Professional Documents
Culture Documents
TECHNICAL TRAINING
Rev-00
MIDDLE GRADE
TIPPING GRID CONVEYOR
MAIN CONVEYOR
FINES CONVEYOR
BELT FEEDER
SCREEN BOX
POWER UNIT
OVERSIZE TRACKS
CONVEYOR
684 MAIN COMPONENTS – 3 DECK
FINES CONVEYOR
OVERSIZE
CONVEYOR
MAIN CONVEYOR
TIPPING GRID
SCREEN BOX
TRACKS
POWER UNIT
MIDDLE GRADE
CONVEYOR OVERSIZE +
BELT FEEDER
CONVEYOR
SCREEN TOP & MIDDLE DECK
Maintenance of the screen is minimal although after the
first 10 hours of Operation the following should be carried out.
A.Check and tension the clamping bolts as shown.
B.Continuously check all the screen meshes for clogging.
C.Screen cloths should be tensioned after 2, 8, 16 and 40
hours after replacement.
CLAMPING BOLTS
BOTTOM DECK
Holding pin
End nut
Tensioning bar
When changing the middle deck mesh, it is good practice to remove the top deck as to improve access.
To change the bottom deck mesh, loosen the nut on the tensioning devices on either side of the Screenbox.
Turn the nut anticlockwise using a 7/8’’ spanner. The holding pin can now be removed which holds the cloth
tensioning bar.
The tension bar can now be moved in the direction of the black arrow leaving enough space for the screen cloth
to be unhooked. The screen can now be removed. Once the new screen cloth has been hooked on the tension
bar, place the tension bar back into position ensuring that the tension bar hooks the top lip of the screen cloth, and
replace the holding pin.
Tension the screen cloths by turning the tensioner bolt clockwise on both sides. When tensioning, alternate
between the tensioner’s on both sides, this ensures the cloths are tensioned evenly.
BELT TRACKING & TENSIONING
Belt Tracking is done at the idler drum on each of the conveyors.
To adjust, rotate the nut on the idler drum adjuster, by using the 7/8’’ spanner supplied in the toolbox. A small
movement in the adjuster of 10mm should be sufficient as any greater movement will affect the tension of the belt.
DRAIN PLUG
When changing the gearbox oil in the feeder, ensure the engine is switched off. GEARBOX LOCATION
The fill plug should be removed as this will allow air into the gearbox so it will drain faster. (17mm socket or
7mm Allen key will be required depending on which plug has been fitted.)
The drain plug can now be removed so the oil can fill into a suitable container.
The drain plug can then be replaced once fully drained.
The oil can now be filled through the fill plug at the top.
The Gearbox holds approximately 1.3L of oil.
Oil to be changed at 1st 250Hrs and then every 1000Hrs with VG 150 Gear Oil.
The Feeder Unit Gearbox does NOT use the same type of gear oil as the Track gearbox
MACHINE GREASING
The 684 has low level greasing to all bearings. Grease pipes are returned from each bearing to low level where
maintenance can be performed with ease.
All of the following grease points require 4 grams/2 pumps per point every 50 Hours.
Main Conveyor drive
& idler drums (RHS
shown)
The screen box bearings on the 694+ can be accessed from the catwalk. Grease pipes are returned from
each bearing to a bracket on the screen box where maintenance can be performed with ease.
Both of the screen box bearings require 16 grams/8 pumps per point every 50 Hours.
The grease to be used is Maxol Heavy Duty Synthetic 220.
SCREEN
BEARINGS
MACHINE GREASING
OVERSIZE PLUS SIDE CONVEYOR
SWIVEL SUPPORT PIVOT BOSS &
PIVOT BLOCKS
FINES
CONVEYOR
IDLER DRUM
FINES CONVEYOR DRIVE
& IDLER DRUM
SCRAPER ADJUSTMENT
It is important to keep sufficient tension on the belt scrapers at all times, to ensure proper cleaning of the
belt and to stop smaller rocks getting caught between the scraper and the belt causing damage to both.
The Rosta scraper rubbers can be turned once.
SUPPORT STRUT
When the desired conveyor discharge position has been achieved, the support strut must be pinned in
place.
The conveyor can be folded to and from transport position when the locking pin is removed.
SUPPORT STRUT
CAT C4.4
The watertrap should The in line fuel filter should be The secondary fuel filters should be
be checked and drained if changed every 500 hours of changed every 500 hours of
required on a weekly operation. operation.
basis. It is located before the fuel
pump beside the oil level dipstick.
CAT C4.4 - AIR
The air filter service indicator The air filter should be The crankcase breather element
should be checked on a daily cleaned regularly. should be replaced every 1500 hours
basis. The air filter should be of operation.
The air filter must be cleaned or changed every 500 hours
replaced if the indicator is red. of operation.
CAT C4.4 - OIL
An oil drain tap is located on The oil filter should be The oil can be refilled through the
the bottom of the sump. changed every 250 hours filler cap.
A hose can be attached and the of operation. The capacity of the engine is 7.3l
oil can be drained by opening the (1.61Gals) and should be changed
tap. every 250 hours.
The oil dipstick is located under the
water trap filter.
TRACK TENSION
Carrier roller or
skid plate
(whichever is
fitted)
Forward Direction
Stop the machine on solid & level ground & drive 2 meters (min) in a forward direction.
Measure the sag on the top part of the track on the longest section of unsupported track, as shown above.
PLEASE NOTE THAT SOME OF THE ILLUSTRATIONS SHOWN ARE NOT THE SAME AS THOSE ON ACTUAL MACHINE
TRACK GREASE TENSIONING
The track system uses a grease cylinder to keep each track in tension. Screwed into the end of the grease
cylinder is a grease fitting, Figure 1, enabling grease to be pumped into the grease chamber and released from
it, tightening and slackening the track respectively.
The grease adapter, Figure 2, is supplied in the tool box and is used to couple onto the grease fitting.
THE GREASE CONTAINED IN THE TRACK TENSIONER IS PRESSURISED SO CARE MUST BE TAKEN
WHEN LOOSENING THE GREASE FITTING.
GREASE TENSION LOCATION
1 Loosen the 2 screws and swing the access cover away from the access aperture on the side of the track,
(Figures 1 & 2)
2 Ensure the grease fitting and grease gun adapter are clean, ingress of dirt into the grease fitting can
result in failure. Connect a grease gun to the grease fitting, (Figure 3), and add grease until the track
tension is within the specified values given on the last page.
3 Drive the plant 50 meters backwards and repeat the above procedure if the track slackens.
PLEASE NOTE THAT SOME OF THE ILLUSTRATIONS SHOWN ARE NOT THE SAME AS THOSE ON ACTUAL MACHINE
TRACK GEARBOX
FINAL DRIVES
The first oil replacement for the final drive should be carried out after the first 250hrs, thereafter
replace the oil every 1000hrs.
The oil level should be checked once a month.
The track gearboxes hold 5 litres of oil (1.3 Gals).
PLEASE NOTE THAT SOME OF THE ILLUSTRATIONS SHOWN ARE NOT THE SAME AS THOSE ON ACTUAL MACHINE
GEARBOX OIL CHANGE
OIL DRAINING
OIL FILLING
Regular checks on fluids and the lubrication of the machine, in accordance with the schedule is essential.
A different type of grease is used for lubricating the screen bearings than that used on the rest of the
machine. Always use the correct grease as specified.
It is the operators responsibility to ensure that all bearings are greased with the correct quantity and type of
grease at the correct intervals specified.
Welding can cause damage to the engine and machine electronics. The
following precautions should be taken before and during welding.
Turn the engine OFF.
Turn off the battery isolator switch and lock out.
Disconnect the engine ECM plugs.
Disconnect the screen plug.
Clamp the ground cable of the welder to the component that will be
welded, placing the clam as close as possible to the weld.
Protect any wiring harnesses, belts and hoses from welding splatter.
*ADVISE CAUTION WHEN WELDING NEAR ANY FLAMABLE MATERIALS AND TAKE PRECAUTIONS WHERE NECESSARY.
ELECTRICAL COMPONENTS & FUNCTIONS
ELECTRICAL COMPONENT LOCATIONS
MCU 300 CONTROL PANEL
The home screen will be displayed on the control panel display screen.
The indicator lamps in the centre of the screen will illuminate and extinguish after two seconds if there
are no faults present.
If the indicator lamps do not extinguish refer to the engine fault code screen
The e-stop healthy and fuel on symbols only should light up green.
Do not start the engine if any other lights are illuminated red or if there are any other faults shown on
the display screen.
MCU 300 CONTROL PANEL
On Tier 4 machines the wait to start lamp is illuminated briefly on the home screen.
The engine can be started after this lamp goes out.
To view engine information, press the button under the engine symbol.
MCU 300 CONTROL PANEL
MAIN MENU PAGE
SOFTWARE VERSION
1st number = A1 (Display)
2nd Number = A2 (Master PLC)
3rd Number = A3 ( Slave PLC)
MCU 300 CONTROL PANEL
MAIN MENU PAGE
ALARM NUMBER
FAULT CODE
ALARM GRAPHIC
RELAYS &
CONTACTORS
SCREEN
TRACKING REPROGRAMMING
FUSES PLC
RELAYS CABLE
RELAYS & CONTACTORS
F1 – 10amp, Ignition
F2 – 30amp, Tracks Supply/Fuel Pump Supply The Fuses for the machine are located inside
F3 – 30amp, Starter Solenoid/Oil Coolers Supply the main control panel.
F4 – 5amp, Ignition to ECU 3 Main Power Fuses are locate in the engine
F5 – 15amp, Hydraulic Oil Cooler #1 canopy.
F6 – 15amp, Hydraulic Oil Cooler #2 These are of a larger rating and can be
F7 – 15amp, Tracks Supply accessed by opening the black cover.
F8 – 10amp, Fuel Pump Supply
PLC & SCREEN
When reading the schematic diagrams, it is sometimes difficult to get a full understanding of the components
and their respective locations. Therefore the components, cables, and connection points have been labelled to
provide the user with an easy method to find specific functions etc.
The electrical schematics use a colour code to identify wires in the
WIRE COLOUR CODE
panel.
B=BLACK K=PINK
The example below indicates the colour of the specific wire which
G=GREEN N=BROWN
the user may be trying to identify.
O=ORANGE R=RED
This info is telling the user that #START REQ is also
P=PURPLE S=SLATE
represented/continued on page 6, row D, column 6 on the electric
U=BLUE Y=YELLOW
schematic.
W=WHITE
STARTING SEQUENCE
1. 12v power supply
2. Key turned to ignition
3. Signal sent to PLC PLC
4. PLC waits 7 Seconds
5. Signal sent to K4 Relay, closing
contact to Starter Solenoid
Connection
6. Starter motor engages
E-STOP AND FUEL SOLENOID CIRCUIT
STARTING SEQUENCE
1. 12v power supply
2. Key turned to ignition
3. Signal sent through E-Stop Circuit
4. K2 Relay energised.
5. Fuel Pump, Track Supply and PLC
energised.
6. An E-Stop Healthy signal is sent to
the PLC Input IN0
E-STOP CIRCUIT
RUNNING SEQUENCE
1. With the key switch in ‘on’ position,
power is sent through E-stops to
power the K2 coil.
STOPPING SEQUENCE
1. The power supply is broken when
the E-Stop is pressed
2. The K2 Relay de-energises and
the contact opens.
3. The E-Stop Health signal to the
PLC is lost.
4. The PLC cuts the power to Relay
K5 shutting down the fuel system.
HYDRAULIC OIL COOLER
If the emergency stop is pressed on the dog lead a signal is sent to the PLC Input
IN10 within the main control panel and the machine will shut down.
This will result in the e-stop button light on the control panel illuminate
permanently
The hydraulic tank holds +/-564lts of oil, and has 3 suction lines, with
strainers, and 1 return line, with a 10 micron Absolute filter.
Bleed lines from the motors are piped directly to the side of the tank.
All other hydraulic lines run through a return manifold.
The 3 suction lines have ball valves which may be closed for maintenance.
If the oil level drops below minimum it will shut the engine down and will
display ‘a hydraulic oil level’ warning signal on the starter panel.
The level gauge is located beside the visual indicator.
The return filter should be changed every 500hrs while the suction filters
should be changed every 1000hrs.
HYDRAULIC TANK - COMPONENTS
CAT 4.4 TIER 4 - 2 DECK
T- Tank line
C- Pressure/Return line to
RHS track
P2- Pressure line from control
bank
Hyd Cooler #1
Hyd Cooler #2
Power connection
BELT FEEDER
OVERSIZE & TRANSFER
SCREEN BOX SPEED CONTROL