Part 2 I44 Electrical Operational Manual REV000

McCloskey I44 Operational Manual Page 1 of 33
Issue 0
Control System
Electrical Specification Overview
For Use With
McCloskey I44
Impact Crusher
Fitted With a
JMG Systems
Control System
Issue 0; 27th June 2011
JMG Systems Ltd

68 Derry Road, Omagh, Co. Tyrone
N. Ireland
http://www.jmgsystems.co.uk
© JMG Systems Ltd. 2011

Issue 0
COPYRIGHT
FOREWORD / RESERVATION OF RIGHTS
All JMG Systems products are manufactured to the highest quality, incorporating highly sensitive components
and parts.
In the interest of continuous plant reliability, it is essential that the equipment is maintained with meticulous
care and attention. This operation manual has been produced to assist the user to obtain maximum
effectiveness from the equipment and to trace and remedy faults, should they arise. We recommend that the
user should pay particular attention to the safety sections of this manual.
Consider this manual a permanent part of your machine. Keep a copy of this manual at the operational site.
No copies or reproductions may be made from this manual without prior consent of
JMG SYSTEMS Ltd. This manual, complete or in part, must not be loaned to a third party.
JMG Systems Ltd

68 Derry Road, Omagh, Co. Tyrone, N. Ireland, BT78 5ED
Tel. 028 8224 4131; Fax: 028 8225 5686
www.jmgsystems.co.uk
JMG SYSTEMS Ltd. Reserve the right to change specification without prior notice.

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Contents
1 SAFETY OVERVIEW-----------------------------------------------------------------------------------------------------------4
1.1 Safety Introduction ....................................................................................................... 4

1.2 Electrical Safety ........................................................................................................... 4
1.3 Safety before and during Operation ................................................................................... 5
1.4 Machine Shutdown Procedure........................................................................................... 5
1.5 General Maintenance ..................................................................................................... 5
2 FAMILIARISATION ------------------------------------------------------------------------------------------------------------7
2.1 System Overview .......................................................................................................... 7

2.2 I44 M-PROS Control System Operational Instructions ............................................................... 7
3 OPERATIONS ------------------------------------------------------------------------------------------------------------------8
3.1 Introduction ................................................................................................................ 8

3.2 Operation ................................................................................................................... 8
3.3 Setting the Date & Time ................................................................................................. 9
3.4 Main Menu ................................................................................................................. 10
3.5 Machine Run............................................................................................................... 11
3.6 Diagnostics ................................................................................................................ 13
3.7 Maintenance .............................................................................................................. 16
3.8 Parameter Adjustments ................................................................................................. 18
3.9 Language................................................................................................................... 24
3.10 Optional Extras.......................................................................................................... 25
4 RADIO REMOTE & HANDSET ---------------------------------------------------------------------------------------------- 26
4.1 Handset Operation ....................................................................................................... 26

4.2 Radio Remote Tracking Operation .................................................................................... 27
4.3 Radio Remote Feed Conveyor Operation............................................................................. 28
5 MACHINE FAULTS ---------------------------------------------------------------------------------------------------------- 29
5.1 Machine Faults ............................................................................................................ 29

5.2 Engine Faults.............................................................................................................. 31
6 COMPONENT LAYOUT ----------------------------------------------------------------------------------------------------- 32
6.1 External Connections .................................................................................................... 32

6.2 Relays ...................................................................................................................... 33
6.3 Fuses ....................................................................................................................... 33

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1 SAFETY OVERVIEW
Before operating this Machine you must
WARNING read the Safety instructions as detailed in

the Operational manual
1.1 Safety Introduction
All personnel who operate this equipment must be trained to correctly and safely use it as it was intended
Before operation the operator must:
 Have received specific and adequate training in the task to be carried out.
 Have read and understood the machine operating Manual and the Safety signs on the Machine
 Know the location and function of controls and safety features such as remote Machine Stop buttons
and isolator switches.
 Be aware of all moving parts on the Machine.
1.2 Electrical Safety
While this equipment is rated at only 24 volts safety should not be taken lightly. This equipment can cause
serious burns and injuries if connected wrongly or if tampered with. Remember batteries can explode.
 Never work on the electrical system of any equipment unless you are thoroughly familiar with the
systems details.
 Work on the electrical system must only be carried out by a qualified electrician.
 Special care should be taken when disconnecting, replacing and/or charging the batteries. Ensure
that the batteries are re-connected correctly. Contact across the terminals can cause sparks or
explosions.
 The electrical equipment of the Machine should be inspected at regular intervals. Damaged cables or
loose connections must be repaired immediately. Use only the manufacturer’s replacement parts
with the specified current rating, especially fuses.
 ALWAYS Isolate the batteries when welding on the Machine

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1.3 Safety before and during Operation
 Read and understand your Operation Manual before you start the Machine. Study the DANGER,
WARNING, CAUTION and IMPORTANT safety signs on your Machine.
 Before starting walk completely around the Machine. Make sure no one is under it, on it or close to it.
 Let all other operators and bystanders know you are starting up and do not start until everyone is
clear of the Machine.
 Ensure that all control levers are in the neutral position.
 Check that all electrical connections including battery connections are fitted correctly and are not
damaged or worn.
 Only use Remote stop buttons or Remote stop lines (if fitted) in Emergency situations or during safety
drills.
 Before moving the machine, ensure everyone is clear from the surrounding area.
1.4 Machine Shutdown Procedure
The JMG Systems Control Panel, when fitted to the McCloskey I54, comes complete with 4 Fixed Machine
Stops and 1 key switch for normal starting and stopping of the machine.
The machine stops are located at opposite sides of the power unit, and at either end of the Chassis.
1.5 General Maintenance
JMG control panels are specifically manufactured precise pieces of equipment. Therefore, to ensure that
the equipment continually operates effectively the owner should ensure that the following "Good
housekeeping" measures are carried out:
 Ensure that only qualified and trained personnel operate and/or maintain this equipment.
 Electrical connections are susceptible to wet and dirt, therefore, every step should be taken to avoid
such elements affecting this equipment:
 Always keep the Control Panel Lid closed and locked at all times. Keep the key of the Panel in a safe
place.
 Regularly check the Control Panel and all connectors such as Battery Terminals and Solenoid
Connectors etc. for corrosion or build up of dirt.
 When carrying out any repairs ensure that the equipment is kept covered from rain and that all dirt
etc. has been cleaned from the equipment.
 Ensure that the electrical system is adequately protected during any machine power washing, and
that no jets of water are pointed directly at the electrical systems.

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 Check daily for any damaged or worn gauges, switches, wires or connectors and replace immediately
if necessary.
 Never adjust any of the components on this equipment without the authorization of JMG Systems.
Warranty may be affected where unauthorized adjustments have been made.
 Always replace damaged or faulty components/parts with compatible replacements. Always check
ratings before replacement.

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2 FAMILIARISATION
2.1 System Overview
The I44 electrical kit comes complete with Control Panel, Engine Harness Loom, Solenoid Loom, Stop
circuitry, Tracking Handset and Battery Leads, Sensors and so on which are fitted directly to the machine
engine, powerunit and chassis sections.
Below is a graphic outlining the main sections of the control panel, which are explained in the following
sections;
2.2 I44 M-PROS Control System Operational Instructions
This document highlights all the operational characteristics of the electrical control panel used on the
McCloskey I44 Impact Crusher. The M-PRO S product software has been developed to operate and monitor the
machine. The control system will highlight alarms, display warnings to the operator and allow some
parameters to be adjusted to enhance the machine operation and efficiency.
Any adjustable parameters have been agreed with McCloskey engineers, and as a result some elements
require passwords and controls which can be obtained from McCloskey or JMG Systems engineers upon
request.
This Operational Manual should be used in conjunction with any safety or operational information supplied by
McCloskeys to the operator. It is assumed that the operator has been fully trained on this equipment and is
aware of all safety considerations.
All Operations are performed using the interface screen on the Main control Panel.

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3 OPERATIONS
Control Software
McCloskey I44 – M-PROS Control System Start Up Screens
A1 Start Up Screen
3.1 Introduction
This overview manual explains the main menu options for use on the McCloskey I44 Impact Crusher.
Each Section will identify the menu options available and a brief description of each function.
All settings and procedures identified in this document are accessed via the numbered buttons on the display
panel.
To enter any command or access a new sub menu, simply press the relevant button.
To exit a particular sub-menu and go back one level, press the ESC button or a return button which will be
highlighted.
Instructions in this document are referenced by pressing the relevant button on the main screen to navigate
through the menus.
A function in operation is highlighted by a yellow circle appearing around the number corresponding to the
function.
3.2 Operation
Before starting up the machine ensure that:
 All emergency stop buttons are not enabled on the machine, handset or remote if fitted
When the Ignition switch is turned to the ‘On’ position the Start Up Screen A1 will appear. After a few
seconds the Main Menu Screen A2 will be displayed. Start the machine by turning the ignition key to the
‘Crank’ position, the warning sirens will sound for 10 seconds before starting up the engine.

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3.3 Setting the Date & Time
Date and Time may be altered by using the following steps:
From the Main Menu Screen A2, press and hold for three seconds.
The “YEARS” field will be highlighted first and begin to flash.

To increase the years press the Up arrow button.
To decrease the years press the Down arrow button.
Press the arrow right button to move to the next field.
The “MONTHS” field will begin to flash.

To increase the months press the Up arrow button.
To decrease the months press the Down arrow button.
The “DAYS” field will begin to flash.

To increase the days press the Up arrow button.
To decrease the days press the Down arrow button.
The “HOURS” field will begin to flash.

To increase the hours press the Up arrow button.
To decrease the hours press the Down arrow button.
The “MINUTES” field will begin to flash.

To increase the minutes press the Up arrow button.
To decrease the minutes press the Down arrow button.
The “SECONDS” field will begin to flash.

To increase the seconds press the Up arrow button.
To decrease the seconds press the Down arrow button.
Finally press the arrow right button to store the new date/time - the highlighted option will disappear from
the date/time fields.

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3.4 Main Menu
A2 Main Menu Screen
Below are the functions of the Buttons;
Button 1 Machine Run Screen A3 Appears

Button 2 Tracking Mode Operation
Button 3 Maintenance Touch once to bring you to Screen A4, Twice
to bring you to Screen A9
Button 4 Language Selection English, Spanish, German, French
Button 5 Engine Values Brings you to Screen A6
Button 6 Impact Crusher Adjustment Brings you to Screen A8
Button 7 Feeder Adjustment Brings you to Screen A7
Button 8 Optional Extras Brings you to Screen A10

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3.5 Machine Run
A3 Machine Run Screen

When the Machine Run button has been selected the operator has the option to run the crusher by pressing
the Ok button, with the main conveyor running the siren will sound for 10 seconds after the 10 seconds the
control system will start to ramp the crusher to is previous set speed (A18 Crusher Adjustment Screen)
exit the screen via the ESC button...
A4 Feeder Adjustment Screen
When in the Main Menu Screen A2, if you press Button 7, you will be navigated to the Feeder Adjustment
Screen A4.

Button 1 – Pre-screen On/Off... enabled after the crusher has reached its set speed.
Button 2 – Feeder On/Off
Button 3 – Adjust Down Stream OFF delay
Button 4 – Adjust Down Stream ON delay
Button 5 – Adjust Feed Pressure, when crusher pressure reaches this value the feeder will switch off.
Button 6 – Allows the operator to adjust the feeder control Pressure, when the crusher pressure
reaches this value it start to decrease the feeder speed.
Arrow Down - Decreases Feed Conveyor Speed Setting
Arrow Up - Increases Feed Conveyor Speed Setting

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The Control System will only allow the Pre-Screen and Feeder to start if, the crusher has reached full speed,
the crusher drive pressure is within its operating limits, the Down Stream control, if fitted, is ready to run
and the crusher material level is within its operating limits.
A5 Crusher Adjustment Screen
When in the Main Menu Screen A2, if you press Button 6, you will be navigated to the Crusher Adjustment
Screen A5. If you press Button 1, The Radio Control Function is selected. Before selecting this option the
operator must switch the transmitter on.
When using the Radio Remote whilst crushing the operator can;
-adjust the feeder speed

-switch the feed conveyor On/Off
-Shut Down the machine
As soon as the transmitter starts communicating with the receiver, the radio remote stop circuit becomes
active. Shut down will be applied if there is any loss of radio communication between the transmitter and
receiver as a result of the transmitter moving out of range or if the transmitter runs low.
Button 1 – Enable Radio Control Functions.

Button 3 – Increases Impactor speed.
Button 4 – Decreases Impactor speed.

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3.6 Diagnostics
A6 Output Diagnostic Screen
By Pressing Button 3 on the Main Menu Screen A2, you will be brought to the Output Diagnostic Screen A6 as
shown above.
Each feedback circuit provides details of voltage or current which relates to the normal operating conditions
of the particular circuit.
From here it is possible to determine whether or not, for example, a function is actually on or off, or if there
is a short circuit in the overall system, etc.
These screens are beneficial if a problem occurs and an engineer is providing off-site support.
When in the Output Diagnostic Screen A6, if you press Button 5 you will be navigated to the Input Diagnostic
Screen A7.

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A7 Input Diagnostic Screen
Engine Speed - Engine Speed INFORMATION Supplied via the engine ECM, displayed in RPM.
Engine Load – Engine Percent load at current speed, Information supplied via the engine ECM,
displayed as a percentage.
Battery Voltage - System Voltage information supplied via the engine ECM, displayed in Volts.
Crusher Level - Input from the ultrasonic level sensor, value displayed in CM.
Sensor Value - Level sensor, displayed in Frequency
Conveyor pressure - Input from the conveyor pressure transducer, displayed in Bar
Pump Pressure - Input from the main pump pressure transducer displayed in Bar
Hydraulic Oil Temp - Input from the hydraulic temperature sensor value displayed in °C
This screen will tell you the vital statistics of the running machine. To return back to the Output Diagnostic
Screen, Press the ESC Button.
A8 Tracking Inputs

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When you are in the Output Diagnostic Screen A6, if you press Button 2, you will be navigated to the Tracking
Input Diagnostic Screen A8.
This screen can only be accessed when in Tracking Mode; each feedback field will provide details of voltage
or current which relates to the normal operating condition of the particular circuit.
From here it is possible to determine whether or not, for example, a function is actually on or off, or if there
is a short circuit in the overall system, etc.
When in screen A8, if you press button 8 you will be diverted to screen A9.This screen shows you which
functions are being used; you will see visual representation of what buttons you are physically pressing, when
controlling the tracks by either method. (By Radio Remote, illustrated on Left of screen, or by Manual
Handset as represented on the Right of the screen)
A9 Tracking Controls
A10 Security Code Input Screen
When you press button 3 twice, in the Output Diagnostic Screen A6, You will be brought to the Security Code
Input Screen A10, Where you will be asked to input a unique four digit pin. This pin is only available to
Qualified Personnel, who can obtain it by contacting their dealer or McCloskey International Direct. After
successfully entering the correct code you will be navigated into Screen A11.

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3.7 Maintenance
A11 Maintenance Screen
Whilst in Screen A11, if you press (Maintenance) Button 4 once, you will be brought into the Impact Crusher
Start/Stop Screen A12.
A12 Impact Crusher Start/Stop Screen

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Whilst in Screen A11, if you press (Maintenance) Button 4 twice, you will be brought into the Feeder
Start/Stop Screen A13. The percentage can be increased or decreased by using the up or down arrow buttons.
A13 Feeder Start/Stop Screen
Whilst in Screen A11, if you press (Maintenance) Button 4, three times you will be navigated into the Engine
Information Screen A14. You will only be able to exit out of Screens A12, A13 & A14, if you press Button 4, a
fourth time, this will bring you back to Screen A9.
When you have navigated back to Screen A11, be aware that if you press ESC, you will be navigated back to
the Output Diagnosis Screen A6. If this happens you will then be required to navigate back to the Security
Code Input Screen A10.
You will then be required to input the Security Code again to circumnavigate back through to the other
Screens that you may need to access to.
A14 Engine Information Screen

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3.8 Parameter Adjustments
When in Screen A11, If you Press Button 5, you will navigate to Crusher Parameter Adjustment Screen (A)
A15.
A15 Crusher Parameter Adjustment Screen (A)
When in the Crusher Parameter Adjustment Screen A15(A), You can scroll up and down through the list using
the Up and Down Arrow Buttons, until you find the setting you want to edit, the current selection will be
highlighted by a green bar which moves up and down accordingly with each press of the buttons.
When you have correctly selected the setting you want to change, Press Button 4 – Note the corresponding
illustration changes from a Screwdriver to a Disc, this indicates that you have selected a value to be changed,
successfully. You may also notice that the writing inside the highlighted green bar changes colour to red, as
shown in Crusher Parameter Adjustment Screen A15(B).
It is now that you can begin to change the values by increments using the Up and Down Arrow Buttons, to
increase the value use the Up Arrow Button and to decrease the value use the Down Arrow Button.

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A15 Crusher Parameter Adjustment Screen (B)
The Following are the options for adjustment in the Crusher:
Enable Greaser__________________________________________________________ On/Off

(Switches the Auto Greasing Function On or Off)
Greaser Pause Time______________________________________________________ Sec

(Sets the Auto Greaser pause time in Seconds)
Greaser Pause Time______________________________________________________ Mins

(Sets the Auto Greaser Pause time in Minutes)
Crusher Max PWM________________________________________________________ mA

(Sets the Maximum Current Value that supplies the solenoid valve on the crusher Pump
Which controls the maximum speed of the Crusher)
Crusher Step Range Time__________________________________________________

(This is the step size of change in output over Ramp Up and Ramp Down Time on the
Crusher)
Crusher Ramp Up Time____________________________________________________

(Time Crusher takes to increase its set speed in Milliseconds)
Crusher Ramp Down Time__________________________________________________

(Time Crusher takes to increase its set speed in Milliseconds)
Hydraulic Temperature System Shut Down____________________________________°C

(Sets the temperature at which the Crusher shuts down and flags a warning)
Oil Cooler Start Temperature_______________________________________________°C

(Sets the temperature at which the Hydraulic Oil Cooling Fan turns on)
High Pump Pressure Value_________________________________________________ bar

(Sets the value at which the Control System shuts down the Main Pump)

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This same format will apply, when adjustments need to be made on the Track Speeds and Feeder
Parameters, as shown in the Screens below.
A16 Tracking Parameter Adjustment Screen - Snail Mode (A)
When you want to move between Preset Modes; Snail, Tortoise & Hare, use the Arrow Down Button to go the
whole way Up or Down the List until you can go no further. Then you will be able to use the Right and Left
Arrow Buttons to Toggle between Modes.
The Modes are in Sequence, For Example; automatically you are in Snail Mode, you must Toggle fully down
through the list, you are then able to toggle Right to enable the transition into Tortoise Mode, and again
Toggle fully down through list, again you are now able to Toggle into Hare Mode.
This Sequence works in reverse to go back to Snail Mode.
The Following are the options for adjustment when Tracks are in Snail Mode:
Low Track Maximum Engine RPM____________________________________________ Rpm

Low Track Maximum PWM Pump 1___________________________________________ mA
Low Track Maximum PWM Pump 2___________________________________________ mA
Low Track Ramp Up Time__________________________________________________
Low Track Ramp Down Time________________________________________________
Low Track Step Range_____________________________________________________

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A16 Tracking Parameter Adjustment Screen - Snail Mode (B)
A17 Tracking Parameter Adjustment Screen - Tortoise Mode
The Following are the options for adjustment when Tracks are in Tortoise Mode:
Intermediate Track Maximum Engine RPM_____________________________________ Rpm

Intermediate Track Maximum Pump 1 PWM____________________________________ mA
Intermediate Track Maximum Pump 2 PWM____________________________________ mA
Intermediate Track Ramp Up Time___________________________________________
Intermediate Track Ramp Down Time_________________________________________
Intermediate Track Step Range______________________________________________

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A18 Tracking Parameter Adjustment Screen - Hare Mode
The Following are the options for adjustment when Tracks are in Hare Mode:
Fast Track Maximum Engine RPM____________________________________________ Rpm

Fast Track Maximum Pump 1 PWM___________________________________________ mA
Fast Track Maximum Pump 2 PWM___________________________________________ mA
Fast Track Ramp Up Time__________________________________________________
Fast Track Ramp Down Time________________________________________________
Fast Track Step Range______________________________________________________

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A19 Feeder Parameter Adjustment Screen
The Following are the options for adjustment in the Feeder:
Feeder Maximum PWM_____________________________________________________ mA

(Sets the maximum current value in milliamps that supplies the solenoid valve on the
Feed Conveyor Control Valve)
Feeder Minimum PWM_____________________________________________________ mA

(Sets the minimum current value in milliamps which controls the start valve on the
Feed Conveyor)
Hydraulic Temperature Feed Adjust_________________________________________ °C

(Sets the temperature at which the feed conveyor goes at half speed)
High Pressure Stop Delay___________________________________________________ s

(Sets the delay on the input that controls the shut down for the Feed Conveyor on
High Pump Pressure)
High Pressure Restart Time_________________________________________________ s

(Sets the delay on the Feed Conveyor restarting when the Pump Pressure returns to
Normal)
Conveyor Sensor __________________________________________________________ On/Off

(Switches the Main Conveyor Sensor On or Off. When in the Off position it disables the
Shut Down and Warning Features when the Main Conveyor has a speed Fault)

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3.9 Language
A2 Main Menu Screen
When in the Main Menu Screen A2, if you press Button 4, you can change the language the M-PROS System
uses, Each Press of Button 4, Bring up a different country flag, representing the language, the options are as
follows;
English is the Default Setting.
Spanish can be set by pressing Button 4 once.
German can be set by pressing Button 4 twice.
French can be set by pressing Button 4 three times, a fourth press of Button 4 will return you to
English.

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3.10 Optional Extras
A20 Optional Extras
Button 1 Dust Suppression Switches Spray Bars On/Off (Only when the main conveyor is running)
Button 2 Fuelling Switches Fuelling Pump On/Off
Button 3 Work Lamps Switches Work Lamps On/Off
When in the Main Menu Screen A2, if you press Button 5, you will be brought to A21 Engine Values Screen.
This gives you all the information you require at a glance. Engine Run Hours, Crusher Run Hours, Hydraulic
Values, Battery and Fuel Values are contained on this ‘at a glance’ page.
A21 Engine Values Screen

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4 RADIO REMOTE & HANDSET

4.1 Handset Operation
Ensure that the Handset is connected to the Machine, and that the Handset Machine Stop is not pressed.
Start the Engine as per the Engine start up procedure
Switch the Handset On.
Note: At this point the Tracking Safety Siren should sound. There is a ten second delay on the handset before
the Tracks will operate. Ensure that the Machine is clear of any obstacles before operating the Tracks.
The Machine can now be tracked using the controls on the Handset, as shown above.

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4.2 Radio Remote Tracking Operation
Radio Receiver
To start the remote tracking function ensure the toggle switch (on the top left of unit beside red Stop Botton)
is in “I” position. Then press the On Button (top button on the right hand side of the unit). The LED on the
transmitter should flash red then green indicating that the battery in the transmitter is OK. If the LED
remains off or stays red check the transmitter battery.
The Track On Switch must be selected to start the tracking sequence.
When this is selected the main conveyor will automatically raise, the tracking siren will then sound for 10
seconds and pulse for 1 second to indicate that the machine is ready to track.
When tracking is selected it will start to track in the low speed, indicated in Snail Mode on the MPROS screen.
The tracking speed can be changed using the screen sequences described in the previous section 3.8.
Using the forward and reverse directional switches will allow the machine to move.

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4.3 Radio Remote Feed Conveyor Operation
To start the remote Feed Conveyor Function ensure the toggle switch is in “On” position.
The Feed Conveyor On Switch (bottom left hand button) must be selected to start the Feeder Operations.
The operator can then use the radio transmitter to operate the Feed Conveyor…switch the Conveyor on or
off, and adjust the feed conveyor speed.
Pressing the red stop button at any time will stop the engine.
Feeder speed
increase button
Feeder speed
decrease button

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5 MACHINE FAULTS
5.1 Machine Faults
Machine Stop Pressed…

4 machine stops are fitted on the chassis of the I54. This warning
will be displayed when a switch is pressed or if there is a fault on
Machine Stop Pressed the machine stop system.
Pressing the OK button will reset the warning only if the switch is
reset or the fault is cleared.
Turn to release stop button
Radio Stop Pressed…When the radio control has been selected

the radio stop becomes active. Pressing the red stop button on
the transmitter will shut down the engine and display the fault
Radio Stop Pressed on the screen.
Pressing the OK button will reset the warning only if the switch
is reset or the fault is cleared.
Low Hydraulic Oil Level…This warning will be displayed when the

hydraulic oil level switch detects a fault.
Low Hydraulic oil Level
When fault is cleared pressing the OK button will reset fault
screen.

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High Hydraulic Oil Temperature...This warning will be displayed

when the hydraulic oil temperature sensor detects high oil
temperature.
High Hydraulic oil
When fault is cleared pressing the OK button will reset fault
Temperature
screen.
No Radio Signal When the radio control has been selected and the
control system has not received a signal from the transmitter this
warning will appear.
No Radio Signal
The warning can be cleared by pressing the OK button when the
radio signal is restored.
High Pump Pressure If the Main Pump is running and the

system detects a high drive pressure the system will shut down
the pump and display this warning.
High Pump Pressure
The fault can be cleared by pressing the OK button.
Auto Greaser Malfunction If the auto greaser stops pumping or

runs out of grease then it will shut down the crusher and display
the warning but it will allow the machine to be restarted.
Auto Greaser Malfunction
The fault can be cleared by pressing the OK button.
Conveyor Speed Fault When the crusher is started it checks the

pressure on the conveyor circuit if the pressure is either too high too
low it will shut down the crusher and display the warning.
Conveyor Speed Fault
The warning can be cleared by pressing the OK button.
Manual Handset Stop Pressed…When the manual hand set is

connected the stop on the handset becomes active and Pressing the
yellow button will shut down the engine and display the fault on the
screen, repress the yellow button to release.
Manual Handset Stop Pressed Pressing the OK button will reset the warning only if the switch is reset
or the fault is cleared.
Impactor Door Open... This warning will be displayed when the

chamber switches have been opened when the crusher is running.
Impactor Door Open When fault is cleared pressing the OK button will reset fault
screen.

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5.2 Engine Faults;
Engine faults detected by the engine’s ECU will be displayed on the screen. The engine ECU will determine,
depending on the fault, whether the engine is shut down or allowed to run.
When the fault has been cleared pressing the OK button will reset the fault screen.
Engine Fault
SPN 000 FMI 000
SPN: Fault Code FMI: Fault Code

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6 COMPONENT LAYOUT
6.1 External Connections
Location Of Fuse & Relay Panel on Machine
Fuse & Relay Panel
Connections on Bottom of Fuse & Relay Panel
X5A X5B X5C

Refuelling Dust Work Lamps
Pump Suppression
Connection Pump
Connection
Connections on Bottom of Fuse & Relay Panel
HCP Radio
Radio Remote Remote
Battery Charger Battery
Connection

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6.2 Relays
RL6 RL1 RL2 RL3 RL4 RL5

Oil Cooler Oil Cooler Oil Cooler Work Lamps Dust Refuelling
#3 #1 #2 Relay Suppression Pump Relay
6.3 Fuses
FL5 FL6
Work Lamp Dust Suppression
FL1
Fuse (RL3) Fuse (RL4)
Oil Cooler
#1
FL2
Oil Cooler
#2
FL3
Panel
Power
FL4 FL7 FL8

CAT ECU Refuelling Pump Remote Charger
Unit Fuse (RL5) Power Plug Fuse
FL5
Oil Cooler
#3

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McCloskey I44 Operational Manual Page 1 of 33

Issue 0; 27th June 2011

JMG Systems Ltd

© JMG Systems Ltd. 2011

FOREWORD / RESERVATION OF RIGHTS

JMG Systems Ltd

© JMG Systems Ltd. 2011

1.1 Safety Introduction ....................................................................................................... 4

2.1 System Overview .......................................................................................................... 7

3.1 Introduction ................................................................................................................ 8

4 RADIO REMOTE & HANDSET ---------------------------------------------------------------------------------------------- 26

4.1 Handset Operation ....................................................................................................... 26

5 MACHINE FAULTS ---------------------------------------------------------------------------------------------------------- 29

5.1 Machine Faults ............................................................................................................ 29

6 COMPONENT LAYOUT ----------------------------------------------------------------------------------------------------- 32

6.1 External Connections .................................................................................................... 32

© JMG Systems Ltd. 2011

Before operating this Machine you must

WARNING read the Safety instructions as detailed in

1.1 Safety Introduction

Before operation the operator must:

 Be aware of all moving parts on the Machine.

1.2 Electrical Safety

 ALWAYS Isolate the batteries when welding on the Machine

© JMG Systems Ltd. 2011

1.3 Safety before and during Operation

 Ensure that all control levers are in the neutral position.

1.4 Machine Shutdown Procedure

1.5 General Maintenance

© JMG Systems Ltd. 2011

© JMG Systems Ltd. 2011

2.2 I44 M-PROS Control System Operational Instructions

© JMG Systems Ltd. 2011

Before starting up the machine ensure that:

© JMG Systems Ltd. 2011

3.3 Setting the Date & Time

Date and Time may be altered by using the following steps:

The “YEARS” field will be highlighted first and begin to flash.

Press the arrow right button to move to the next field.

The “MONTHS” field will begin to flash.

Press the arrow right button to move to the next field.

The “DAYS” field will begin to flash.

Press the arrow right button to move to the next field.

The “HOURS” field will begin to flash.

Press the arrow right button to move to the next field.

The “MINUTES” field will begin to flash.

Press the arrow right button to move to the next field.

The “SECONDS” field will begin to flash.

© JMG Systems Ltd. 2011

3.4 Main Menu

A2 Main Menu Screen

Below are the functions of the Buttons;

Button 1 Machine Run Screen A3 Appears

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3.5 Machine Run

A3 Machine Run Screen

A4 Feeder Adjustment Screen

Below are the functions of the Buttons;

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A5 Crusher Adjustment Screen

-adjust the feeder speed

Below are the functions of the Buttons;

Button 1 – Enable Radio Control Functions.

© JMG Systems Ltd. 2011