Metrotrak 18 4 05

METROTRAK
900 x 600
36 x 24
JAW CRUSHER
Advanced Crushing Technology

M SERIES JAWCRUSHER
Jawguard
Flywheel
Upper Cheek
Plate Eccentric
Shaft
Wedge
Jawstock
Jaw bolt
Toggle
Seat
Mainframe
Toggle
Fixed jaw Plate
Swing jaw Toggle
Seat
Lower cheek Drawback
Plate Rod
Spring

METROTRAK PRODUCT CURVES + TONNAGES
•40mm (1 1/2” )minimum closed side setting in demolition 75mm (3”)open side
setting.
•50mm (2”)minimum closed side setting in rock 85mm (3 3/8” ) open side
setting.
•Capacities and product curves are only guide lines only and vary depending
on the material.

START UP
Battery Isolator Switch
Check that the battery isolator switch is in the on position.
Always remove the key when carrying out maintenance, especially if welding
Off
On

START UP
Daily - check oil + water
Inspect air filter regularly and blow
out as necessary rpm
Temp Oil pressure

1st stage on ignition switch should
sound the siren for 10 seconds. If not
an emergency stop is pressed in
The over-ride switch bypasses the oil

Diesel Amps
and water sender units when starting up Hour
clock
The engine will shut down under high Ignition
temperature or low oil pressure Switch
Over-ride Circuit
switch Breakers

CIRCUIT BREAKERS
The circuit breakers need to be pressed in to reset
them if they trip out
The only thing on the Pegson side that can trip out the
breakers is the air blast cooler.

START UP
Check position of the remote control on / off switch.
In the on position the engine will not start unless the transmitter is
switched on.

PLANT LOADING/OFF LOADING
Remote Control
LED
Red/Green
Remote On
Track Siren
Remote Feeder
Start/Stop
Remote Off

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

NEW CHARGER
The new type chargers are 12 / 24 volts.

The charger clips into the back of the transmitter.
The output voltage from the charger is 9.6 volts.

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

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

UMBILICAL CONTROL
The old type umbilical controls were fitted with a 6 or 15 pin plug.
The function of the buttons are the same as the remote.

UMBILICAL CONTROL
The latest type umbilical is fitted with a heavy duty 16 pin plug and socket.
The function buttons remain the same.

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

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

Switch positions for operating frequency’s-

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

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

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

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

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

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

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

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

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

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

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

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

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

01 434.650
02 434.600
03 434.550
04 434.500

METROTRAK ENGINE THROTTLE
The engine rpm can be increased by either pressing the red button in and
pulling the throttle out or by turning the throttle anticlockwise.
Once the engine rpm is set, tighten the throttle lock to prevent the throttle
from moving whilst the machine is operating.
Throttle
Button Lock
Engine
Throttle

PLANT LOADING/OFF LOADING
Load / unload the machine on level ground
Long shallow ramps enable easier loading
Load / unload the machine on engine idle using the both tracks forwards/back
The machine will pull one way if the hydraulic oil is less than 5ºc (<41ºf) with
high rpm
Ramp
PLANT SET UP
All of the controls for setting up and moving the plant are all situated on the
electrical panel at the front of the machine.

PLANT CONTROLS
All of the controls that run the
plant are situated on the side of
the chassis other than the crusher
start button.
The cable to the control box is long

enough to reach the maintenance
platform should you choose to move
it. If you want to move the control
box, verify compliance with local
health and safety regulations.
The pressure fault light indicates

a low pressure fault on the
hydraulic clutch circuit. With this
light illuminated the feeder will
not run.
HYDRAULIC FOLDING HOPPER
There are two types of hopper fitted to the Metrotrak, one is a fixed hopper
and the other is a folding hopper.
The hopper sides are hydraulically folded up from

a switch on the electrical panel. The plant / trak
switch must to be in the plant position for this to
operate.

The hopper is held in position with wedges.
The wedges are fitted with chains to attach them to the chassis so that if one
should fall out it doesn’t get lost.
Hopper side front wedge
Hopper side rear wedge Hopper back wedges
gussets.

Ensure there is nothing in the feeder and fold the hopper sides up. Drop the
side wedges in position and attach the retaining chain.
The hopper back is then folded up by hand and drive the rear wedges in
place with a hammer.
Pressurise the folding cylinders down so that the hopper sides pull tight onto
the side wedges.
Retaining chain

DIRT CONVEYOR
The dirt conveyor has a chain wrapped around the head drum and the feeder
lifting lug as a safety precaution for when the machine is being transported.
Ensure the chain is removed before the conveyor is folded out otherwise the
conveyor could get twisted.
The dirt conveyor is folded out the same as the hopper with a switch on the
front of the electrical panel.

DIRT CONVEYOR
The head guard and barge boards must be fitted before using the dirt
conveyor.
The barge boards prevent material rolling back which reduces the amount of
belt stoppages and belt damage due to roll back or spillage.
NOTE. The dirt conveyor cannot be folded up with the barge boards fitted.
Head guard
Barge boards

DIRT CONVEYOR
The barge boards also act as guards for the hydraulic cylinders to prevent
any falling stones from damaging the chrome pistons or breaking off the
hydraulic pipes.

BELT SCRAPERS
Ensure that the belt scrapers on the dirt conveyor and product conveyor are
correctly tensioned and touching the belt.
Failure to do this will result in material building up on the rollers and

causing the belt to run off track.

FEEDER SCALPINGS
There are various ways that the product that passes though the feeder
grizzly section can be distributed.
1. A rubber blanking mat can be fitted to carry all of the material down the
dirt chute and onto the product conveyor.
2. A choice of 4 screen meshes can be fitted ( 10mm 20mm 30mm 40mm).
3/8 3/4 1 3/16 1 1/2
The product passing through the meshes goes onto the dirt conveyor and
the oversize goes down the dirt chute onto the opc.
3. The under side of the grizzly section can be left open so that all of the
product passing through the grizzly goes onto the dirt conveyor.
Blanking mat Screen mesh

FEEDER SCREEN MESH ACCESS
The meshes / mat are removed from the back side of the machine.
The retaining bolts need removing on each side of the access door and the
door can be hinged down.
Retaining bolts
Door

FEEDER SCREEN MESH REMOVAL
Dropping down the door reveals the adjusting rods.
Wire brush the threads on the adjusters and lightly oil them. Undo the
outside three nuts to the end of the threads.
Loosen the two retaining bolts on the tension bar and knock it forward to
release the screen mesh.
Tension bar Adjusters Retaining bolt
Nut 2 Nut 1

FEEDER SCREEN MESH REMOVAL
A lifting hook is provided to lower down between the grizzly bars to lift the
screen mesh off the front retaining lip. With the screen mesh lifted up pull
the mesh out from the rear of the machine.
Retaining lip

RUBBER BLANKING MAT
If the rubber blanking mat is being fitted ensure the side seals are upright
and they sit flat so there is no spillage. Grease the sides of the mat to ease
fitting.
On the support brace for the screen mesh there should be a rubber strip
fitted to stop the mesh or mat from vibrating and wearing away.
Tighten every back up in the reverse order.
Side Seals
Rubber strip

TENSIONER BAR
Before tightening the the side bolts on the tension bar ensure that it is pulled
back level by measuring from the back of the slot to the bolt head.
Retaining bolt
Measuring point

DUST SUPPRESSION
The water supply needs to to be at least 42 psi (2.9 bar) for the spray nozzles
to work properly.
The inlet port is 1 inch bsp thread which splits off to three outlets which can
be individually turned off by the shut off valve.
1. To the crusher feed chute 3. To the opc head drum
2. To the crusher discharge
1 inch bsp inlet

42 psi (2.9 bar)
1 2 3
Shut off valves
Drain valves

SPRAY NOZZLES
Opc head drum
Crusher feed chute
Crusher discharge

SET UP
O Sit the machine on reasonably level ground and slew it side to side
O Leave the remote on if the feeder needs to be operated with the handset.
O switch the machine to plant
O Rev up to 1100 rpm
O Start the product conveyor ( HFO )
O Start the crusher
O Rev up to 1850rpm
O Start the dirt conveyor (if it is being used)
O Start the feeder ( remote )

O If the feeder is being used in the remote mode the feeder start button will
need to be pressed on the electrical panel before it can be started from the
transmitter.

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

MAGNET DISCHARGE
The magnet can be reversed to discharge the steel on the other side.
The barge board can be swapped to the other side along with the shedder
plate.
Barge Board Plough Shedder plate

MAGNET DISCHARGE
The magnet can be reversed by swapping the two pipes. They both have male
fittings so it is a straight swap.
The plough bracket is handed so a R/H one would be required. It is imperative
that the bracket and rubber is fitted otherwise stone gets inside the barge
boards,knocks down the wing rollers and damages the transom brackets.
Plough bracket Rubber Quick Release Couplings

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

CHOKE FEEDING
• Ensures maximum capacities
• Maximum reduction
• Maximum jaw life

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

DE-RIG
• Remove the barge boards and head guard from the dirt conveyor.
• Remove the rear hopper wedges and fold down the hopper back.
• Fold the hopper sides up to take the weight off the side wedges and remove
all four.
• Fold up the dirt conveyor and fit the safety chain.
• Fold the hopper sides down and stow the head guard + barge boards on the
machine
• Remove all loose stones from the machine.
• Travel height with the hopper

down 3200 mm(10’ 6”).
• Travel height with the

hopper up 3400 mm.(11’ 2”)

JAW SETTINGS
Wire brush the threads on the adjusting rods and loosen off both pairs of
nuts.
Hit the end of the adjusting rods with a hammer to release the wedges. If they
won’t release hit the wedges directly with a punch to release them.
Adjusting rod Wedge ‘L’ bracket
Shims
Adjusting
cylinders
Adjusting nuts

TOGGLE BEAM UNLOCKING
When the wedge is knocked forwards it releases the pressure it was applying
on the toggle beam.
‘L’ bracket
Wedge
Toggle beam

DRAWBACK ROD ASSEMBLEY
Wire brush threads and and remove nut 1.
Remove the retaining pin and drawback rod guard as it can get bent
Lightly oil the threads and remove nut 2 to release the spring tension
Drawback
Rod Guard Spring
Retaining
Spring Cap
Pin
Nut 1
Spring
Retainer Nut 2
Bracket
Drawback
205mm ( 8 inch) Spring Compression
Rod
JAW SETTINGS
Before jacking the jaw stock forward clean all of the dirt from the top of the
toggle beam, shims and crossbeam.
Cross beam
Shims Toggle beam

HYDRAULIC ADJUSTMENT PACK
Push lever 1 forward and pump the jaw stock forward using the hydraulic
lever.
Always remove all of the shims Oil Filler
Hydraulic
Pump Lever & Dipstick
Hydraulic
Pump
1
Adjustment Valve
for Shimming Hydraulic Cylinder
HYDRAULIC PACK CIRCUIT
Hydraulic Cylinder Hydraulic Cylinder
32 or 46 grade
hydraulic oil

JAW SETTINGS
With all of the shims removed place a steel block in the shim area (60mm x
60mm x 115mm, 2 1/2” x 2 1/2” x 4 1/2”) to prevent the jaw stock coming back
should the lever get knocked or a hydraulic pipe fail.
Clean the whole of the shim area with a scraper and remove any dirt.
Toggle beam
Socket
Shim
area
Adjustment
cylinders
Cross-beam

SHIMS
Scrape off any dirt from the shims. Check for burrs and remove if necessary.
•Shims 1:2 Ratio to the Jaw Setting.
There are three sizes of shims •19mm •11.5mm •7mm
Always fit thick shims first then the thinner ones.

Ensure that all of the shims locate onto the jaw stock location key and they are
all sat level.
Jawstock Key Location

HYDRAULIC ADJUSTMENT PACK
Slowly pull back lever 1 to let the jaw stock back. Pump the lever so the
double acting cylinders pull the beam back tight onto the shims.
Hydraulic Oil Filler

Pump Lever & Dipstick
Hydraulic
Pump
Adjustment Valve
for Shimming Hydraulic Cylinder
DRAWBACK ROD ASSEMBLEY
Lightly grease the threads and tighten the spring up to 205mm(8 inch)
Ensure the cut out on the draw back guard is fitted the correct way round
205mm(8 inch) Spring Compression

LOCKING WEDGES
Tighten both locking wedges as tight as possible and tighten up the locking
nuts. As soon as the machine starts crushing tighten the wedges up some
more.
Adjusting rod Wedge
Locking nut
Adjusting nuts

TOGGLE BEAM LOCKING SYSTEM
When the wedge is pulled tight it pushes down onto the toggle beam which
holds it in place.
‘L’ bracket
Wedge
Toggle beam

TOGGLE BEAM KEY
The purpose of the toggle beam key is to keep the toggle beam centralised
within the cross beam.
Toggle plate seat

Toggle beam
Toggle beam
Cross beam
key

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

(Tip to Root)
GENERAL MAINTENANCE

MANUAL CLUTCH
High temperature grease
Grease Nipples 1 Shot

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

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

to measure the engagement force
when adjusting the clutch

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

All Greasing and Adjustment Instructions on Plate

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

GREASING POINTS L/H SIDE
Two Shots A Week (EP2)
Magnet
Product conveyor
tail drum
Dirt Con Head Drum

GREASING POINTS L/H SIDE
Remote grease nipples for Grease pipes

the product conveyor head
drum

GREASING POINTS R/H SIDE
Dirt conveyor tail drum
Magnet Product conveyor tail drum

JAW GREASING POINTS
Grease Nipples (72 Grams(2.5 ounces) per week of E.P 2)

MAGNET MAINTENANCE
The magnet belt is designed to run with the belt sagging. Over tensioning the
belt will enable steel to puncture through it causing rips and the belt to fail.
The belt tracking / tensioning is done on adjusters on the L/H drum
Pushing the R/H side of the drum out will move the belt over to the left.
Belt sag on the
Adjuster x 2 underside

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

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

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

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

FEEDER MAINTENANCE
EP220 Gear Oil, 200 hour oil change

Check the oil level every week
3.5 litres 0.9 USG capacity (approx) each
side
Filler Plug
Oil Level
Sight Glass
Side Case
Drain Plug

FEEDER MAINTENANCE
Check bolts regularly to ensure nothing is loose
Cracked paint often indicates something is moving
If any bottom cover bolts come loose re-fit them using stud lock
Unit Housing and Feeder Bottom cover

Motor Retaining Bolts bolts (18 off)

FEEDER MAINTENANCE
The feeder is made from hardox so there are no liner plates fitted.
the grizzly section can be hard faced to prolong life or compensate for wear.

SWING JAW BOLTS
Access to tighten the four swing jaw bolts is achieved by removing the guard
complete with the rubber skirt.
Retaining bolts
Guard

FIXED JAW BOLTS
Lifting lug
Dirt chute Retaining bolts
The fixed jaw bolts can be

tightened using a tube on the end
of the spanner in between the main
frame and dirt chute.
Alternatively the dirt chute can be

un-bolted, lifted up and off the
retaining pins and lowered into the
feed boot of the product conveyor.
Retaining pin

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

JAW LOCATION
Main Frame Clearance
May Burr Over

Nut
Washer
Jaw Wedge
Fiber Washer
Washer
Jaw
Jaw Bolt
JAW REMOVAL
Turn or change the jaws when the ribs of the jaw first become flat.
Continued use will pocket the jaws causing packing and excessive power draw.
Wearing too much off the fixed jaw allows the material to wear away the jaw
support teeth causing them to fail.
Wearing too much off the jaw may cause it to crack.
The fixed jaw wears quicker than the swing jaw.
4 Jaw Support teeth

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

Wedges
Side Clearance Upper

Cheek Plates
Fixed Jaw Lower

Cheek Plates

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

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

CHEEK PLATE REMOVAL
Try to time the cheek plate changes to fit in with the jaw change as the jaws
needs to be taken out for the cheek plate removal.
Weld a suitable lifting lug to the cheek plate and take the weight. Remove the
retaining bolts and lift out the cheek plate.
Ensure the mainframe is clean before bolting on the new cheek plate.
The lower cheek plates will wear two to three times quicker than the uppers.
Chamfer the lower cheek plate with the gas if it is proud of the upper cheek
plate.
Ensure the cheek plates are replaced before they wear through to the mainframe.
Countersunk
bolt

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

SWING JAW
The swing jaw removal / turning is the same process as the fixed jaw.
The jaw guard is a replaceable wear part to protect the Swing jaw.
The jaw guard is replaced in the same manor as the cheek plates by welding a
lifting lug to it and taking the weight before the bolts are removed.
Jaw Guard
retaining
bolts x 3
Jaw Guard
Swing Jaw

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

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

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

(Tip to Root)
TOGGLE PLATE REMOVAL
Remove all of the shims and let the jaw stock back.
Remove the drawback rod assembly.
Wrap a sling around the middle two spokes of the toggle plate and take the
weight. Push the jaw stock forward with the detachable cylinder from the
hydraulic pack until the toggle plate drops out of its seat. Lower the plate onto
the belt and drag it up the belt until it can be lifted off.
The new toggle plate is fitted in reverse order.
To the hydraulic
pack

TOGGLE PLATE REMOVAL
The toggle plate can be removed by lifting it out from the top.
Remove the cover off the crusher, remove the shims and let the jaw stock
back.
Remove the two ‘L’ brackets from the mainframe.
Take the weight of the toggle plate through the centre two spokes.
Wrap a chain around the drawback rod and pull the jaw stock forward
with a chain block until the toggle plate drops out of its seat. Remove
the toggle plate and re-fit the new one in reverse order.
‘L’ brackets

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

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

FLYWHEEL ALIGNMENT
Place a wooden block or stone in the jaw to prevent it from turning.
Re-fit the end cap but don’t tighten up the retaining bolts. Ensure the dowel
hole in the shaft lines up with the dowel in the end cap.
Turn the flywheel around until the arrows line up and remove the end cap.

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

TIGHTENING SEQUENCE
Tighten the ringfedder in sequence up to 195 N.m. It will be necessary to
tighten around the the clamp several times before it is clamped correctly
Failure to tighten sufficiently will result in the flywheel slipping unnecessarily.
7 1
6 2
5 3
4 4
Dowel hole 195 N.m
3 5 Ring fedder
2 6
1 7
12mm allen
keys 7 8 Brass bush
6 1
5 2
4 3

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

FLYWHEEL ALIGNMENT
The same alignment procedure applies for the non drive side flywheel.
As this flywheel is slightly smaller and doesn’t carry as much inertia so it

doesn’t always spin when the drive side does.

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

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

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

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

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

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

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

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

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

CRUSHER DRIVE BELT ADJUSTMENT
Slacken off the the 4 retaining bolts on the guard underneath the hydraulic
adjustment pack.

CRUSHER BELT ADJUSTMENT
Loosen the four retaining bolts on each corner of the engine
Engine retaining bolts

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

SPB Belt section
Basically tension the belts so that when one belt is pressed with your finger it
deflects 10mm(3/8”).
There are 9 grooves cut into the flywheel but the first groove is not used with
the HFO clutch.
Belt deflection

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

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

HYDRAULIC PUMP BELTS
Check the belt tension weekly and adjust as necessary.
The belt deflection should be kept to approximately 5mm (1/4”)at all times.
Always look down the belts and square up the pump. The back-nuts enable
you to push the rear end for alignment.
Adjusting Bolts Drive Belts Pump Locking Bolts Back nuts

(4 off)

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

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

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

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

Air Blast Cooler

BASIC HYDRAULIC
SYSTEM

HYDRAULIC PUMP TANK SIDE
Two identical pumps are mounted either side of the engine, belt driven from
the engine crankshaft
This pump supplies oil to the two bank valve
The oil is drawn through a suction filter into the pump, through an inline
pressure filter and into the two bank valve
Drive belts
To the 2
bank valve
Pump
Suction
Pressure
Filter

TWO BANK VALVE
The two bank valve is mounted in the engine compartment to the rear of the
pump
The end section is the feed and return to the valve.
The 1st splice goes to the tracks
The 2nd splice goes to the product conveyor + magnet. If a hydraulically
operated clutch is fitted, it tee’s in on the feed line for the conveyor
H.F.O Clutch
Restrictor
valve
Feed
Product
conveyor
Return
L/H Track
Load
Sensing Line
TRACK DRIVE
Three pipes run into the track drive motor
Case drain Feed and return pipes

TRACK DRIVE
The feed comes in to the cross line check valve block and automatically
releases the brake.
The two track motors tee the case drains together before going to tank.
The purpose of the cross line check valve is to prevent the machine from
running away on a steep slope or if a pipe bursts.
Track feeds Track Motor Brake Release Motor Case Drain
Cross line
check
valve
block

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

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

MAGNET MOTOR
The magnet is driven from the return oil from the product conveyor.
The oil passes through a pressure compensated valve to bleed off the required
amount of oil to set the correct belt speed for the application.
If the magnet needs to stopped, do it on the speed control because if it is

stopped by removing the snap connectors a partial dead head will occur
raising the hydraulic pressure causing the product conveyor to stop under
load.
Snap
Speed
connector
control
HYDRAULIC PUMP CRUSHER SIDE
The pump nearest the crusher supplies oil to the 4 or 5 bank valve at the rear
of the machine.

FIVE BANK VALVE
If the machine has a hydraulic folding hopper a 5 bank valve is fitted.
If the machine has a fixed hopper a 4 bank valve is fitted.
Splice 1 goes to the tracks Splice 4 goes to the dirt conveyor fold
Splice 2 goes to the feeder Splice 5 goes to the folding hopper sides
Splice 3 goes to the dirt conveyor
Tank
2
1 3 4 5
Feed
In

R/H TRACK DRIVE

FEEDER MOTOR
The one way valve is fitted in the feeder line to protect the feeder motor.
The one way valve prevents any oil from back pressuring up the return line
when the feeder is stopped.
The feeder will work the same regardless of which direction the motor is
turning but it should be turning clockwise as you look at it. The reason for this
is so the gears pick up the oil and carry it through the middle where they
contact.
One way valve Feed Feeder motor Return
DOR

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

DIRT CONVEYOR CHECK VALVE
Both cylinders are piped up through a check valve to hold the conveyor up
without it creeping back down.
Retract the cylinders

(dirt conveyor up) To the bank valve
To the Bank
2 Valve
1
3
Extend the cylinders
(dirt conveyor down)

DIRT CONVEYOR FOLDING CYLINDERS
The pipe work from the check valve tee’s off to both the cylinders
Dirt conveyor up
Dirt conveyor down

FOLDING HOPPER CYLINDERS
The hopper cylinders have the check

valve built in with the solid steel pipe
work. The check valve prevents the
hopper from falling.
Hopper down
Hopper up

HYDRAULIC SYSTEM

HYDRAULIC PUMP
The hydraulic pump only only delivers oil flow on demand, unlike fixed gear
pumps. The standby pressure is set at 30 bar(435psi) and the pump will
deliver a small amount of oil to maintain that pressure. When a function is
operated, the pump detects a pressure drop on the 30 bar(435psi) and the
swash plate is moved to pump more oil. This happens in a split second. The
system always maintains 30 bar(435psi) more in the pressure line than the
load sensing line.
Case Drain
Load Sensing
Line
Standby
Pump Relief Valve
Pressure Relief
(300 bar)
(30 Bar)
(4350)
(435psi)

HYDRAULIC PUMP
When all functions are switched off the pump will de-swash and return to a
low flow maintaining the 30 bar (435psi)stand by pressure.
The pump has its own relief valve set at 300 bar(4350psi). If the pressure
exceeds 300 bar(4350psi), the pump will de-swash, drop to a low flow but
maintain 300 bar(4350psi).
Case Drain
Load Sensing
Line
Standby Pump Relief Valve

Pressure Relief (300 bar)
(30 Bar)
(4350psi)
(435psi)
SECTION VEIW - 57 CC/REV. FULL STROKE
Servo Piston Rotating Kit

Swash plate
Tapered
Tapered Roller
Roller Bearing
Bearing
Shaft Seal
Valve Plate
Bias Piston
Piston
SWASH PLATE OPERATION
Servo Piston Swash plate
• Two piston design.
• Bias piston uses system pressure

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

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

LOAD SENSING CIRCUIT
Engine running. No function selected.
M Port blocked.
0 bar.
CONTROL
Bank valve
VALVE
X PORT
B Port
30 bar(354psi).
BIAS
Remote Port
Stroked to
give 2cc / rev Bleed Orifice (LB
Control)Plug (LS Control)
.
M4 Port
L1,L2 Ports S port

Gain Orifice (Optional)
Engine running. Product conveyor selected.
M 55 litres min @ 50 bar (13.2 US gal min @ 725psi)

50 bar (725psi).
CONTROL
Bank valve
VALVE
X PORT
B Port
80 bar (1160psi).
BIAS
Remote Port
Stroked to
give 31 / rev Bleed Orifice (LB
.
M4 Port
L1,L2 Ports S port

Engine running. Tracks selected.
M 65 litres min @ 180 bar(17 US gal @ 2610psi)

180 bar(2610 psi).
CONTROL
Bank valve
VALVE
X PORT
B Port
210 bar(3045psi).
BIAS
Remote Port
Stroked to give
36cc / rev Bleed Orifice (LB
M4 Port
L1,L2 Ports S port

Engine running. Tracks selected + stalled
M LS WITH LOAD
3 litres minAT
@PC SETPOINT
300 bar(0.8 US gal @ 3915psi)
270 bar(3915psi)
CONTROL
Bank valve
VALVE
X PORT
B Port
300 bar(4350psi). BIAS
Stroked to give
2cc / rev Bleed Orifice (LB
. Control)Plug (LS Control)
M4 Port
L1,L2 Ports S port

Ga in Orifice (Optional)

TWO BANK VALVE
The two bank valve has a main relief valve set at 360 bar(5220psi). This is a
last line relief to protect the pump should the pump relief not respond quick
enough. The product conveyor relief is set at 180 bar(2610psi)
The hydraulic pressure in the system can be taken from a test point on the
bank valve. On the 5/7 bank valve when there are two circuits are working at
once, the pressure gauge will only read the highest of the two, not the
combination of the two.
Product
conveyor relief
(180 bar)
(2610 psi)
System Test
Main Point
pressure
relief
( 360 bar) Load sensing
(5220 psi) Line
H.F.O CLUTCH CIRCUIT
The hydraulic operated clutch needs to maintain 33 bar(479psi) operating
pressure, but not exceed it. This is achieved by passing oil through a relief
valve set at 33 bar(479psi). A pressure switch is fitted in the circuit to stop the
feeder if the pressure drops below 23 bar(333psi).
Pressure Switch
(23 Bar)
(333psi) Test Point
Divertor
Valve
A Relief Valve
Feed from C (33 Bar)
B
restrictor valve (479psi)
Tank line Clutch Feed

Tank line

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

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

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

5 BANK VALVE RELIEFS
The premier trak can be fitted with a 4 or 5 bank valve.
As with the two bank valve the track splice doesn’t have a relief valve built
into it. The pump will de-swash or it will relieve through the main bank valve
if the pressure gets too high.
The feeder and dirt conveyor circuits are set at 180 bar (2610psi)on the relief
valves.
All folding circuits are set at 100 bar (1450psi)on the relief valves.
Relief Valves Hopper

(180 Bar) Track Dirt con fold
Feeder Dirt con
fold
2610psi
DC
Main Bank
Relief Valves
Valve Relief
(100 Bar)
(360 Bar)
1450psi
5220psi

APPROXIMATE BANK VALVE VOLTAGES
Tracks Feeder Conveyors + Folding Cylinders
Reverse Low Speed 16v 16-20v 24v

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

fold fold

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

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

SPOOL TRAVEL
Lever travels down to

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

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

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

Spool Direction
•In the event of a feeder speed control switch failure, a link wire between
the supply voltage and the variable voltage on the hersman plug will give
full speed.
ACTUATOR IDENTIFICATION
Three types of actuator are fitted to the bank valves. The track and feeder
actuator look the same but are different. The feeder actuator is more sensitive
and can move the spool more gradually for a wider range of oil flows. The
feeder actuator can also be identified by an LED. The track and feeder work
on a variable voltage where as the others are either on or off.
LED Feeder
Track Dirt con Dirt con Hopper
fold fold
pvem pveh
Track Number
Conveyors Or Hydraulic Cylinders Feeder Number 157B4128
157B4088
157B4228
PVEM/PVEH/PVES
+8
+6
+4
+2
0
20% 4% 0,2%
-2
P tank: 8 bar
-4 U DC : 24 V
Freq: 0,02 Hz
-6
-8

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

unit
ACTUATOR OPERATION
O rings Locator pin

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

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

SPOOL SIZES (Litres Per Minute)
The oil flow through each splice depends on the size of the spool fitted.
The spools should move smoothly in the body.
The spool can be removed by unscrewing the four allen bolts from the
aluminium cover and removing. The spool can then be pulled out. Oil loss can
be reduced by blanking off the feed and return pipes to the bank valve.
•Product Folding Circuits

Conveyor 25
100 6.6 USG
26.3 USG
Tracks Feeder
100 65
26.3 US 17.1 USG
Dirt Conveyor
•Spool 25
Removal 6.6 USG
SPOOL SIZES
The size of the oil groove in the spool determines the oil flow.
The bigger the groove the greater the flow.
The spool size can be identified by the Danfoss number etched into the end of
it.

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

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

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

METROTRAK HYDRAULIC CIRCUIT
Hopper fold
R/H
65
65

CROSS LINE CHECK VALVE
65
SPEEDS + PRESSURES
Euro/Metrotrack Plant Test Sheet
Item Measured Position Reading Tolerance Limits Actual
/Time Required Upper Lower Reading
Stand by Pressure - Bar Front 29 30 28
Rear 29 30 28
Pump Stall Pressure – Bar Front 300 310 290
Rear 300 310 290
Right Hand Track Fast Running Bar Start N/A N/A N/A
Running < 150 150 N/A
Left Hand Track Fast Running - Bar Start N/A N/A N/A
Running < 150 150 N/A
Product Conveyor Pressure – Bar Start < 180 180 60
Running <110 110 N/A
Product Conveyor Belt Speed – metres/min 120 125 115
Dirt Conveyor Pressure – Bar Start < 100 100 40
Running < 60 60 N/A
Dirt Conveyor Belt Speed – metres/min 77 80 75
Feeder Pressures – Bar Start < 180 180 N/A
Running < 80 80 N/A
Feeder Speed Without Dirt Conveyor – rpm > 900 930 900
Feeder Speed With Dirt Conveyor – rpm < 900 910 890
Feeder Throw 10 11 9.5
Clutch Control Bar 30.5 30 31
Feeder Speed Minimum – rpm < 550 550 N/A

HYDRAULIC TROUBLE SHOOTING
FEEDER SLOW
CHECK HYDRAULIC PUMP BELTS
IS THE FEEDER SLOW WITHOUT THE DIRT CONVEYOR RUNNING
YES.THE FEEDER IS STILL SLOW THE FEEDER IS NOW AT CORRECT

SPEED
CHECK AND RECORD THERES NO PROBLEM WITH THE FEEDER

THE FEEDER SPEED CIRCUIT.THE DIRT CONVEYOR MUST BE
RUNNING TOO FAST.SET THE DIRT CONVEYOR
BELT SPEED TO 77 METRES /MINUTE
CHECK AND RECORD STANDBY

PRESSURE. SHOULD BE 30 BAR. CHECK AND RECORD FEEDER
SPEED.SHOULD BE 900 RPM WITH
DIRT CONVEYOR, 930 RPM
WITHOUT

STANDBY PRESSURE OK STANDBY PRESSURE LOW
OPERATE THE FEEDER SET THE STANDBY PRESSURE TO 30 BAR

MANUALLY.
IS THE FEEDER SPEED OK NOW?
FEEDER STILL SLOW FEEDER SPEED NOW OK.
YES. CHECK VOLTAGE GOING

INTO ACTUATOR.SHOULD BE
75% OF SUPPLY VOLTAGE.IF NOT
PROBLEM IS ELECTRICAL. FEEDER STILL SLOW
IF VOLTAGE IS CORRECT. CHECK SPOOL LIMIT SCREWS.ANYTHING LESS

THAN 13mm WILL RESTRICT OIL FLOW
ACTUATOR FAULTY
LIMIT SCREWS RESET LIMIT SCREWS.
CORRECT.FEEDER STIL SLOW FEEDER OK
SPOOL STICKING.REMOVE AND
INSPECT.

DEAD HEAD FEEDER CIRUIT AND CHECK RELIEF VALVE IS AT 180 BAR.
PRESSURE OK PRESSURE LOW.ADJUST TO 180

BAR.(1 TURN =100 BAR APPROX)
FIT FLOW METER IN FEEDER CIRCIUT AND CHECK FEEDER SPEED OK

THE FLOW.
FLOW MEASURING LESS THAN 45

LITRES /MIN.
FLOW MEASURING APPROX 55
LITRES /MIN.FEEDER MOTOR AT
FAULT
CHECK THE FLOW INTO THE
BANK VALVE
LESS THAN 45 LITRES/MIN. PUMP 55 LITRES/MIN. BANK VALVE AT

AT FAULT. FAULT.

HYDRAULIC TROUBLE SHOOTING
PRODUCT CONVEYOR RUNNING SLOW.
CHECK AND RECORD THE BELT SPEED
CHECK HYDRAULIC PUMP BELTS. TIGHTEN IF NECESSARY
THE BELT IS STILL SLOW. SCREW IN THE NEEDLE VALVE ON THE BELT IS NOW RUNNING AT
THE HFO AND BACK IT OFF 1/4 OF A TURN THE CORRECT SPEED
THE BELT IS STILL SLOW. CHECK THE STANDBY THE BELT IS NOW RUNNING AT
PRESSURE. ADJUST IF IT IS BELOW 30 BAR THE CORRECT SPEED
THE BELT IS STILL SLOW. CHECK THE RUNNING PRESSURE THE BELT IS NOW RUNNING AT
OF THE BELT. IT SHOULD BE APPROX 65 BAR THE CORRECT SPEED

THE RUNNING PRESSURE IS HIGH
SLACKEN OFF THE BELT SO THE HEAD DRUM CAN TURN WITHOUT THE
BELT
IF THE PRESSURE HAS DROPPED RIGHT DOWN THE IF THE PRESSURE IS STILL HIGH THERE IS A
IS A PROBLEM WITH THE BELT. IE. A TRAPPED PROBLEM WITH THE MOTOR OR THERE IS A
STONE, BELT TOO TIGHT OR THE SKIRT RUBBERS RESTRICTION IN THE HYDRAULIC LINE
TOO TIGHT
THE RUNNING PRESSURE IS

OK
CHECK THE SPOOL LIMIT SCREW. IT SHOULD NOT BE

LESS THAN 13MM. ADJUST IT BACK OUT IF IT IS
THE LIMIT SCREW IS CORRECT. THE BELT IS STILL THE BELT IS NOW RUNNING AT
SLOW THE CORRECT SPEED

DEAD HEAD THE CONVEYOR CIRCUIT.YOU SHOULD REGISTER 208 BAR
FROM THE TEST POINT. BACK OFF THE RELIEF AND RESET IF IT IS LOW
THE BELT IS NOW RUNNING AT

THE CORRECT SPEED
OPERATE THE BELT MANUALLY.
NO CHANGE IN THE BELT SPEED. FIT A IF THE BELT IS NOW RUNNING AT THE
FLOW METER IN THE PRODUCT CORRECT SPEED EITHER THE
CONVEYOR LINE. YOU SHOULD ACTUATOR IS AT FAULT OR THE
REGISTER APPROX 55 LITRES / MIN SPOOL IS STICKING.
LESS THAN 45 LITRES. FIT THE FLOW 55 LITRES. THE PRODUCT CONVEYOR
METER AFTER THE PUMP MOTOR IS AT FAULT

LESS THAN 45 LITRES MIN 55 LITRES A MINUTE
TRACK THE MACHINE. IF THERE IS 65 THRERE IS AN INTERNAL LEAK WITHIN

LITRES MIN THERE IS A FAULT WITHIN THE BANK VALVE
THE LOAD SENSING.
IF THERE IS LESS THAN 45 LITRES THE

PUMP IS AT FAULT


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Metrotrak 18 4 05

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METROTRAK

Advanced Crushing Technology

Advanced Crushing Technology

Advanced Crushing Technology

Advanced Crushing Technology

Temp Oil pressure

The over-ride switch bypasses the oil

Advanced Crushing Technology

Advanced Crushing Technology

Advanced Crushing Technology

Advanced Crushing Technology

Advanced Crushing Technology

The new type chargers are 12 / 24 volts.

Advanced Crushing Technology

• Green indicates batteries are good

• Red indicates batteries are going flat and

• The siren will sound when the LED turns red

• 12 hours run down time from fully charged

• Charge time approx 1.5 hour from flat

Advanced Crushing Technology

Advanced Crushing Technology

Advanced Crushing Technology

Advanced Crushing Technology

Advanced Crushing Technology

Switch positions for operating frequency’s-

Advanced Crushing Technology

Advanced Crushing Technology

Advanced Crushing Technology

CHANNEL NUMBER FREQUENCY MHz

Advanced Crushing Technology

No. of transmitters programmed Reset button Power supply

Advanced Crushing Technology

Advanced Crushing Technology

1. Turn the function selector switch 2 to the ON position.

Advanced Crushing Technology

1. Switch on the transmitter by pressing buttons 9 + 0 for at least 1 second.

Advanced Crushing Technology

Advanced Crushing Technology

CHANNEL NUMBER FREQUENCY MHz

Advanced Crushing Technology

Advanced Crushing Technology

Advanced Crushing Technology

The cable to the control box is long

The pressure fault light indicates

The hopper sides are hydraulically folded up from

Advanced Crushing Technology

Advanced Crushing Technology

Advanced Crushing Technology

Advanced Crushing Technology

Advanced Crushing Technology

Advanced Crushing Technology

Failure to do this will result in material building up on the rollers and

Advanced Crushing Technology

Blanking mat Screen mesh

Advanced Crushing Technology

Advanced Crushing Technology

Tension bar Adjusters Retaining bolt

Advanced Crushing Technology