A, -SKTFL:D
2 0 -SPL0B:1 Grey RH23 1.00 mm² 2 A7 -SKTR:46 Blue RH39 1.00 mm²
Blue,Blue,Blue,Blue,Blue
3 10X3 -SKTR:16 Blue RH53 1.00 mm²
RH6, RH8, RH10, RH11, RH65
1700
4 11X3 -SKTR:28 Blue RH54 1.00 mm²
1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²
5 0 -SPL0C:1 Grey RH19 1.00 mm²
980
150
HEAT SHRINK APPLIED AT NECK

-SPL64B#4
1650 1520 870 650

350
-SPL116#3 RS SECTION
-SPL0C#4 -PLGRS#3
-SPL116#4
F -SKTMC#3 116 -SKTRS_C#2
F
170 -SPL0C#5
-SKTFRL:1, -SKTRRL:1, -SKTR:8
0
Blue,Blue,Blue
-SKTFRL:2, -SKT9:C, -PLGRS:5, -SPL0B:1, -SKTFL:A
200
RH63, RH62, RH64

230
Grey,Grey,Grey,Grey,Grey
100
1.00 mm²,1.00 mm²,1.00 mm²

RH13, RH17, RH19, RH30, RH66
1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²
MAIN CONVEYOR
-SKTMC#4
1 F1 -SKTR:45 Blue RH50 1.00 mm²
2 0 -SPL0B:1 Grey RH24 1.00 mm²
-SKTRRL_H#1
-SKTRS_CH#1
-SKTRRL#4
-SKTFRL_H#1
1 116 -SPL116:1 Blue RH62 1.00 mm²

0
10
2 0 -SPL0B:1 Grey RH14 1.00 mm²
300
ATTACH 150MM LONG WIRE
-SKTRRL#3
G ROPE TO THIS HOOD G

100
-SKTFRL#3
1
H#
-SKTFRL#4
_
25
-SKTR#6 -SKTR#6 1 116 -SPL116:1 Blue RH63 1.00 mm²

T
-SKTRRL_C#1
1 0 -SPL0A:1 Grey RH12 1.50 mm² 24 12X2 -SKTRSV:2 Blue RH52 1.00 mm² 2 0 -SPL0C:1 Grey RH13 1.00 mm²
-SK
3 110 -SKTRAD:2 U -SKTRAD 1.00 mm² 25 25 -SKTCLH:4 WHT -WRHJ1939

PIN 4 TO HOLD KEY PIN 0413-216-2005 -SKTLT:2 Blue RH44 1.00 mm²
-SKTFRL_C#1
27 15X3
5 107 -SKTCLH:2 Blue RH56 1.00 mm² 28 11X3 -PLGRS:4 Blue RH54 1.00 mm²
6 92 -SKT3:1 Blue RH57 1.00 mm² 29 106 -SKTRAD:1 B -SKTRAD 1.00 mm²
7 0 -SKTCLH:6 SCRN -WRHJ1939 30 C6 -SKTU:8 Blue RH35 1.00 mm² -SKT25#3
8 116 -SPL116:1 Blue RH64 1.00 mm² 31 C2 -SKTU:5 Blue RH33 1.00 mm²
-SKT24_H#1
9 68 -SKTTSV:1 Blue RH61 1.00 mm² 32 B6 -SKTU:1 Blue RH37 1.00 mm²
HOOD
10 D1A -SKTFEE:1 Blue RH46 1.00 mm² 33 A6 -SKT9:B Blue RH60 1.00 mm² -SKT25#4
-SKTR_H#1
11 94 -SKT4:2 Blue RH59 1.00 mm² 34 210 -SKTCLH:1 Blue RH55 1.00 mm² A 5X2B -SKT24:2 Blue RH41 1.00 mm²
-SKTR#4
12 15X2 -SKTFT:1 Blue RH49 1.00 mm² 35 D5A -SKTRT:1 Blue RH48 1.00 mm² B 5X2 -SKTR:37 Blue RH42 1.00 mm²
-SKTRAD:4 N -SKTRAD 1.00 mm² -SKTLT:1 Blue RH47 1.00 mm²
-SKT24#3
13 32 36 D3A
14 64 -SPL64A:1 Blue RH5 1.00 mm² 37 5X2 -SKT25:B Blue RH42 1.00 mm² SIDE INSPECTION DOOR
H H
15 E5 -SKTFEE:2 Blue RH43 1.00 mm² 38 D7 +UPN-SKTUPN:2 Blue RH68 1.00 mm²
-SKT24#4
16 10X3 -PLGRS:3 Blue RH53 1.00 mm² 39 26 -SKTCLH:5 BRN -WRHJ1939
1 64 -SPL64B:1 Blue RH10 1.00 mm²
17 C7 -SKTU:9 Blue RH36 1.00 mm² 40 14 -SKTRAD:5 W -SKTRAD 1.00 mm²
2 5X2B -SKT25:A Blue RH41 1.00 mm²
18 C3 -SKTU:6 Blue RH34 1.00 mm² 41 16X3 -SKTRT:2 Blue RH45 1.00 mm²
-SKTR#5
19 0 -SKTRAD:3 G/Y -SKTRAD 1.00 mm² 43 3X3 -SKTU:12 Blue RH32 1.00 mm²
CONTROL BOX
21 111 -SKTU:13 Blue RH31 1.00 mm² 44 9X3 -SKTFL:C Blue RH67 1.00 mm²
22 11X2 -SKTRSV:1 Blue RH51 1.00 mm² 45 F1 -SKTMC:1 Blue RH50 1.00 mm²
23 4X2 -SKTHOL:3 Blue RH40 1.00 mm² 46 A7 -PLGRS:2 Blue RH39 1.00 mm²
47 A3 -SKTHOT:B Blue RH38 1.00 mm²
Changing Date Name Type COBRA Description: COBRA Assignment =RH
drawing M.-Nr.: ELECTRICAL SCHEMATIC Location +RH
User 14/07/2016 AC
the E3! Proved RIGHT HARNESS MPESD_3109 No. 42 Sh.
1
1 2 3 4 5 6 7 8 9 10 11 12
A A
B B
-PLGAV#1
-PLGAV#2
1 9X1 -SKTTAC:1 1 -WTAC. 0.75 mm²
2 10X1 -SKTTAO:1 1 -WTAO. 0.75 mm²
-PLGAV_H
3 11X1 -SKTBAC:1 1 -WBAC. 0.75 mm²

4 12X1 -SKTBAO:1 1 -WBAO. 0.75 mm²
5 9X2 -SKTCC:1 1 -WCC. 0.75 mm²
C C
6 10X2 -SKTCO:1 1 -WCO. 0.75 mm²
8 0 -SPL0:1 Grey AVH1 1.00 mm²
200
-SPL0#1 -SPL0#2
0
-SKTBAC:2, -SKTBAO:2, -SKTCC:2, -SKTCO:2, -SKTTAC:2, -SKTTAO:2, -PLGAV:8

Black,Black,Black,Black,Black,Black,Grey
2, 2, 2, 2, 2, 2, AVH1
D 0.75 mm²,0.75 mm²,0.75 mm²,0.75 mm²,0.75 mm²,0.75 mm²,1.00 mm²
D
255
180
180
255
E E
210
210
-SKTCO#1
-SKTTAC#1
CHAMBER HOOD OPEN
TOP APRON CLOSE
F F
-SKTTAO#1 -SKTCC#1
TOP APRON OPEN CHAMBER HOOD CLOSE
G G
-SKTBAC#1 -SKTBAO#1
BOTTOM APRON CLOSE BOTTOM APRON OPEN
H TC042-10103 COBRA APRON VALVE HARNESS (=AVH) H
I I
Changing Date Name Type COBRA Description: COBRA Assignment =AVH
drawing M.-Nr.: ELECTRICAL WIRING SCHEMATIC Location +AVH
User 14/07/2016 AC
24789 01/05/2019 DS
the E3! REV ECO Proved APRON VALVE HARNESS MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
MIDI FUSE 2 M8
-SKTAF#2 -SKTECU#2
-TJDH1#2
1 0 -SPL0A:1 Grey JDH17 1.00 mm² 1 25 -SPL25:1 JDH32 1.00 mm²
1 300 -TJDH2:1 Blue JDH1 4.00 mm²
2 307 -SKTECU:41 Blue JDH14 1.00 mm² 2 26 -SPL26:1 JDH31 1.00 mm²
-SKTAF#1 7 206 -SKTENG:J JDH16 1.00 mm²

9 14X1 -SKTENG:H JDH33 1.00 mm²
-TJDH1#1
A 13 304 -SPL305:1 JDH5 1.50 mm² A
-TJDH1_H
AIR FILTER -SPL305:1 JDH4 1.50 mm²
14 304
RESTRICTION SWITCH -R23 TO BE INSIDE CONDUIT
22 308 -SKTCL:C JDH15 1.00 mm²
WITH LEGS SPLICED INTO
-SKTFB#2 -SPL26 & -SPL25. THIS NEEDS 23 304 -SPL305:1 JDH3 1.50 mm²
4 304 -SPL305:1 Blue JDH6 2.50 mm² TO BE 100 MM AWAY FROM 24 304 -SPL305:1 JDH7 1.50 mm²
-SKTECU. -SPL0A:1 JDH25 1.50 mm²
ATO FUSES 27 0
120
-SPL26#2 -SPL25#2 28 350 -SKTENG:M JDH34 1.00 mm²
26 25 41 307 -SKTAF:2 JDH14 1.00 mm²
-SPL305#2 -SKTENG:W, -SKTECU:2 -SKTENG:V, -SKTECU:1 43 0 -SPL0A:1 JDH24 1.50 mm²
250
1080
304 Brown,Blue White,Blue 44 0 -SPL0A:1 JDH23 1.50 mm²
-SKTFB:4, -SKTECU:13, -SKTECU:14, -SKTECU:23, -SKTECU:24 BRN, JDH31 WHT, JDH32 53 351 -SKTENG:C JDH20 1.00 mm²
B B
Blue,Blue,Blue,Blue,Blue 1.00 mm² 1.00 mm²
-SKTECU#1
-SKTFB#1 JDH6, JDH5, JDH4, JDH3, JDH7
2.50 mm²,1.50 mm²,1.50 mm²,1.50 mm²,1.50 mm²
-R23#1
-TJDH7#2 -SPL305#1 -SPL26#1 120 Ohm -SPL25#1
1 + -SPL+:1 Blue JDH35 6.00 mm² 250
POSITIVE BUS BAR
-TJDH7#1
-SPL0A#1
NEGATIVE BUS BAR M10 -SPL0A#2 -SKTECU_H
-TJDH5#1 0
C C
-SKTECU:27, -SKTECU:43, -SKTECU:44, -SPL0B:1, -SKTAF:1
530
-TJDH5#2 ENGINE CONTROL UNIT
Grey,Grey,Grey,Grey,Grey
1 0 -SPL0B:1 Grey JDH21 6.00 mm²
JDH25, JDH24, JDH23, JDH30, JDH17
1.50 mm²,1.50 mm²,1.50 mm²,2.50 mm²,1.00 mm²
560
280
400
-SKTENG#2 -SKTENG_H
D D
-TJDH4#1
400 60 60 530 790 170 750 -TJDH4#2
1 301 -TJDH3:1 Blue JDH2 4.00 mm²
STARTER MOTOR SOLENOID
-SKTENG#1
-SPL+#1 -SPL0B#1
CONTROL BOX -SPL+#2 -SPL0B#2
500
+ 0
-SKTENG:B, -SKTENG:G, -SKTENG:D, -TJDH7:1 -TJDH5:1, -SKTSMR:2, -SKTAHR:2, -SKTENG:E, -SKTCL:B, -SKTAU:B, -SPL0A:1
-SKTENG#3 Blue,Blue,Blue,Blue Grey,Grey,Grey,Grey,Grey,Grey,Grey
-SKTAU#2
B + -SPL+:1 Blue JDH8 2.50 mm² JDH8, JDH9, JDH10, JDH35 JDH21, JDH27, JDH26, JDH28, JDH22, JDH29, JDH30
B 0 -SPL0B:1 Grey JDH29 1.00 mm²
E C 351 -SKTECU:53 Blue JDH20 1.00 mm² 2.50 mm²,2.50 mm²,2.50 mm²,6.00 mm² 6.00 mm²,1.00 mm²,1.00 mm²,2.50 mm²,1.00 mm²,1.00 mm²,2.50 mm² E
460
C 209 -SKTENG:K Blue JDH18 1.00 mm²
D + -SPL+:1 Blue JDH10 2.50 mm²
E 0 -SPL0B:1 Grey JDH28 2.50 mm² -SKTAU#1
-SPL+:1 Blue JDH9 2.50 mm² ENGINE AUXILIARY CONNECTOR
G +
H 14X1 -SKTECU:9 Blue JDH33 1.00 mm² -SKTSMR#1 -SKTSMR#2
J 206 -SKTECU:7 Blue JDH16 1.00 mm²
1 f7 -SKTENG:P Blue JDH11 1.00 mm²
K 209 -SKTAU:C Blue JDH18 1.00 mm² 70 2 0 -SPL0B:1 Grey JDH27 1.00 mm²
L 106 -SKTCL:A Blue JDH19 1.00 mm²
M 350 -SKTECU:28 Blue JDH34 1.00 mm² 120
P f7 -SKTSMR:1 Blue JDH11 1.00 mm²
SCRN -WJDH1939 STARTER MOTOR AUX RELAY
70
T 0 -TJDH2_H M6
F V 25 -SPL25:1 WHT -WJDH1939 -TJDH2#2 F
W 26 -SPL26:1 BRN -WJDH1939 1 300 -TJDH1:1 Blue JDH1 4.00 mm²
70 -TJDH2#1
-TJDH6#2 M6
-TJDH3#2
1 303 -SKTAH:B Blue JDH12 1.00 mm²
120
1 301 -TJDH4:1 Blue JDH2 4.00 mm²
-TJDH6#1
-TJDH3_H -TJDH3#1
70
120
G AIR HEATER RELAY G
-SKTAHR#1
70
1170
-SKTAHR#2 COOLANT LEVEL SWITCH
1 306 -SKTAH:A Blue JDH13 1.00 mm² -SKTCL#1
2 0 -SPL0B:1 Grey JDH26 1.00 mm² -SKTCL_H
900
H H
-SKTCL#2
A 106 -SKTENG:L Blue JDH19 1.00 mm²
B 0 -SPL0B:1 Grey JDH22 1.00 mm²
C 308 -SKTECU:22 Blue JDH15 1.00 mm² TC042-11701_MK04 COBRA 230 JOHN DEERE ENGINE HARNESS (=JDH)
1250
-SKTAH#2
I A 306 -SKTAHR:1 Blue JDH13 1.00 mm² SEALING PLUGS MUST BE USED ON ALL UNUSED PINS FOR ALL CONNECTORS I
B 303 -TJDH6:1 Blue JDH12 1.00 mm² DIMENSIONS BETWEEN T/Y PIECES ARE ON CENTERS
-SKTAH#1 SPLICES ARE TO BE 50MM AWAY FROM NEAREST CONNECTOR / T/Y PIECE
AIR HEATER ENGINE CONNECTOR
Changing Date Name Type COBRA Description: COBRA Assignment =JDH

drawing M.-Nr.: ELECTRICAL WIRING SCHEMATIC Location +JDH
User 14/07/2016 AC
only in 5
the E3! REV ECO Revision text Date Name Proved JD ENG HARNESS MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
A A
B B
-TVOH1#2
1 0 -SPL0:1 Grey VOH4 2.50 mm²
C C
NEGATIVE BUS BAR M10
-TVOH1#1
-SPL+#2
+
-SKTENG:B, -SKTENG:G, -SKTENG:D, -TVOH2:1

420
D Blue,Blue,Blue,Blue D
VOH1, VOH2, VOH3, VOH10
2.50 mm²,2.50 mm²,2.50 mm²,6.00 mm²
-SKTENG#1 -SPL+#1
-SKTECU#1
-SKTENG#2 -SKTECU#2
390 660 1700
1 26 -SKTENG:W BRN -WVOH1939
2 25 -SKTENG:V WHT -WVOH1939
5 206 -SKTENG:J Blue VOH5 2.50 mm²
-SPL0#1 -SKTECU_H
ENGINE CONTROL UNIT
E CONTROL BOX -SKTENG_H -SPL0#2 E
0
-TVOH1:1, -SKTENG:E, -SKTCL:B
-SKTENG#3
740
Grey,Grey,Grey
B + -SPL+:1 Blue VOH1 2.50 mm²
VOH4, VOH6, VOH7
D + -SPL+:1 Blue VOH3 2.50 mm²
2.50 mm²,2.50 mm²,1.00 mm²
E 0 -SPL0:1 Grey VOH6 2.50 mm²
G + -SPL+:1 Blue VOH2 2.50 mm²
J 206 -SKTECU:5 Blue VOH5 2.50 mm²
L 106 -SKTCL:A Blue VOH8 1.00 mm² -TVOH2#1
N 14X3 -SKTCL:C Blue VOH9 1.00 mm² 270 -TVOH2#2
F T 0 SCRN -WVOH1939 1 + -SPL+:1 Blue VOH10 6.00 mm²
F
V 25 -SKTECU:2 WHT -WVOH1939
STR POSITIVE M10
W 26 -SKTECU:1 BRN -WVOH1939
2300
G G
-SKTCL_H
-SKTCL#1
H H
COOLANT LEVEL SWITCH
-SKTCL#2
A 106 -SKTENG:L Blue VOH8 1.00 mm²
B 0 -SPL0:1 Grey VOH7 1.00 mm² TC042-11711_MK03 COBRA 230 VOLVO ENGINE HARNESS (=VOL)
C 14X3 -SKTENG:N Blue VOH9 1.00 mm²
I SEALING PLUGS MUST BE USED ON ALL UNUSED PINS FOR ALL CONNECTORS I
Changing Date Name Type COBRA Description: COBRA Assignment =VOH
drawing M.-Nr.: ELECTRICAL WIRING SCHEMATIC Location +VOH
User 14/07/2016 AC
24789 01/05/2019 DS
the E3! REV ECO Proved VOLVO ENG HARNESS MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
-TVOH1#4 -TVOH2#4
1 0 -SPL0:1 Grey VOH4 2.50 mm² 1 + -SPL+:1 Blue VOH10 6.00 mm²
A A
-TVOH2#3
STR POSITIVE M10
-TVOH1#3
-SPL+#4
+
B B
300
1150
Blue,Blue,Blue,Blue
2.50 mm²,2.50 mm²,2.50 mm²,6.00 mm²
-SKTENG#4
-SPL+#3 -SKTECU#3
-SKTECU_H#1
-SKTENG#5 -SKTECU#4
500 230 50 1800
1 26 -SKTENG:W BRN -WVOH1939
-SPL0#3
ENGINE CONTROL UNIT
C CONTROL BOX -SKTENG_H#1 -SPL0#4 C
0
-SKTENG#6
Grey,Grey,Grey
2800
VOH4, VOH6, VOH7
2.50 mm²,2.50 mm²,1.00 mm²
G + -SPL+:1 Blue VOH2 2.50 mm²
L 106 -SKTCL:A Blue VOH8 1.00 mm²
N 14X3 -SKTCL:C Blue VOH9 1.00 mm² TC043-11711_MK04 COBRA 290 VOLVO T4/SV ENGINE HARNESS
T 0 SCRN -WVOH1939
D V 25 -SKTECU:2 WHT -WVOH1939
D
W 26 -SKTECU:1 BRN -WVOH1939 T/Y PIECES & CONDUIT MUST BE SUITABLY SIZED BY THE HARNESS MANUFACTURER
-SKTCL_H#1
-SKTCL#4
A 106 -SKTENG:L Blue VOH8 1.00 mm² -SKTCL#3 SPLICES ARE TO BE 50MM AWAY FROM NEAREST CONNECTOR / T/Y PIECE
B 0 -SPL0:1 Grey VOH7 1.00 mm²

E E
-TVOH1#6 -TVOH2#6
1 0 -SPL0:1 Grey VOH4 2.50 mm² 1 + -SPL+:1 Blue VOH10 6.00 mm²

-TVOH2#5
STR POSITIVE M10
-TVOH1#5
F F
-SPL+#6
+
300
1150
Blue,Blue,Blue,Blue
2.50 mm²,2.50 mm²,2.50 mm²,6.00 mm²
-SKTENG#7
-SPL+#5 -SKTECU#5
-SKTECU_H#2
-SKTENG#8 -SKTECU#6
500 230 50 2100
G 1 26 -SKTENG:W BRN -WVOH1939 G
-SPL0#5
ENGINE CONTROL UNIT
CONTROL BOX -SKTENG_H#2 -SPL0#6
0
-SKTENG#9
Grey,Grey,Grey
2800

VOH4, VOH6, VOH7
2.50 mm²,2.50 mm²,1.00 mm²
H G + -SPL+:1 Blue VOH2 2.50 mm² H
L 106 -SKTCL:A Blue VOH8 1.00 mm²
N 14X3 -SKTCL:C Blue VOH9 1.00 mm² TC043-11701_MK04 COBRA 290 VOLVO T3 ENGINE HARNESS (=VOL)
T 0 SCRN -WVOH1939
V 25 -SKTECU:2 WHT -WVOH1939
W 26 -SKTECU:1 BRN -WVOH1939 T/Y PIECES & CONDUIT MUST BE SUITABLY SIZED BY THE HARNESS MANUFACTURER
-SKTCL_H#2

-SKTCL#6
A 106 -SKTENG:L Blue VOH8 1.00 mm² -SKTCL#5 SPLICES ARE TO BE 50MM AWAY FROM NEAREST CONNECTOR / T/Y PIECE
I I
B 0 -SPL0:1 Grey VOH7 1.00 mm²
Changing Date Name Type COBRA Description: COBRA Assignment =VOH

drawing M.-Nr.: ELECTRICAL WIRING SCHEMATIC Location +VOH
User 14/07/2016 AC
only in 5
the E3! REV ECO Revision text Date Name Proved VOLVO ENG HARNESS MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
A A
TC042-11715_MK05 COBRA 230 12TS2 400 CLUTCH HARNESS (=CLU)
B SEALING PLUGS MUST BE USED ON ALL UNUSED PINS FOR ALL CONNECTORS B
-SKTPWM#2
1 604 -SKTG:9 Purple CLU9 1.00 mm²
2 0 -SPL0:1 Black CLU7 1.00 mm²
C C
-SKTPWM#1
PWM COIL
-PLGCLH#2
1 210 -SKTG:8 Red CLU1 1.00 mm²
-SKTPWM_H
2 107 -SPL107:1 Orange CLU3 1.00 mm²
4 25 -SKTB:7 G -WCLH1 0.75 mm²
5 26 -SKTB:8 Y -WCLH1 0.75 mm²

6 0 SCRN -WCLH1
D -PLGCLH#1 D
-SKTB#2
RIGHT HARNESS INTERFACE
2 607 -SKTCOS:1 R -WCLH3 0.75 mm²
3 608 -SKTCOS:2, -SKTCOS:3 B, SCRN -WCLH3 0.75 mm²,
7 25 -PLGCLH:4 G -WCLH1 0.75 mm²
8 26 -PLGCLH:5 Y -WCLH1 0.75 mm²
-PLGCLH_H
10 611 -SKTCPS:2 R -WCLH5 0.75 mm²
11 612 -SKTCPS:1 B, SCRN -WCLH5 0.75 mm²,
12 613 -SKTCPS:4 W -WCLH5 0.75 mm²
E E
-SPL0#2
320
CLUTCH CONTROLLER BLACK
0
1
B#
-SKTG:7, -SKTPWM:2, -SKTCON:2, -PLGCLH:3

KT
Black,Black,Black,Black
-S
CLU6, CLU7, CLU8, CLU2

1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²
-SPL107#2
-SPL0#1 107
180
-SKTG:1, -SKTG:4, -PLGCLH:2
-S
KT 34 Orange,Orange,Orange
CL 0
B _H -SPL107#1 CLU4, CLU5, CLU3
F 1.00 mm²,1.00 mm²,1.00 mm² F
CLUTCH CONTROLLER GRAY -SKTCON#1
CLUTCH ON/OFF
-SKTCON_H -SKTCON#2
-SKTG#1
370 540 155 280 560 320

1 605 -SKTG:10 Green CLU10 1.00 mm²
LED
34
-SKTCLG_H 0
-SKTG#2 -S
K TC
1 107 -SPL107:1 Orange CLU4 1.00 mm² P S_
180
4 107 -SPL107:1 Orange CLU5 1.00 mm² H
G 7 0 -SPL0:1 Black CLU6 1.00 mm² G
8 210 -PLGCLH:1 Red CLU1 1.00 mm²
OR
9 604 -SKTPWM:1 Purple CLU9 1.00 mm²
NS
1
SE
10 605 -SKTCON:1 Green CLU10 1.00 mm² 100 100
S#
-SKTCPS#2
RE
11 614 -SKTCIS:1 Red R 0.75 mm²
CP
1 612
SU
-SKTB:11 Black B 0.75 mm²
12 615 -SKTCIS:2, -SKTCIS:3
KT
Black, B, SCRN 0.75 mm²,
ES
-SKTCOS_H
2 611 -SKTB:10 Red R 0.75 mm²
-SKTCIS_H
-S
PR
4 613 -SKTB:12 White W 0.75 mm²
CH
UT
CL
-SKTCOS#1
-SKTCIS#1
H H
CLUTCH INPUT SPEED SENSOR CLUTCH OUTPUT SPEED SENSOR
-SKTCIS#2 -SKTCOS#2
1 614 -SKTG:11 R -WCLH4 0.75 mm² 1 607 -SKTB:2 R -WCLH3 0.75 mm²
2 615 -SKTG:12 B -WCLH4 0.75 mm² 2 608 -SKTB:3 B -WCLH3 0.75 mm²
3 615 -SKTG:12 SCRN -WCLH4 3 608 -SKTB:3 SCRN -WCLH3
I I
Changing Date Name Type COBRA Description: COBRA Assignment =CLU
drawing M.-Nr.: ELECTRICAL WIRING SCHEMATIC Location +CLU
User 14/07/2016 AC
24789 01/05/2019 DS
the E3! REV ECO Proved CLUTCH HARNESS MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
A A
CL
UT
CLUTCH ON/OFF CH
PR
-SKTCON#4 ES
-S SU
1 605 -SKTG:10 Green CLU10 1.00 mm² KT RE
CP SE
LED
B 2 0 -SPL0:1 Black CLU8 1.00 mm² S# NS B
3 OR
-SKTCON#3
-SKTCPS#4
1 612 -SKTB:11 Black B 0.75 mm²
2 611 -SKTB:10 Red R 0.75 mm²
4 613 -SKTB:12 White W 0.75 mm²
#1
-SKTCON_H#1
S _H
CP
KT
-S
C C
260
23
-PLGCLH#4
1 210 -SKTG:8 Red CLU1 1.00 mm²
2 107 -SPL107:1 Orange CLU3 1.00 mm²
4 25 -SKTB:7 G -WCLH1 0.75 mm²
5 26 -SKTB:8 Y -WCLH1 0.75 mm²
6 0 SCRN -WCLH1
D D
-PLGCLH#3
190
-SKTB#4
-SKTCOS:1 R -WCLH3 0.75 mm² RIGHT HARNESS INTERFACE
2 607
3 608 -SKTCOS:2, -SKTCOS:3 B, SCRN -WCLH3 0.75 mm²,
7 25 -PLGCLH:4 G -WCLH1 0.75 mm² -SKTPWM#3
8 26 -PLGCLH:5 Y -WCLH1 0.75 mm²
-SKTPWM_H#1 -SKTPWM#4
10 611 -SKTCPS:2 R -WCLH5 0.75 mm² 230
1 604 -SKTG:9 Purple CLU9 1.00 mm²
11 612 -SKTCPS:1 B, SCRN -WCLH5 0.75 mm²,
12 613 -SKTCPS:4 W -WCLH5 0.75 mm²
E E
-PLGCLH_H#1
PWM COIL
CLUTCH CONTROLLER BLACK -SPL0#4
0
#3
-SKTG:7, -SKTPWM:2, -SKTCON:2, -PLGCLH:3
TB
K
Black,Black,Black,Black
-S
CLU6, CLU7, CLU8, CLU2
-SKTCIS_H#1 -SKTCIS#4
1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²
-SPL107#4 1 614 -SKTG:11 R -WCLH4 0.75 mm²
185
-SPL0#3 107 2 615 -SKTG:12 B -WCLH4 0.75 mm²
-SKTG:1, -SKTG:4, -PLGCLH:2 3 615 -SKTG:12 SCRN -WCLH4
150
-S
KT
CL 44 Orange,Orange,Orange
F B_ 0 F
H# -SPL107#3 CLU4, CLU5, CLU3 -SKTCIS#3
1 1.00 mm²,1.00 mm²,1.00 mm²
100 CLUTCH INPUT SPEED SENSOR
CLUTCH CONTROLLER GRAY
480 275 150 500
-SKTG#3
-SKTCLG_H#1
-SKTG#4
1 107 -SPL107:1 Orange CLU4 1.00 mm²
G 4 107 -SPL107:1 Orange CLU5 1.00 mm² 100 -SKTCOS_H#1 G
-SKTCOS#4
7 0 -SPL0:1 Black CLU6 1.00 mm² 1 607 -SKTB:2 R -WCLH3 0.75 mm²
8 210 -PLGCLH:1 Red CLU1 1.00 mm² 2 608 -SKTB:3 B -WCLH3 0.75 mm²
9 604 -SKTPWM:1 Purple CLU9 1.00 mm² 3 608 -SKTB:3 SCRN -WCLH3
10 605 -SKTCON:1 Green CLU10 1.00 mm²
11 614 -SKTCIS:1 Red R 0.75 mm²
-SKTCOS#3
12 615 -SKTCIS:2, -SKTCIS:3 Black, B, SCRN 0.75 mm², CLUTCH OUTPUT SPEED SENSOR
H H
TC043-11715_MK05 COBRA 290 12TS2 400 CLUTCH HARNESS (=CLU)
I I
Changing Date Name Type COBRA Description: COBRA Assignment =CLU

drawing M.-Nr.: ELECTRICAL WIRING SCHEMATIC Location +CLU
User 14/07/2016 AC
only in 5
the E3! REV ECO Revision text Date Name Proved CLUTCH HARNESS MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
A A
B B
-TWPH1#2 -TWPH2#2
1 309 -FWP:2 Blue WPH2 4.00 mm² 1 310 -TWPH3:1 Blue WPH3 4.00 mm²
-TWPH1#1
C C
-TWPH2#1
M6 M6
WATER PUMP RELAY
-TWPH1_H -TWPH2_H
60
60
D D
-TWPH3#2
1 310 -TWPH2:1 Blue WPH3 4.00 mm²
220
M6
-TWPH3#1
80
E E
-TWPH6#1
250 80 5200
WATER PUMP CONNECTION
M10
NEGATIVE BUS BAR
-TWPH6#2
1 0 -TWPH4:1 Grey WPH4 4.00 mm²
80
-FWP#1
M6
-FWPH
F -TWPH4#1 F
120
-TWPH4#2
-TWPH5#1
G G
M10
-TWPH5#2 POSITIVE BUS BAR
1 + -FWP:1 Blue WPH1 4.00 mm²
TC042-10105_MK04 COBRA 230 WATER PUMP HARNESS (=WPH)
H H
I I
Changing Date Name Type COBRA Description: COBRA Assignment =WPH
drawing M.-Nr.: ELECTRICAL WIRING SCHEMATIC Location +WPH
User 14/07/2016 AC
24789 01/05/2019 DS
the E3! REV ECO Proved WATER PUMP HARNESS MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
A A
-TWPH1#4 -TWPH2#4
1 309 -FWP:2 Blue WPH2 4.00 mm² 1 310 -TWPH3:1 Blue WPH3 4.00 mm²
B M6 M6 B
-TWPH1#3
-TWPH2#3
WATER PUMP RELAY
-TWPH1_H#1 -TWPH2_H#1
50
50
C C
-TWPH3#4
1 310 -TWPH2:1 Blue WPH3 4.00 mm²
180
M6
-TWPH3#3
50
D D
6850
WATER PUMP CONNECTION
50
M6
-TWPH4#3
90
E E
-TWPH4#4
-TWPH6#3
250
M10
NEGATIVE BUS BAR
-TWPH6#4
F F
-FWP#2
400
-FWPH#1
G G
-TWPH5#3
M10
-TWPH5#4 POSITIVE BUS BAR
1 + -FWP:1 Blue WPH1 4.00 mm²
H H
TC043-10105_MK04 COBRA 290 WATER PUMP HARNESS
I I
Changing Date Name Type COBRA Description: COBRA Assignment =WPH

drawing M.-Nr.: ELECTRICAL WIRING SCHEMATIC Location +WPH
User 14/07/2016 AC
only in 5
the E3! REV ECO Revision text Date Name Proved WATER PUMP HARNESS MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
A A
-SKTPDM1#2
-SKTPDM1#1 1 213 -SPL213:1 BRN -WPDM1 0.34 mm²
2 A3I -SPLA3I:1 WHT -WPDM1 0.34 mm²
3 0 -PLGOP:9 BLU -WPDM1 0.34 mm²
4 A3O -SPLA3O:1 BLK -WPDM1 0.34 mm²
B B
5 106 -PLGOP:8 GRY -WPDM1 0.34 mm²
PDM POWER & I/O
-PLGPDM2#1 -PLGPDM2#2
4 14 -PLGOP:11 BLK -WPDM2 0.34 mm²
530 5 32 -PLGOP:10 GRY -WPDM2 0.34 mm²
C PDM CANOPEN C
500
-PLGPDM5#1
-SPL213#2 -SPLA3O#2 -PLGPDM5#2
213 A3O 4 26 -PLGOP:18 BLK -WPDM5 0.34 mm²
-SKTKS:1, -SKTPDM1:1, -PLGOP:1 -SKTPDM1:4, -SPT1:2(1) 5 25 -PLGOP:17 GRY -WPDM5 0.34 mm²
Brown,Brown,Blue Black, 430
BRN, BRN, OPH1 BLK, GRY/PNK

PDM J1939
0.75 mm²,0.34 mm²,1.00 mm² 0.34 mm²,0.34 mm²
D -PLGOP_H D
-SPL213#1 -SPLA3O#1
-SKTLS#1 -SKTLS#2
180 220 1 114 -PLGOP:29 BRN -WLS. 0.34 mm²
4 72 -PLGOP:30 BLK -WLS. 0.34 mm²
LIGHT SWITCH
-SPLA3I#1
-SPLA3I#2
A3I 620 -SPT1#1
-SKTPDM1:2, -SPT1:4(4)
White,Grey
E WHT, GRY E
-PLGOP#1 0.34 mm²,0.34 mm²
400
-PLGOP#2
PANEL SWITCHES SPLITTER BOX
470
-SKTKS#1
LEFT HARNESS INTERFACE -SKTKS#2
F F
1 213 -SPL213:1 BRN -WKS 0.75 mm²
-PLGOP#3
2 3X5 -PLGOP:3 BLU -WKS 0.75 mm²
1 213 -SPL213:1 Blue OPH1 1.00 mm²
4 216 -PLGOP:2 WHT -WKS 0.75 mm²
2 216 -SKTKS:4 WHT -WKS 0.75 mm²
3 3X5 -SKTKS:2 BLU -WKS 0.75 mm² IGNITION KEYSWITCH
6 5X1 -SPT1:4(1) WHT -WSPT 0.34 mm²
7 106 -SPT1:1(1-4) BRN -WSPT 0.34 mm²
8 106 -SKTPDM1:5 GRY -WPDM1 0.34 mm²
9 0 -SKTPDM1:3 BLU -WPDM1 0.34 mm² -SKTIFM#1 -SKTIFM#2
10 32 -PLGPDM2:5 GRY -WPDM2 0.34 mm²
4 14 -PLGOP:21 BLK -WIFM 0.34 mm²
11 14 -PLGPDM2:4 BLK -WPDM2 0.34 mm²
5 32 -PLGOP:20 G/Y -WIFM 0.34 mm²
G 12 6X1 -SPT1:4(2) GRN -WSPT 0.34 mm² G
15 4X3 -SPT1:4(3) YEL -WSPT 0.34 mm² IFM SERVICE TOOL
16 6X3 -SPT1:2(3) WHT/GRN -WSPT 0.34 mm² CONNECTION POINT
17 25 -PLGPDM5:5 GRY -WPDM5 0.34 mm²
18 26 -PLGPDM5:4 BLK -WPDM5 0.34 mm²
19 0 -SPT1:3(1-4) BLU -WSPT 0.34 mm²
20 32 -SKTIFM:5 G/Y -WIFM 0.34 mm²
21 14 -SKTIFM:4 BLK -WIFM 0.34 mm² TC042-10106_MK03 COBRA OPERATOR PANEL HARNESS (=OPH)
29 114 -SKTLS:1 BRN -WLS. 0.34 mm²
30 72 -SKTLS:4 Black BLK 0.34 mm²
33 13X2 -SPT1:2(2) RED/BLU -WSPT 0.34 mm² T/Y PIECES & CONDUIT MUST BE SUITABLY SIZED BY THE HARNESS MANUFACTURER
H H
42 25 -R21:2 SEALING PLUGS MUST BE USED ON ALL UNUSED PINS FOR ALL CONNECTORS
44 26 -R21:1
45 32 -R22:2 DIMENSIONS BETWEEN T/Y PIECES ARE ON CENTERS
46 14 -R22:1 SPLICES ARE TO BE 50MM AWAY FROM NEAREST CONNECTOR / T/Y PIECE
CONNECT R21 ACCROSS
PINS 42 & 44
CONNECT R22 ACCROSS
PINS 45 & 46
I I
Changing Date Name Type COBRA Description: COBRA Assignment =OPH
drawing M.-Nr.: ELECTRICAL WIRING SCHEMATIC Location +OPH
User 14/07/2016 AC
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the E3! REV ECO Proved OPERATOR PANEL HARN MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
-SKTWL1#1
TC042-10108 COBRA 230 LED LIGHT TOWER HARNESS (=WLH)
A A
(OPTIONAL)
T/Y PIECES & CONDUIT MUST BE SUITABLY SIZED BY THE HARNESS MANUFACTURER -SPL71#2
SEALING PLUGS MUST BE USED ON ALL UNUSED PINS FOR ALL CONNECTORS 72
-SKTWL1:1, -SKTWL2:1, -SKTWL3:1, -PLGWL:1 220
DIMENSIONS BETWEEN T/Y PIECES ARE ON CENTERS Brown,Brown,Brown,Blue
SPLICES ARE TO BE 50MM AWAY FROM NEAREST CONNECTOR / T/Y PIECE N, N, N, WLH1
0.75 mm²,0.75 mm²,0.75 mm²,1.00 mm²
-SPL71#1
B B
-SKTWL2#1
-PLGWL#1
2400
220
-PLGWL#2 -SPL0#1
-SPL0#2
1 72 -SPL71:1 Blue WLH1 1.00 mm²
0
C 2 0 -SPL0:1 Grey WLH2 1.00 mm² C
-SKTWL1:2, -SKTWL2:2, -SKTWL3:2, -PLGWL:2
Blue,Blue,Blue,Grey
U, U, U, WLH2
0.75 mm²,0.75 mm²,0.75 mm²,1.00 mm²
220
-SKTWL3#1
D D
E E
-SKTWL1#2
TC043-10108_MK04 COBRA 290 LED LIGHT TOWER HARNESS (=WLH)
(OPTIONAL)
F F
T/Y PIECES & CONDUIT MUST BE SUITABLY SIZED BY THE HARNESS MANUFACTURER -SPL71#4
SEALING PLUGS MUST BE USED ON ALL UNUSED PINS FOR ALL CONNECTORS 72
-SKTWL1:1, -SKTWL2:1, -SKTWL3:1, -PLGWL:1 100
DIMENSIONS BETWEEN T/Y PIECES ARE ON CENTERS Brown,Brown,Brown,Blue
SPLICES ARE TO BE 50MM AWAY FROM NEAREST CONNECTOR / T/Y PIECE N, N, N, WLH1
0.75 mm²,0.75 mm²,0.75 mm²,1.00 mm²
-SPL71#3
G -SKTWL2#2 G
-PLGWL#3
2250
100
-PLGWL#4 -SPL0#3
-SPL0#4
1 72 -SPL71:1 Blue WLH1 1.00 mm²
0
2 0 -SPL0:1 Grey WLH2 1.00 mm²
-SKTWL1:2, -SKTWL2:2, -SKTWL3:2, -PLGWL:2
Blue,Blue,Blue,Grey
H U, U, U, WLH2 H
0.75 mm²,0.75 mm²,0.75 mm²,1.00 mm²
100
-SKTWL3#2
I I
Changing Date Name Type COBRA Description: COBRA Assignment =WLH

drawing M.-Nr.: ELECTRICAL WIRING SCHEMATIC Location +WLH
User 14/07/2016 AC
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the E3! REV ECO Revision text Date Name Proved WORK LAMPS MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
-SKTREC#1
-SKTREC#2
1 11X2 -PLGRSV:1 1 -WREC. 0.75 mm²
A 2 0 -PLGRSV:3 2 -WREC. 0.75 mm² A
250
RECIRC VALVE
B -PLGRSV#1 B
-PLGRSV#2
1 11X2 -SKTREC:1 1 -WREC. 0.75 mm² -PLGRSV_H
100
2 12X2 -SKTSF:1 1 -WSF. 0.75 mm²
3 0 -SKTREC:2 2 -WREC. 0.75 mm²
4 0 -SKTSF:2 2 -WSF. 0.75 mm²
RIGHT HARNESS
INTERFACE
C C
250
TC042-10109 COBRA 230 RS PU HARNESS (=RSPH) -SKTSF#1
-SKTSF#2
1 12X2 -PLGRSV:2 1 -WSF. 0.75 mm²

T/Y PIECES & CONDUIT MUST BE SUITABLY SIZED BY THE HARNESS MANUFACTURER 2 0 -PLGRSV:4 2 -WSF. 0.75 mm²
D SEALING PLUGS MUST BE USED ON ALL UNUSED PINS FOR ALL CONNECTORS D
SPLICES ARE TO BE 50MM AWAY FROM NEAREST CONNECTOR / T/Y PIECE SCREENS/FINES VALVE
E E
-SKTREC#3
-SKTREC#4
1 11X2 -PLGRSV:1 1 -WREC. 0.75 mm²
2 0 -PLGRSV:3 2 -WREC. 0.75 mm²
250
RECIRC VALVE
F F
-PLGRSV#3
-PLGRSV#4
1 11X2 -SKTREC:1 1 -WREC. 0.75 mm² -PLGRSV_H#1
320
2 12X2 -SKTSF:1 1 -WSF. 0.75 mm²
3 0 -SKTREC:2 2 -WREC. 0.75 mm²
4 0 -SKTSF:2 2 -WSF. 0.75 mm²
G RIGHT HARNESS G
INTERFACE
250
H H
TC043-10109 COBRA 290 RS PU HARNESS (=RSPH) -SKTSF#3
-SKTSF#4
1 12X2 -PLGRSV:2 1 -WSF. 0.75 mm²
T/Y PIECES & CONDUIT MUST BE SUITABLY SIZED BY THE HARNESS MANUFACTURER 2 0 -PLGRSV:4 2 -WSF. 0.75 mm²
SPLICES ARE TO BE 50MM AWAY FROM NEAREST CONNECTOR / T/Y PIECE SCREENS/FINES VALVE
I I
Changing Date Name Type COBRA Description: COBRA Assignment =RSPH
drawing M.-Nr.: ELECTRICAL WIRING SCHEMATIC Location +RSPH
User 14/07/2016 AC
24789 01/05/2019 DS
the E3! REV ECO Proved RS PU HARNESS MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
-SKTSLL#1
-SKTSLL#2
1 10X3 -PLGRSA:3 1 -WSLL. 0.75 mm²
A 2 0 -SPL0:1 2 -WSLL. 0.75 mm² A
170
SLEW LEFT
-SPL0#2
0
-SKTSLL:2, -SKTSLR:2, -PLGRSA:5
Black,Black,Grey
2, 2, RSDH1
0.75 mm²,0.75 mm²,1.00 mm²
B -PLGRSA#1 B
-PLGRSA#2 -SPL0#1
1 64/A7 -PLGRSA:2 Blue RSDH2 1.00 mm² -PLGRSA_H
2 64/A7 -PLGRSA:1 Blue RSDH2 1.00 mm² 1750
3 10X3 -SKTSLL:1 1 -WSLL. 0.75 mm²
4 11X3 -SKTSLR:1 1 -WSLR. 0.75 mm²
5 0 -SPL0:1 Grey RSDH1 1.00 mm²
RS CABLE
CONNECTION
C C
170
TC042-10110 COBRA 230 RS DETACHABLE SECTION HARNESS (=RSDH)
-SKTSLR#1
SEALING PLUGS MUST BE USED ON ALL UNUSED PINS FOR ALL CONNECTORS -SKTSLR#2
DIMENSIONS BETWEEN T/Y PIECES ARE ON CENTERS 1 11X3 -PLGRSA:4 1 -WSLR. 0.75 mm²
2 0 -SPL0:1 2 -WSLR. 0.75 mm²
D SPLICES ARE TO BE 50MM AWAY FROM NEAREST CONNECTOR / T/Y PIECE D
SLEW RIGHT
E E
-SKTSLL#3
-SKTSLL#4
1 10X3 -PLGRSA:3 1 -WSLL. 0.75 mm²
2 0 -SPL0:1 2 -WSLL. 0.75 mm²
F 300 F
SLEW LEFT
-SPL0#4
0
-SKTSLL:2, -SKTSLR:2, -PLGRSA:5
Black,Black,Grey
2, 2, RSDH1
0.75 mm²,0.75 mm²,1.00 mm²
-PLGRSA#3
-PLGRSA#4 -SPL0#3
-PLGRSA_H#1
1 64/A7 -PLGRSA:2 Blue RSDH2 1.00 mm²
2 64/A7 -PLGRSA:1 Blue RSDH2 1.00 mm² 1700
G G
3 10X3 -SKTSLL:1 1 -WSLL. 0.75 mm²
4 11X3 -SKTSLR:1 1 -WSLR. 0.75 mm²
5 0 -SPL0:1 Grey RSDH1 1.00 mm²
RS CABLE
CONNECTION
300
H H
TC043-10110 COBRA 290 RS DETACHABLE SECTION HARNESS (=RSDH)
-SKTSLR#3
SEALING PLUGS MUST BE USED ON ALL UNUSED PINS FOR ALL CONNECTORS -SKTSLR#4
DIMENSIONS BETWEEN T/Y PIECES ARE ON CENTERS 1 11X3 -PLGRSA:4 1 -WSLR. 0.75 mm²
2 0 -SPL0:1 2 -WSLR. 0.75 mm²
I SLEW RIGHT
I
Changing Date Name Type COBRA Description: COBRA Assignment =RSDH

drawing M.-Nr.: ELECTRICAL WIRING SCHEMATIC Location +RSDH
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the E3! REV ECO Revision text Date Name Proved RS DETACHABLE HARN MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
A A
BATTERY POSITIVE TO ISOLATOR SWITCH CABLE -TB1B_H
-TB1A_H 1600
DC PUMP POSITIVE CABLE
-TB1B#1 -TB5B_H
1100
-TB5A#1 -TB5B#1
1/1
B +WB1 M10 B
1/1 M10 M8
-TB1B#2
1 + +WB1-TB1A:1 Red WB1 70.00 mm² +WB5 +WB5
-TB5A#2 -TB5B#2
1 + +WB5-TB5B:1 Red WB5 35.00 mm² 1 + +WB5-TB5A:1 Red WB5 35.00 mm²
-TB1A#1
+WB1
-TB1A#2
1 + +WB1-TB1B:1 Red WB1 70.00 mm²
C BATTERY LINK CABLE
C
500 DC PUMP NEGATIVE CABLE
-TB6A_H 950
-TB2B#1 -TB2A#1
-TB6A#1 M10
1/1
M8 -TB6B#1
1/1
1/1 +WB6 +WB6
-TB2B_H -TB2A_H -TB6A#2 -TB6B#2
1 0 +WB6-TB6B:1 Black WB6 35.00 mm² 1 0 +WB6-TB6A:1 Black WB6 35.00 mm²
+WB2 +WB2
-TB2B#2 -TB2A#2
D 1 BL +WB2-TB2A:1 Black WB2 70.00 mm² 1 BL +WB2-TB2B:1 Black WB2 70.00 mm²
D
BATTERY NEGATIVE TO BUS BAR CABLE
1500
-TB3B#1 -TB3A#1
E M10 E
1/1
-TB3B_H +WB3
-TB3A#2
1 B- +WB3-TB3B:1 Black WB3 70.00 mm²
+WB3
-TB3B#2
1 B- +WB3-TB3A:1 Black WB3 70.00 mm²
F F
BATTERY ISOLATOR TO POSITIVE BUSBAR CABLE
2000
-TB4A_H -TB4A#1
M10
1/1
M10 -TB4B#1
+WB4 +WB4
G -TB4A#2 -TB4B#2 G
TC042-11703_MK03 COBRA 230 BATTERY CABLE KIT (=BCK)
H H
I I
Changing Date Name Type COBRA Description: COBRA Assignment =BCK
drawing M.-Nr.: ELECTRICAL WIRING SCHEMATIC Location +BCK
User 14/07/2016 AC
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the E3! REV ECO Proved BATTERY CABLES MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
A A
BATTERY POSITIVE TO ISOLATOR SWITCH CABLE -TB1B_H#1

-TB1A_H#1 2300
DC PUMP POSITIVE CABLE
-TB1B#3
1000 -TB5B_H#1
-TB5A#3 -TB5B#3
1/1
B +WB1 M10 B
1/1 M10 M8
-TB1B#4
1 + +WB1-TB1A:1 Red WB1 70.00 mm² +WB5 +WB5
-TB5A#4 -TB5B#4
-TB1A#3
+WB1
-TB1A#4
1 + +WB1-TB1B:1 Red WB1 70.00 mm²
C BATTERY LINK CABLE

C
-TB2B_H#1 500 -TB6A_H#1 DC PUMP NEGATIVE CABLE
1250
-TB2B#3 -TB2A#3
-TB6A#3 M10
1/1
M8 -TB6B#3
1/1
1/1 +WB6 +WB6
-TB2A_H#1 -TB6A#4 -TB6B#4
1 0 +WB6-TB6B:1 Black WB6 35.00 mm² 1 0 +WB6-TB6A:1 Black WB6 35.00 mm²
+WB2 +WB2
-TB2B#4 -TB2A#4
D 1 BL +WB2-TB2A:1 Black WB2 70.00 mm² 1 BL +WB2-TB2B:1 Black WB2 70.00 mm²
D
BATTERY NEGATIVE TO BUS BAR CABLE

1850
-TB3B#3 -TB3A#3
E M10 E
1/1
-TB3B_H#1 +WB3
-TB3A#4
1 B- +WB3-TB3B:1 Black WB3 70.00 mm²
+WB3
-TB3B#4
1 B- +WB3-TB3A:1 Black WB3 70.00 mm²
F F
BATTERY ISOLATOR TO POSITIVE BUSBAR CABLE

1750
-TB4A#3
-TB4A_H#1 M10
1/1
M10 -TB4B#3
+WB4 +WB4
G -TB4A#4 -TB4B#4 G
H H
TC043-11713_MK04 COBRA 290 BATTERY CABLE KIT (=BCK)

I I
Changing Date Name Type COBRA Description: COBRA Assignment =BCK

drawing M.-Nr.: ELECTRICAL WIRING SCHEMATIC Location +BCK
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the E3! REV ECO Revision text Date Name Proved BATTERY CABLES MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
A A
B B
AIR HEATER RELAY SUPPLY CABLE
-TJDB4A_H 1500 -TJDB4B_H
STARTER POSITIVE CABLE
-TJDB1B_H
2100 -TJDB4A#1 -TJDB4B#1
-TJDB1A#1
1/1 -TJDB1B#1
M8 M6
M10 +WJDB4 +WJDB4
M12 -TJDB4A#2 -TJDB4B#2
+WJDB1 +WJDB1 1 302 +WJDB4-TJDB4B:1 Red WJDB4 25.00 mm² 1 302 +WJDB4-TJDB4A:1 Red WJDB4 25.00 mm²
-TJDB1A#2 -TJDB1B#2
1 + +WJDB1-TJDB1B:1 Red WJDB1 70.00 mm² 1 + +WJDB1-TJDB1A:1 Red WJDB1 70.00 mm²
C C
D D
STARTER NEGATIVE CABLE AIR HEATER SWITCH CABLE
2250 -TJDB2A_H -TJDB5A_H 2300 -TJDB5B_H
-TJDB2B#1
1/1 -TJDB2A#1 -TJDB5A#1 -TJDB5B#1
M10
M6 M6
M12
+WJDB2 +WJDB2 +WJDB5 +WJDB5
-TJDB2B#2 -TJDB2A#2 -TJDB5A#2 -TJDB5B#2
1 0 +WJDB2-TJDB2A:1 Black WJDB2 70.00 mm² 1 0 +WJDB2-TJDB2B:1 Black WJDB2 70.00 mm² 1 303 +WJDB5-TJDB5B:1 Red WJDB5 25.00 mm² 1 303 +WJDB5-TJDB5A:1 Red WJDB5 25.00 mm²
E E
FUSE BOX POSITIVE CABLE
650 -TJDB6B_H
-TJDB6A#1 -TJDB6B#1
F 1/1 F
CHARGE ALT CABLE
-TJDB3A_H 3500 -TJDB3B_H M10
M8
-TJDB3A#1 +WJDB6 +WJDB6
-TJDB3B#1 -TJDB6A#2 -TJDB6B#2
1 + +WJDB6-TJDB6B:1 Red WJDB6 25.00 mm² 1 + +WJDB6-TJDB6A:1 Red WJDB6 25.00 mm²
M8 M8
+WJDB3 +WJDB3
-TJDB3A#2 -TJDB3B#2
1 C+ +WJDB3-TJDB3B:1 Red WJDB3 25.00 mm² 1 C+ +WJDB3-TJDB3A:1 Red WJDB3 25.00 mm²
G G
TC042-11704_MK03 COBRA 230 JOHN DEERE BATTERY CABLE KIT (=JDB)
H H
I I
Changing Date Name Type COBRA Description: COBRA Assignment =JDB
drawing M.-Nr.: ELECTRICAL WIRING SCHEMATIC Location +JDB
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the E3! REV ECO Proved JD BATTERY CABLES MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
A A
STARTER POSITIVE CABLE

-TVOB1B_H
1550
-TVOB1A#1 -TVOB1B#1
+WVOB1 M10 M10

-TVOB1A#2 +WVOB1
B -TVOB1B#2 B
1 + +WVOB1-TVOB1B:1 Red WVOB1 70.00 mm²
1 + +WVOB1-TVOB1A:1 Red WVOB1 70.00 mm²
C C
STARTER NEGATIVE CABLE

1700 -TVOB2A_H
-TVOB2B#1 -TVOB2A#1
+WVOB2 M10 M10

-TVOB2B#2 +WVOB2
-TVOB2A#2
1 0 +WVOB2-TVOB2A:1 Black WVOB2 70.00 mm²
1 0 +WVOB2-TVOB2B:1 Black WVOB2 70.00 mm²
D D
TC042-11714 COBRA 230 VOLVO STARTER CABLE KIT (=VOB)
E E
STARTER POSITIVE CABLE -TVOB1B_H#1
1050
F F
-TVOB1A#3 -TVOB1B#3
+WVOB1 M10 M10

-TVOB1A#4 +WVOB1
-TVOB1B#4
1 + +WVOB1-TVOB1B:1 Red WVOB1 70.00 mm²
1 + +WVOB1-TVOB1A:1 Red WVOB1 70.00 mm²
G G
STARTER NEGATIVE CABLE -TVOB2A_H#1

1550
-TVOB2B#3 -TVOB2A#3
H H
+WVOB2 M10 M10
-TVOB2B#4 +WVOB2
-TVOB2A#4
1 0 +WVOB2-TVOB2A:1 Black WVOB2 70.00 mm²
1 0 +WVOB2-TVOB2B:1 Black WVOB2 70.00 mm²
TC043-11714_MK04 COBRA 290 VOLVO STARTER CABLE KIT (=VOB)

I I
Changing Date Name Type COBRA Description: COBRA Assignment =VOB

drawing M.-Nr.: ELECTRICAL WIRING SCHEMATIC Location +VOB
User 14/07/2016 AC
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the E3! REV ECO Revision text Date Name Proved VOLVO STARTER CABLES MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9
TC042-11780 COBRA CONTROL BOX REV1 (=PCB) -U1
A A
-K5A -K5B
-K3A
1
-K4B
-F2 -F5
1 1
2
-F1 -F3 -F4
2 2
-K3B -K4A
-F7 -F6
2
1
2
1
-F16
2
1
-F9
-K2 -K6
2
1
B B
1
-F10
2
-F14 -A1
2
1
-F15
2
1
-F13
2
1
-F12
2
1
-F11
2
1
-K1 -A2
-F8
2
1
C -R10 C
INTERNAL FRONT VIEW
D D
-PLGL
E E
-PLGR -PLGENG
F F
EXTERNAL BACK VIEW
User 14/07/2016 AC
the E3! Proved CONTROL BOX MPESD_3109 No. 42 Sh.
1 2 3 4 5 6 7 8 9
C Schematics

Page C-2 Cobra 290 and 290R
EVOQUIP COBRA 290 SET-UP VALVE BANKS
COBRA 290
SIDE CONVEYOR MAIN CONVEYOR
RAISE / LOWER FOLD & RAISE / LOWER
P2 A1 B1 A2 B2 T2
T1
P1 C
2 BANK DCV SHEET 1
REF-01
PVEA - 157B4735 PVEA - 157B4735 PVEO - 157B4228 PVEA - 157B4735 PVEO - 157B4228
A B A B HPCO M A B A B
A - RHS TRACK
B - RHS TRACK
A - LHS TRACK
B - UNDERPAN
B - LHS TRACK
B - FEEDER
FORWARD
FORWARD
BLANK
ANK
REVERSE
REVERSE
(OPTION)
A - DCV
A - BL
157B2014
157B6200
157B6200
157B5940
157B2014
157B6203
157B6203
11117252
PVG VALVE
157B9764
157B9764
11116734
T LS P LSA LSB LSA LSB
PROJECT: EVOQUIP COBRA 290 NAME DATE TITLE
DRAWN R.Y. 07-Nov-17 EVOQUIP COBRA 290 - SET-UP VALVE BANKS
FILE: TC043-1003
CHECKD SHEET 3 OF 3
0 FIRST ISSUE R.Y. 07-Nov-17 DO NOT SCALE, IF IN DOUBT ASK SCALE: NOT TO SCALE EVOQUIP ISSUE: 0
© COPYRIGHT
REV REVISION DETAILS BY DATE THIS CAD GENERATED DRAWING MUST NOT BE ALTERED MANUALLY
Oil Specifications D
Appendix D Oil Specifications

D.1 Oil Specification
NOTICE
The values shown are typical values and must not be used as quality control parameters
to either accept or reject product.
D.1.1 Engine Oil 5W-30

Specification
ACEA E4/E7
API CI-4
Cat ECF-2
Typical Characteristics:
Density at 15 °C, kg/l 0.885
Viscosity -20 °C, mm²/s 6420
Viscosity 40 °C, mm²/s 71.6
Viscosity Index 168
Flash Point COC, °C 224
Pour Point, °C -48
Total Base Number, mgKOH/g 12.2
Sulphate Ash, % 1.35
Approved Brands:
Maxol Super U.H.P.D. 3W/30
Cat DEO Cold Weather SAE 0W-40

Cobra 290 and 290R Page D-1
D Oil Specifications
D.1.2 Engine Oil 15W-40

Specification
ACEA A3/B4, E7
API CI-4/SL
Cat ECF-1-a/ECF-2
Viscosity -20 °C, mm²/s 6300
Viscosity Index 135
Pour Point, °C -35
Total Base Number, mgKOH/g 10.7
Approved Brands:
Maxol Sirios 15W/40
Cat DEO Cold Weather SAE 0W-40
CAT DEO 15W/40

Page D-2 Cobra 290 and 290R
D.1.3 Gear Oil Grade 68/220 Synthetic Blend

Specification
AGMA 4EP
Viscosity 40 °C, mm²/s 152
Viscosity Index 183
Flash Point, °C 251
Pour Point, °C -33
Channel Point,°C -54
Sulphate Ash, % -31
Approved Brands:
Petro-Canada Enduratex XL Synthetic Blend 68/220
D.1.4 Gear Oil 80W/90
Specification
API GL-3/GL-4/GL-5/MT-1
Viscosity Index 105
Pour Point, °C -31
Approved Brands:
Maxol Uni Gear 80W/90 LD

D.1.5 Gear Oil Grade 150 Synthetic

Specification
DIN 51517-3 CLP
AGMA 250.04/9005-D94
Viscosity Index 159
Flash Point, °C 209
Pour Point, °C -45
Acid number, mgKOH/g 0,80
Approved Brands:
Maxol Permiline Synthetic HD 150
D.1.6 Gear Oil Grade 220
Specification
DIN 51517-3 CLP
AGMA 9005-E02
Viscosity Index 95
Pour Point, °C -20
Approved Brands:
Maxol Indusol 220

D.1.7 Gear Oil Grade 320

Specification
DIN 51517-3 CLP
ISO 11158 HV
Viscosity Index 95
Pour Point, °C -15
Approved Brands:
Maxol Indusol 320

D.1.8 Hydraulic Oil Grade 32 (cold climate)

ISO Grade 32
Density at 15 °C, kg/l 886
Viscosity Index >300
Flash Point COC, °C >100
Pour Point, °C -60
Approved Brands:
Maxol Polar 32
Shell Tellus S4 VX
D.1.9 Hydraulic Oil Grade 68 (hot climate)
Specification
DIN 51524-3 HVLP
ISO 11158 HV
ASTM D 6158 HV
Viscosity Index 157
Pour Point, °C -35
Acid number, mgKOH/g 0.4
Approved Brands:
Maxol Multivis 68

D.1.10 Hydraulic Oil Grade 46 (standard climate)

Specification
DIN 51524-2 HLP
ISO 11158 HM
ASTM D 6158 HM
Viscosity Index 110
Pour Point, °C -30
Acid number, mgKOH/g 0.4
Approved Brands:
Maxol Hydramax 46


200 Coalisland Road, Dungannon, Co. Tyrone, BT71 4DR, N.Ireland.
Tel +44 (0) 2887 718500, Fax +44 (0) 2887 747231, E-mail: EvoQuip@terex.com
Printed in United Kingdom

Cobra 290 & 290R Operations Manual Revision 2.3 (En)

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Cobra 290 & 290R Operations Manual Revision 2.3 (En)

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Cobra 290 &

Issue Date: 16/05/2019

Parts Manual On USB Inside Front Cover

Operations Manual Revision 2.3 16-05-2019

Intentionally Left Blank

16-05-2019 Revision 2.3 Operations Manual

Operations Manual Revision 2.3 16-05-2019

3.1 General Information ....................................................................................... 3-2

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(4) Options .................................................................................................... 4-13

Operations Manual Revision 2.3 16-05-2019

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(2) Hydraulic Filtration................................................................................... 9-25

Operations Manual Revision 2.3 16-05-2019

(a) DEF Tank Location.............................................................................. 9-73

16-05-2019 Revision 2.3 Operations Manual

(3) Accessing Stage V Information ............................................................. 10-18

Operations Manual Revision 2.3 16-05-2019

Intentionally Left Blank

16-05-2019 Revision 2.3 Operations Manual

Operations Manual Revision 2.3 16-05-2019

(2) Optional Equipment

16-05-2019 Revision 2.3 Operations Manual

1.2 Safety Information

(2) ANSI Hazard Classification System

(3) California Proposition 65 Warnings

Operations Manual Revision 2.3 16-05-2019

1.3 Intended Use

1.4 Prohibited Use

1.5 Declaration of Conformity

16-05-2019 Revision 2.3 Operations Manual

1.7 Bulletin Distribution and Compliance

1.8 Contacting the Manufacturer

1.9 Transfer of Machine Ownership

Operations Manual Revision 2.3 16-05-2019

1.10 Machine Identification Plate

Figure 1.1 - Identification Plate

Figure 1.2 - Location of Machine Identification Plate

16-05-2019 Revision 2.3 Operations Manual

Operations Manual Revision 2.3 16-05-2019

Figure 2.1 - Safety Alert Symbol

16-05-2019 Revision 2.3 Operations Manual

(3) Property Damage Messages

(4) Description of Safety Symbols

Stay sufficient distances from electrical power lines.

Stay clear of conveyor.

Install covers and guards before operation.

Turn off machine and remove the key.

Read and understand operations manual before using equipment.

Operations Manual Revision 2.3 16-05-2019

When checking for leaks use cardboard or wood.

Stay clear of support legs and jacks.

Falling material hazard

Stay clear of hopper during operation.

Do not climb onto the machine.

Use personnel lift to reach high places.

Check tire pressures before transportation.

16-05-2019 Revision 2.3 Operations Manual

Keep hands clear of openings.

Hand entanglement in pulley/ winch

Keep hands clear of moving components

Wear hearing personal protective equipment.

Keep open flame away.