HQR1112 Manual 13012017

STRIKER HQR1112
Unlimited Solutions
for Limited Resources
TRACKED IMPACTOR MANUAL

HQR1112
SECTION : Contents
ISSUE: 01/2017
1. General Information
2. Safety
3. Plant Identification
4. Transport
5. Set Up
6. Operating Instructions
7. Shut Off Crusher
8. Maintenance
9. Trouble Shooting
10. Risk Assessments
11. Parts List
12. Recommended Spare Part
13. Hydraulic Schematics
14. Electrical Schematics
15. Impactor Crusher
16. Engine
17. Tracks
18. Clutch
19. Magnet
20. Remote
21. Warranty
Unlimited Solutions For Limited Resources

HQR1112
SECTION : General Information
ISSUE: 01/2017
Table of Contents

1.1.1 Introduction A-2
1.2.1 General information A-2
1.3.1 Designated Use A-2
1.4.1 Copyright A-2

A-1
HQR1112
SECTION : General Information
ISSUE: 01/2017
1.1.1 Introduction 1.3.1 Designated Use

This manual contains important information The machine is defined as a self‐contained
on how to operate the machine safely, mobile unit for crushing materials. It is for
properly and efficiently. Please observe use in a wide range of quarry, demolition
these instructions to avoid danger, reduce and recycling applications. The operator
repair costs and downtime and increase the firstly deposits material into the feeder
reliability and life of the machine. hopper where it is fed over a section of
grizzly bars into impactor crusher.
These instructions must always be available
wherever the machine may be in use. Using the machine for uses not specified in
this manual may result in a loss of warranty
Make sure these instructions are read and and the manufacturer/supplier cannot be
applied by any persons responsible for held liable for any damages. The risk of such
operating this machine. misuse lies entirely with the user.

This manual is NOT intended to be assemble 1.4.1 Copyright
/ disassemble instructions, though
sometimes helpful in the process of The copyright of this manual is reserved by
assembly/disassembly. Striker Australia Pty Ltd.

1.2.1 General Information It contains regulations and technical
drawings. Copies and reproductions may not
This machine has been manufactured, be made from any information contained
assembled and tested with the upmost care. within it. This manual, complete or in part
It was built with first class materials and may not be loaned to a third party.
close attention has been paid to all details in
every aspect of design, manufacture and Due to ongoing changes and revisions by our
testing. many suppliers it is often impossible to show
all variations of any given assembly.
The machine is designed to be safe, reliable Therefore the right is reserved to alter any
and efficient when used and maintained in details contained in this manual without
accordance with the manual. notice Copyright 2017.

Please read the following paragraphs and
give the required effort and time to
maintenance, cleaning and inspection. This
will assure faultless operation of this
machinery.

This machine is easy to operate, adjustments
are easily made and expert assistance is
rarely required, if of course the correct
procedures as stated in this manual are
carried out.

Misuse of this machine may constitute a risk
to life or cause damage to the machine.


A-2
HQR1112
SECTION : Safety
ISSUE: 01/2017
Table of Contents

2.1.1 Warnings and Symbols B-2
2.2.1 Safety Notice B-3
2.3.1 Organisational Measures B-4
2.4.1 Basic personnel responsibilities B-4
2.5.1 Standard Operation B-5
2.6.1 Special work B-5
2.7.1 Hazardous/Flammable Materials B-6
2.8.1 Special dangers warning B-7
2.9.1 Hydraulic equipment B-8
2.10.1 Transport recommissioning B-8
2.11.1 Location of emergency stops B-9

B-1
HQR1112
SECTION : Safety
ISSUE: 01/2017
2.1.1 Warnings and Symbols

The following signs and designations are
used in the manual to designate instructions
of particular importance:

This is the safety alert symbol. When it is
shown on the machine or in the manual, be
alert to the potential for personal injury.

DANGER
This symbol indicates an imminently
hazardous situation which, if not avoided,
will result in death or serious injury.

CAUTION
This symbol indicates a potentially
hazardous situation which, if not avoided,
could result in death or serious injury.

WARNING
This symbol indicates a potentially
hazardous situation which, if not avoided
may result in minor or moderate injury. It
may also be used to alert against unsafe
practices. This statement indicates company
policy as the message relates directly or
indirectly to the safety of personnel and
protection of property.

The following stickers are an example of the
many warnings that are placed around the
machine to notify the operator of potential
hazard.


B-2
HQR1112
SECTION : Safety
ISSUE: 01/2017
2.2.1 Safety Notice

Before operating the plant ensure you have
read this manual carefully and understand
the equipment and the process.

The manual has guidance for safety
regulations but please ensure that you are
aware of all local laws and safety regulations
that may cover the use of your equipment.

We emphasize the importance of complying
with instructions supplied, particularly
aspects concerned with safety.

For further information and advice –
contact:

a. Your local Striker dealer
b. Striker Australia Pty Ltd
9 Egmont Road
Henderson WA 6166
AUSTRALIA

P.O. Box 1214
Fremantle WA 6959
Phone: +61 (0) 8 9437 3533
Fax: +61 (0) 8 9437 3544


B-3
HQR1112
SECTION : Safety
ISSUE: 01/2017
2.3.1 Organisational Measures 2.4.1 Basic Personnel Responsibilities

Loose or baggy clothing may get caught in Trained or authorised personnel ONLY must
running machinery. Always wear correct execute any work on and/or with plant.
PPE. Please observe statutory minimum age
requirements.
Where possible when working close to
engines or machinery, only do so when they Skilled electricians or instructed persons
are switched off. Remember to keep tools, under the supervision of a skilled electrician
test equipment and all parts of your body ONLY must carry out work on electrical
well away from the machinery. systems and equipment, in accordance with
the electrical engineering rules and
If the warning stickers and safety regulations.
instructions are not obeyed, the person/s
involved may result injury or death. Observe Only personnel with specific knowledge and
all safety instructions and warnings attached experience in fluid control and hydraulic
to the machines. components and equipment must carry out
work on the hydraulic systems on the plant.
Make sure all safety instructions and System leaks should always be checked in
warnings attached to the machine are the correct manner. A piece of cardboard is
complete and perfectly legible. Keep acceptable and under NO CIRCUMSTANCE is
warning and instruction labels clean. any part of the body to be used. Hazardous
Understand service procedure before doing material should be handled with care and
work. Keep area clean and dry. procedures should be in place to do so.
Hazardous materials should have correct
When maintenance is taking place on the identification, clearly labelled and stored in
plant, the machine must be secured from assigned areas. Procedures for use and
accidental starting. By switching off the disposal should also be in place. All
engine and removing the ignition key and procedures and instructions must adhere to
attaching the appropriate safety signs and the manufacturers standards and that all
lock out plant to reduce the chance of your relevant regulations and conditions are
machine starting inadvertently. If any observed at all times.
material blockage, any malfunction or
operational difficulty, stop the plant
immediately. Correct any defects
immediately.

Keep all machine parts in good condition,
ensuring they are properly installed.

Ensure that all maintenance work is carried
out as detailed. Short cuts may make the job
easier but inherently more dangerous.


B-4
HQR1112
SECTION : Safety
ISSUE: 01/2017
2.5.1 Standard Operation 2.6.1 Special Work

Take precautions to ensure that the machine Make yourself aware of the maintenance,
is used only when in a safe and reliable adjusting and designated times set in this
state. manual.

Before carrying out any maintenance on the Exceptions:
plant, ensure that all units are shut down  Immediate action is called upon
and stationary. when the warning lights/horn/gauge
indicates a problem.
NEVER make adjustments while the machine Where the weather conditions may require
is operating. more frequent servicing.

Never run machines above their Replacement of parts and equipment must
recommended maximum speeds. This is in ONLY be executed by skilled and trained
the interests of safety and efficient personnel.
operation.
The machine must be secured against
Do not climb on the machine whilst in starting when it is shut down for
operation. Never use machine parts as a maintenance. Be sure to:
climbing aid as it can cause injury or even  Switch off the engine and remove
death. All platforms on the plant are for the ignition key.
maintenance access only.  Implement the lockout procedure.
 Attach a warning sign to the
When maintenance is taking place on the machine.
plant, the machine must be secured from
accidental starting. By switching off the Once the plant is positioned on stable and
engine and removing the ignition key and level ground, carry out maintenance and
attaching the appropriate safety lock out via repair work.
battery or engine isolation switch to reduce
the chance of your plants inadvertently Trained, reliable and authorised personnel
starting. If any material blockage, any ONLY must execute any work on and/or with
malfunction or operational difficulty, stop plant.
the plant immediately. Correct any defects
immediately. To avoid the risk of accidents, individual
parts and large assemblies being moved for
Do not reach into an unguarded machine. replacement purposes should be carefully
Your limb could be pulled in and amputated. attached to rated lift equipment and
secured.
Switch off and isolate plant before removing
any guarding and safety devices if Never stand or work under suspended loads.
maintenance must take place.
To avoid risk of injury or death, keep away
All guards should be checked for from the feeder and discharge conveyors
wear/damage during routine maintenance. when loading or removing materials.

Specially designed or otherwise safety
orientated ladders and working platforms
must be used when carrying out overhead
assembly.

B-5
HQR1112
SECTION : Safety
ISSUE: 01/2017
Always use provided safety and secure 2.7.1 Hazardous/Flammable Materials

platforms approved by the regional safety
enforcing authorities. Please dispose of potentially harmful waste
items properly. The improper disposal of
Keep all handrails, platforms, steps, handles, waste may result in the threatening of the
landings and ladders free from debris. ecology and environment. Such items
include oil, coolant, filters and batteries. Use
Without adequate rated lift equipment, approved containers when draining fluids.
never allow unqualified or untrained Do not pour waste onto the ground or into a
personnel to lift and remove heavy or large water source drain and make sure that
components of the plant. Never stand or replaced parts are disposed of correctly
work under suspended loads. incurring minimal impact on the
environment.
Keep away from the main movement areas
of the plant. These include the feed hopper DIESEL FUEL IS HIGHLY FLAMMABLE
and the conveyor discharge areas. There is
great risk of serious injury or death from Never remove the filler cap or add fuel with
dropping of material. the engine running. Never add petrol or any
other fuels mixed to diesel because this adds
After cleaning, you must examine fuel, an increased risk of explosion.
lubricant and hydraulic fuel lines for leaks,
loose connections, chafe marks and damage. Do not smoke cigarettes or carry out
Any defects found must be rectified without maintenance such as welding or other
delay. sources of sparks near or on the fuel system.

When removing any safety devices for set‐
up, maintenance or repair, they must be re‐
fitted and checked upon completion of
maintenance or repair work.


B-6
HQR1112
SECTION : Safety
ISSUE: 01/2017
2.8.1 Special Danger Warnings Before carrying out any welding always

disconnect the remote control aerial and
Switch off the plant immediately if trouble receiver card multi cable as well as the
occurs in the electrical system. Only original battery leads and cables to the electrical
fuses with accordance to the specified system. The battery contains sulphuric acid,
current rating should be used. Prior to an electrolyte which can cause serious burns
activating the main isolator switch, be sure and produce severe explosive gases. You
the plant is suitably earth bonded by a must avoid contact to the skin, clothing and
qualified electrician. eyes.

Be well aware of any overhead electric lines Always operate internal combustion engines
that run when working on the plant. and operated heating systems in a well
ventilated area.
If work is required to take place near electric
lines, the equipment used should be kept Make sure that there is sufficient ventilation
well away from them. Check the prescribed before starting the machine in enclosed
safety distances. premises.

In areas of +85 db always ensure the Dust found on the machine or dust produced
operators of the equipment are provided during working should be removed by
with safety ear protection and be sure they extraction and not by blowing.
are worn at all times when the plant is
operating. Ensure operators are supplied Welding, flame‐cutting and grinding work
with suitable safety face protection where should only be carried out on the machine if
they may be exposed to possible harmful authorised as there may be risk of fire or
effects from pollution. explosion.

Work carried out on equipment should only Clean the machine and its surroundings
be carried out by a skilled electrician or by before carrying out welding, flame‐cutting
specially instructed personnel under the and grinding operations.
control and supervision of such an
electrician and in accordance with applicable Make sure the premises are also adequately
electrical engineering rules. ventilated as there may be a risk of
explosion.
The risk of fire and explosion must be
examined before carrying out welding, flame Exercise caution when screening or
cutting and grinding work. Before conveying flammable or hazardous materials
commencing such activities, clean the plant such as coal. The material itself or any dust
from dust and other inflammable may cause a fire or explosion.
substances. Another important factor is
proper ventilation.

Regular intervals are required to occur for
inspection on the electrical system. Worn,
loose, scorched or otherwise damaged
cables must be replaced immediately.


B-7
HQR1112
SECTION : Safety
ISSUE: 01/2017
2.9.1 Hydraulic Equipment 2.10.1 Transport Recommissioning

Only people with special knowledge of Transporting, manoeuvring and
hydraulic systems should carry out work on re‐commissioning:
the hydraulic equipment. Maintenance
should not be conducted while the machine The plant must be loaded and transported in
is running. accordance with the operating instructions‐
Reference section: Plant tracking procedure.
Extreme cleanliness should be practised
when servicing hydraulic components. Please observe the transport position,
admissible speed and itinerary when
Oil may cause injury or fire so be sure to transport the machine.
check all lines, hoses and screwed
connections for leaks and damage. Repair Use only appropriate means of transport
damage immediately. and lifting gear of adequate capacity.

Depressurise all system sections and The braking, signalling and lighting systems
pressure pipes, to be removed in accordance must be checked to ensure they are fully
with the specific instructions for the unit functional before moving the machine.
concerned before carrying out any repair
work. The machine must be checked to ensure all
accessories are stowed away before setting
Hydraulic lines must be fitted and laid the machine in motion.
properly. Ensure that no connections are
interchanged. The fittings, lengths and When travelling on public roads always
quality of the hoses must comply with the observe the valid traffic regulations and
technical requirements. ensure that the machine is in a condition
compatible with these regulations.
Equipment which is raised hydraulically must
be supported with safety supports and Ensure the lighting system is operating
lowered prior to performing maintenance or correctly and turned on when travelling at
repairs on the hydraulic system. night or in conditions of poor visibility.

Before caring out any maintenance or Be aware of the clearance allowances when
adjustments, always relieve pressure for the crossing underpasses, bridges and tunnels or
hydraulic system. If the system is left under when passing under overhead lines.
pressure during the maintenance serious
injury may occur if the hydraulic fluid Always keep the working equipment close to
penetrates the skin. the ground when travelling downhill. Always
adapt your travelling speeds to the ground
conditions.


B-8
HQR1112
SECTION : Safety
ISSUE: 01/2017
2.11.1 Location Of Emergency Stops The manual has guidance for safety

regulations but please ensure that you are
There are 5 E‐stops on this machine and one aware of all local laws and safety regulations
immediate stop on the remote control. that may cover your equipment.

One located on the control panel. For further information and advice – contact

Your nearest dealer
Or
Striker Australia Pty Ltd
9 Egmont Rd
Henderson WA 6166
AUSTRALIA

P.O. Box 1214
Fremantle WA 6959
Two on each side of the machine. Phone: +61 (0) 8 9437 3533
One towards the front and one towards the Fax: +61 (0) 8 9437 3544
back.

Remote control.

Before operating the plant ensure you have
read this manual carefully and understand
the equipment and the process.


B-9
HQR1112
SECTION : Plant Identification
ISSUE: 01/2017
Table of Contents

3.1.1 Serial Number Plate C-2
3.2.1 Identification and Control Location C-2
3.3.1 Other Functions C-2
3.4.1 Remote Control Unit C-3

C-1
HQR1112
ISSUE: 01/2017
3.1.1 Serial Number Plate The remote control is located in a carry case

and is located with the machine accessories.
This aids identification of plant for customer
and manufacturer.

3.3.1 Other Functions

3.2.1 Identification and Control Set Up
Locations
There are to valve banks at the rear of the
There are two main isolators on the machine under the feeder, the one on the
HQR1112. Both isolators have to be right operates the wings and the one on the
switched on and are located in the battery left operates the wing locks.
box.

1. One isolates all plant electrics.
2. Second isolates engine starter motor
only. (This is to aid electronic diagnostics
whilst isolating the engine against
accidently starting).

R/Hand side (Wing controls)

The main control panel which is located on
the left hand side of the machine. All
functions are laid out in the operator section
of this manual.
L/Hand side (wing locks)


C-2
HQR1112
ISSUE: 01/2017
Water Pump

The water pump control is mounted on the
front right hand side of the plant and is
factory preset.

3.4.1 Remote Control Unit

The remote control has two functions:
 to track the machine
 to start/stop the feeder

Magnet There are several controls on the remote
unit, which are all labelled.
On the engine/hydraulic tank platform there
is another flow control, this is for the 1. Off/Emergency Stop
magnet belt speed. 2. Frequency (Setup Only)
3. Micro/Reset (Setup)
4. Tramming Forward / Reverse/Steer
Right / Forward / Reverse
5. Tramming / Steer
6. Feeder On/ Feeder Off
7. Feeder Speed
8. Steer Left / Forward / Reverse
9. Button Not Applicable
10. On switch 5
7
6
Recycler

The recycler as two valves for setup. One
located at on the return conveyor support
and the other on the front LH support leg.

8 4

9
10 1 2 3
A joystick for each track. (LH/RH) – used to
drive the tracks either forward or back.

The lower diagram opposite shows the
direction of forward travel. The track
joysticks control the track speed
proportionally.


C-3
HQR1112
ISSUE: 01/2017
An on/off toggle switch for the feeder is also
install in this remote and is for operator
convenience.

The Off/E‐stop button when in track mode if
pressed will shut off the engine, in feeder
mode it will only stop the feeder and located
above the E‐Stop is the feeder speed
control.

A start switch is used to turn the remote unit
on.

The micro frequency increase and decrease
buttons are for set up only and should be
only used by experienced persons.

C-4
HQR1112
SECTION : Transport
ISSUE: 01/2017
Table of contents

4.1.1 Safety Information D-2
4.2.1 Loading of Machine D-2
4.3.1 Plant Loading / Off Loading D-2
4.4.1 HQR1112 Operation D-3
4.5.1 HQR1112 Transport D-4

D-1
HQR1112
SECTION : Transport
ISSUE: 01/2017
4.1.1 Safety Information 4.3.1 Plant Loading/ Off Loading

Load/unload the machine on reasonable
level ground.

Load/unload the machine on long and
shallow ramps. This will reduce the amount
of shock loading the track will have on the
truck trailer and also allow loading to be an
easy process.

4.2.1 Loading of machine

CAUTION:

Before transporting HQR1112, the machine
needs to have been put in the transport
position correctly as shown in the set up
section.

Procedure: Load/unload the track machine is possible
1. Make sure all safety warnings are when the engine is at low speed using both
observed. of the tracks to manoeuvre forward or
2. Remove all loose materials such as backward.
rocks etc. from the machine
3. Put the machine in the transport
position (see “set up” section).
4. Make sure the machine is securely
fastened to the low loading trailer
(this is normally done by the truck
driver).


D-2
HQR1112
OPERATION ELEVATION VIEW
HQR1112 - 1
D-3
HQR1112
TRANSPORT ELEVATION VIEW
HQR1112 - 1
D-4
HQR1112
SECTION : Set Up
ISSUE: 01/2017
Table of Contents

5.1.1 Safety Information E-2
5.2.1 General Information E-2
5.3.1 Measures before set up E-2
5.4.1 General set up E-2
5.5.1 Daily Check Procedure E-3
5.6.1 Start Engine Procedure E-4
5.7.1 Plant Set up Procedure E-4
5.8.1 Machine set up E-5
5.9.1 Instruction Folding Hopper Wings E-6
5.10.1 Side Conveyor E-7

E-1
HQR1112
SECTION : Set Up
ISSUE: 01/2017
5.1.1 Safety Information 1. The HQR1112 must be placed on solid

ground capable of carrying the machines
weight.
2. Before positioning the HQR1112, it is
important that the chosen site is level.
The machine should be level to within 2
degrees from left to right.
3. Access from both sides.

5.4.1 General Set Up

This section and all the preceding sections of
this manual must be read, understood and
observed before set up of the HQR1112.

To enable easy set up, repair work and
maintenance, allow enough space around
the HQR1112 when setting up.

Machines arranged before and after the
5.2.1 General Information HQR1112 will have to be placed accordingly.

It is recommended that the Only personnel with experience and
assembly/installation work of the HQR1112 specialised knowledge of maintenance and
be carried out by the SCS customer service operation may carry out any work on and
department, your SCS dealer or by trained around the machine.
personnel.
Statutory minimum age limits must be
`The manufacture/supplier will not be liable observed.
for damage caused by improper
assembly/installation.

5.3.1 Measures Before Set Up

1. Ensure all guards are fully secured in
correct/closed position.
2. Remove all loose items from the belt
and feeder areas.

When setting up the HQR1112 pay particular
attention to the following information.


E-2
HQR1112
SECTION : Set Up
ISSUE: 01/2017
5.5.1 Daily Check Procedures Remote Control

 Keep spare battery charged
Engine
 Water In Addition to the above checklist
 Oil  Check engine service records are up
 Air Cleaner & Pre‐Cleaner to date
 Fan and Water Pump Belts  Check KPTO service records are up
 Fuel Level to date.
 Check fire extinguisher service
KPTO records are up to date
 Check oil level  Check service records (ensure all
servicing is up to date)
Hydraulics
Check oil level Note:
For additional daily, weekly and monthly
Drive belts checks see the maintenance section.
 Check belt condition and belts are
tensioned to specification.

Crusher
 Check blow bars for damage and
wear.
 Check impact plates for damage and
wear.
 Check all liner plates for damage and
wear.
 Check top middle and bottom
impact arms for correct gap. (Adjust
if required)

Note:
All the damage and warn components
must be replacement for the crusher is
used

Conveyors
 Check all rollers visually
 Check all skirt rubbers visually
 Check all bearing and tail drums are
clear of material builds‐up

Feeder Gear Box
 Check oil level

Greasing
 Ensure plant is greased according to
schedule.


E-3
HQR1112
SECTION : Set Up
ISSUE: 01/2017
5.6.1 Start Engine Procedure 5.7.1 Plant Set up Procedure

1. Before starting the engine or any Note:
part of the plant ensure the daily
check procedures have been carried Points 1 – 7 only apply if recycler option is
out. fitted to machine.
2. Ensure all emergency stops are
released. 1. Lower front stabilizing legs. Ensure they
3. Turn battery isolator switch to the touch ground firmly and secure with
ON position. pins.
4. Turn the engine ignition to the ON
position. Siren will sound. Allow a
short period of time for the display
to power up. (Display information
appears and oil cooler fans running)

2. Remove all transport (stated on
previous page).

3. Raise returns conveyor to correct
working height and secure with pin.

5. To start the engine, turn the ignition
to the crank position. Crank engine
until started and release.
6. Set engine to desired R.P.M.
(Dependent upon the function
required.).

IMPORTANT NOTE

All transport brackets should remove prior
to set‐up and operations. All transport
brackets are clearly paint yellow and
shown on this page.

E-4
HQR11112
SECTIO
ON : Set Up
ISSUE: 01/2017
0
4. Exteend the reeturns convveyor to itts 13. The togggle on the crusher fee
ed chute
worrking position n and securee with pin. can noww lock the wiings at the frront.
5. Low
wer oversize conveyor to o its working
position.
6. Connnect hydrau ulic hoses frrom oversize
convveyor to retu urns conveyo or.
7. Fold
d out hopperr recycle exttension chute
on sside wing.
8. Ensuure the front toggle boltts are pushed
backk and sit behind
b the crusher feed
chutte. 14. Return to the main
n screen by pressing
9. The plant hopp per can now
w be erected d, F1 ESC.
the hopper wing controls are
a under the
feedder on the R//Hand side. 5.8.1
5 Macchine set up
Re‐position
R lower laddeer section to
o access
engine/hydr
e aulic platform.

10. Both ow be raised
h side winggs should no
follo
owed by the rear wing.
11. All wings
w should be lockedd together by
b
exteending the rear
r wing lo
ock cylinderss,
the controls aree under the ffeeder on the Notice:
N
L/Haand side.
Before
B attemmpting to sset up the machine
ensure
e that the operato
or has read and
a fully
understands
u s this secttion and all the
preceding se
p ections in thee manual.

12. Thee side wingss supports have an overr
ntre lock that must locked into
cen o
possition via weedge supplied d.
Unlimitted Solutio
ons For Limited Res
sources
E-5
HQR1112
SECTION : Set Up
ISSUE: 01/2017
5.9.1 Instruction Folding Hopper Wings 1. The complete wing can be raised so

the weight is taken and the
This instruction refers to HQR1112 units connection brace removed.
fitted with extended hopper wings. 2. Lift wing to 30o angle and attach
support legs.
General Note: 3. The complete wing can now be
raised into the operating position
When using the control valve with and support legs pined in position.
extended wings a smooth and gentle 4. The side wings supports have an
movement of the valves is required. The over centre lock that must locked
bottom side of the support leg is painted into position via wedge supplied.
black. Legs are stamped 1 – 4 as well as the 5. Repeat steps 3 to 11 on the other
lugs that they connect to. side wing.
6. Raise rear wing to full extension.
Folding Out Procedure 7. All wings should be locked together
by extending the rear wing lock
1. Follow engine start procedure. cylinders, the controls are under the
2. Press F4 to enter set up mode and feeder on the L/Hand side.
set RPM to 1200. 8. The front toggle bolts should also be
3. Ensure the front toggle bolts are positioned and fastened into
pushed back and sit behind the position.
crusher feed chute.

4. The weight can be taken via the
cylinders and the travel braces on 9. The front hopper cross brace, chain
one side removed. and ratchet should now be fitted
5. The wing should be lifted half way and secured.
and the longer brace fitted.
6. The wings can be lowered until the 10. Return to the main screen by
standard wing and extension pressing F1 ESC.
become level and lock out.
7. The extension wing can now be NOTE:
bolted to the standard wings. To dismantle the hopper follows the
reverse of the above procedure.


E-6
HQR1112
SECTION : Set Up
ISSUE: 01/2017
5.10.1 Side Conveyor

Note:

If the side conveyor option is fitted whether
it is to be used or not it must be lower
before operating the plant. This is to ensure
no parts are compromised due to vibration
from the feeder or chassis.

Folding Out Procedure:
1. Follow engine start procedure.
2. The side conveyor cylinder controls
are mounted towards the rear of the
machine under the feeder.
3. The side conveyor even if not
required for operation it should now
be folded into its lowered position.
4. Release the securing bolt for
travelling.
5. Lower conveyor into operating
position.
6. Once lowered it should be secured
and all guards should be fitted.
7. Following set up; press F1 ESC to go
back to the main screen.

E-7
HQR 1112R TRACK IMPACT CRUSHER ISSUE:
SETUP PROCEDURE 02/01022016
UNLOAD THE MACHINE WITH IT'S PARTS OFF THE

A TRUCK.THE PARTS ARE GENERALLY STORED IN A BOX
UPON TRANSPORT.
Item
Part No Description Qty
No
1 0002-1127 LOCK WEDGE 2
2 0260-0214 GRIP CLIP 2
3 0012-1078 SKIRT COVER 2
4 0012-1085 SKIRT COVER - RH 1
5 0012-1086 SKIRT COVER - LH 1
8 0007-2492 STEP LADDER EXTENSION 1
E-8
BEFORE ATTEMPTING TO SETUP THE MACHINE ENSURE

B THAT THE OPERATOR HAS READ AND FULLY
UNDERSTAND THIS AND ALL THE PRECEDING SECTIONS
IN THE MANUAL AND USE EWP WHERE REQUIRED
C FOLLOW THE ENGINE START PROCEDURE.
D PRESS F4 TO ENTER SET UP MODE AND SET THE RPM TO 1200.
REMOVE LOCKING PIN FOR THE JACK LEGS. LOWER

DOWN JACK LEGS TO STABILIZE THE MACHINE. ENSURE
E THEY TOUCHING GROUND FIRMLY AND SECURE WITH
PINS. THE CONTROL FOR THE JACK LEGS CAN BE FOUND
AT THE RECYCLE SUPPORT ON THE RIGHT SIDE OF
MACHINE. ENSURE THE LOCK PINS ARE SECURE.
STEP E STEP E
E-9
REMOVE THE LOCKING PIN FOR THE RETURN CONVEYOR SLIDE

F RAIL SUPPORT.
RAISE THE RETURN CONVEYOR TO THE OPERATING HEIGHT

G AND SECURE WITH PIN. THE CONTROLS FOR THE CONVEYOR
CAN BE FOUND AT THE SUPPORT FRAME.
STEP F STEP G
E-10
MOVE THE OVERSIZE CONVEYOR INTO OPERATING POSITION.

H THE CONTROLS FOR THE CONVEYOR CAN BE FOUND AT THE
RECYCLE SUPPORT ON THE RIGHT SIDE OF MACHINE.
STEP H
E-11
RAISE SIDE WING INTO OPERATING POSITION. THE CONTROLS

I ARE UNDER THE FEEDER ON THE RIGHT HAND SIDE.
STEP I
E-12
J RAISE THE REAR WING TO FULL EXTENSION.
ALL WINGS SHOULD BE LOCKED TOGETHER BY

EXTENDING THE REAR WING LOCK CYLINDER, THE
K CONTROLS ARE UNDER THE FEEDER ON THE LEFT
SIDE OF THE MACHINE.
THE SIDE WING SUPPORTS HAVE AN OVER CENTER LOCK THAT

L MUST BE LOCKED INTO POSITION VIA WEDGE SUPPLIED.
M SECURE THE WING LOCK WEDGE INTO POSITION.
STEP L
Item
No
4 0002-1127 LOCK WEDGE 2
STEP K 5 0260-0214 GRIP CLIP 2
E-13
REMOVE BOLT & LOWER THE SIDE CONVEYOR INTO

N OPERATING POSITION.
O FIT ALL SKIRT INTO SIDE CONVEYOR
STEP N
ItemNo Part No Description Qty

4 0012-1085 SKIRT COVER - RH 1
5 0012-1086 SKIRT COVER - LH 1
BF3 0312-0030 BOLT 18
W9 0312-0006 FLAT WASHER 18
STEP O W10 0312-0012 SPRING WASHER 18
E-14
ENSURE THAT THE MACHINE IS ISOLATED AND ANY SITE

P REQUIREMENTS FOR ISOLATION ARE FOLLOWED
BEFORE CLIMBING ONTO THE MACHINE.
Q PULL THE ADJUSTMENT ARM TO UNLOCK IT.
PULL THE LADDER INTO WORKING POSITION & ANGLE.

R ENSURE ALL THE SAFETY PIN ARE SECURELY LOCK.
STEP Q STEP R
E-15
REMOVE THE SAFETY CHAIN ON THE LADDER. UNFOLD

S THE LADDER AND ENSURE IT IS LOCK WITH THE LOCK
PLATE.
STEP S
E-16
REMOVE THE SAFETY CHAIN ON THE LADDER. UNFOLD

T THE LADDER AND ENSURE IT IS LOCK WITH THE LOCK
PLATE.
INSTALL LADDER EXTENSION TO THE HYDRAULIC TANK

U PLATFORM LADDER ONLY.
STEP T
STEP T
Item
No
STEP U
8 0007-2492 STEP LADDER EXTENSION 1
BE4 0310-0030 BOLT 4
N7 0310-0001 NYLOCK NUT 4
10
E-17
REMOVE THE LOCKING PLATES AT THE SCREEN BOX AND

V FEEDER.
W FOLD UP THE BEACON INTO OPERATION POSITION.
STEP W
STEP V
11
E-18
X REMOVE THE LIFTING BRACKETS & STRESS BARS.
12
E-19
BEFORE ATTEMPTING TO DO MAINTENANCE ON THE SCREEN

ENSURE THAT THE OPERATOR HAS READ AND FULLY
Y UNDERSTAND THIS AND ALL THE PRECEDING SECTIONS IN THE
MANUAL AND USE EWP WHERE REQUIRED.
REMOVE THE LOCKING PIN FOR THE SCREEN SUPPORTS ON

BOTH SIDE OF THE SCREEN.
FOLD DOWN JACK LEGS AT FRONT THEN LOWER DOWN THE
Z SCREEN UNTIL TO FULL EXTEND. THE CONTROL FOR THE
SCREEN SUPPORT CAN BE FOUND AT THE JACK LEG SUPPORT
ON THE RIGHT HAND SIDE.
A1 ENSURE THE LOCKING PINS ARE SECURE IN POSIRION.
B1 UN TIGHTEN THE SCREEN MESH CLAMP BOLTS AND STEP Z

REMOVE THE CLAMP FROM THE SCREEN.
C1 REPLACE THE SCREEN MESH.
INSTALL THE SCREEN MESH CLAMPS

D1 AND ENSURE THE BOLTS ARE TIGHTEN.
RAISE THE SCREEN TO IS OPERATION POSITION .
E1 ENSURE THE PINS ARE SECURE BACK IN ITS
POSITION.
STEP Z
13
E-20
HQR1112
SECTION : Operating Instructions
ISSUE: 01/2017
Table of contents

6.1.1 Safety Information F-2
6.2.1 General Information F-2
6.3.1 Start sequence for running the engine F-2
6.4.1 Emergency Stop Operation F-3
6.5.1 Restart after emergency stop devices F-3
6.6.1 Plant tracking procedure – Remote control use F-3
6.6.2 Plant Tracking Procedure – Umbilical Use F-4

6.7.1 Plant Operation Procedure F-5
6.7.2 Start Procedure for the Feeder F-5
6.8.1 Important Notes: General F-13

6.9.1 Engine Pre‐Start‐Up Inspection and Operating Requirement F-14


F-1
HQR1112
ISSUE: 01/2017
6.1.1 Safety Information The feeder area and conveyor belts are

hazardous, possibly causing serious injury or
death due to rejected material from
machinery or danger from other machinery
in the area. Only fully trained operators
should be in this area.

Ensure that stockpiles are removed regularly
by trained operatives in order to ensure no
damage is caused to the conveyors.

6.3.1 Start Sequence For Running The
Engine

Procedure:
1. Before starting the engine or any
part of the plant ensure the daily
check procedures have been carried
out & observe all safety warnings.
2. Ensure all emergency stops are
6.2.1 General Information released.
3. Turn bothisolators switches to the
The HQR1112 may only be operated if all ON position.
previous safety instructions provided have
been observed and followed.

The machine may only be operated if the
protective and safety devices are in place,
fully functional and properly maintained.
This includes equipment such as removable
safety devices, emergency shut off
equipment and exhausts. 4. Ensure plant electrical consul is ON.
5. Turn on ignition. After a short period
During operation, all doors should be closed the display will power up and the
i.e engine, control panel. cooler fans will run.
6. To start the engine, turn the ignition
Malfunctions must be handled in the to the crank position. Crank engine
appropriate manner. Immediately stop and until started and release.
lock out the machine and report to the 7. Set engine to desired R.P.M.
competent authority. Operation should not (Dependent upon the function
resume until the malfunction has been required.)
rectified.

Always wear PPE safety clothing and glasses
when working in the vicinity of the machine.


F-2
HQR1112
ISSUE: 01/2017
6.4.1 Emergency Stop Operation

Notice:

In case of an incident or trouble or the
need to shut down the machine in an
emergency, the following procedure must
be followed:

1. Engage the nearest emergency stop, 5. To turn on the remote ensure the E‐Stop
the location of which can be found is release and pull down the start switch
in the safety section. and release. The LED (Green) will now
2. Switch off the ignition. flash indicating the unit is switched ON.
3. Implement the lockout procedure. 6. In track mode press F2 to activate
remote.
When the machine is fully switched off and
isolated, an attempt can be made to solve
the problem
6.5.1 Restart After Emergency Stop
Devices

1. Ensure the machine is ready to be
put back into service.
2. Make sure all personnel are away
from the machine. MODE ‐ Use the selector switches for
3. Ensure that all safety devices are tramming or steer mode (on remote).
correctly fitted and fully functional. A) TRAMMING ‐ Right hand joystick only.
4. Release all emergency stops. B) STEER – both joysticks.
5. Start the engine again following the
correct procedure. 1. Smooth operation of tracks is effective
and will assist in correct operation of the
6.6.1 Plant Tracking Procedure – system.
Remote Control Use 2. Upon completion of tracking the
machine, press F2 to disable track mode
1. Start engine. (See “Start engine then press ESC to main menu.
procedure) 3. The remote can be turned OFF.
2. Set R.P.M. to a minimum of 1500 4. Depressing the remote “stop” button on
R.P.M. the remote will turn it off.
3. Press F3 for track mode.
4. Turn on the remote control (For full The options are now:
instruction see proprietary STOP THE PLANT
information booklet. Datek remote  To stop the engine, turn the ignition
control unit). key to the off position.

F-3
HQR1112
ISSUE: 01/2017

Notice

When using the umbilical lead, great care
should be taken by the operator to ensure
the lead does not become snagged or
trapped around the operator’s person.

TO OPERATE THE PLANT
 Follow prompts on main page to MODE ‐ Use the selector switches for
enter plant mode. tramming or steer mode (on remote).

6.6.2 Plant Tracking Procedure – A) TRAMMING ‐ Right hand joystick
Umbilical Use only.
B) STEER – both joysticks.
Should the remote control unit have a
battery failure or an aerial receiver problem 7. Smooth operation of tracks is effective
it is possible to use a wire connection to and will assist in correct operation of the
move the plant. system.
8. Upon completion of tracking the
1. Plug in the umbilical as shown machine, press F2 to disable track mode
2. Set R.P.M. to a minimum of 1500 R.P.M. then press ESC to main menu.
3. Press F3 for track mode. 9. The remote can be turned OFF.
4. Turn on the remote control (For full 10. Depressing the remote “stop” button on
instruction see proprietary information the remote will turn it off.
booklet. Datek remote control unit).
The options are now:

STOP THE PLANT
 To stop the engine, turn the ignition
key to the off position..

Notice:

5. To turn on the remote ensure the E‐Stop When using the umbilical lead, great care
is release and pull down the start switch should be taken by the operator to ensure
and release. The LED (Green) will now the lead does not become snagged or
flash indicating the unit is switched ON. trapped around the operator’s person.
6. In track mode press F2 to activate
remote.


F-4
HQR1112
ISSUE: 01/2017
6.7.1 Plant Operation Procedure 6.7.2 Start Procedure for The Feeder

1. Before operating the plant ensure The feeder can be operated in two formats‐
plant is on firm and level ground. Local or Remote.
2. Follow the engine start procedure.
3. From main page press F2 for PLANT 1. Feeder Local Operation
mode.
4. Set engine RPM to 1200 RPM. The feeder can be turned on by depressing
F2:
a. The feeder speed can now be set on
the display, F5 or F6.
b. The speed of the feeder should be
set in conjunction with the crusher
output and settings required.

IF IN DOUBT CONSULT STRIKER DEALER FOR
5. Only fitted options will be displayed. CONFIRMATION!
6. The control panel has a logical
system that must be followed.
7. The flashing button indicates which
functions can be engaged.
8. Press OK to start the stacker. (If
option fitted)
9. Press F3 to start product conveyor.
10. Press F4 to start crusher.
11. Press F5 to start the side conveyor.
(If option fitted)
12. Once crusher is running and 2. Feeder Remote Operation:
stabilised raise the engine RPM a. From feeder page press F3.
between 1800 to 2000. b. The remote control should now be
13. Feeder may now be started as turned on.
desired. Press F6, this page will give c. Press and release the start button.
several options. (Consult Datek manual for further
information).
d. To turn the feeder on use the toggle
switch on the remote and set the
speed as desired on the control pot.

IMPORTANT NOTICE:

When using the remote ensure the battery is
well charged for operation. Should low
battery be on the remote, the low battery
indicator on the remote will illuminate. The
feeder will stop upon complete discharge of
battery.


F-5
HQR1112
ISSUE: 01/2017

Feeder
Use F4 & F5 to adjust
speed
feeder speeds in local
controlled
by remote
control

Local Remote

F-6
HQR1112
ISSUE: 01/2017

Siren will sound indicating the machine
is ready to/or about to move


F-7
HQR1112
ISSUE: 01/2017
Option

Show what options are fitted

Delay timers
Prestart = time delay between pressing
function and function starting
Running = time between function
starting and ability to start next function

Use F4 & F5 to
scroll to option
required and press
F6 to Enter

Feeder settings
Factory set

There are levels of password on the striker plant:

a) Operator level ‐ these allow operator to set plant to
optimum running condition. Operator code is 1234.
b) Factory setting – these can only be changed on connection
with factory technician.

Note:

If a Striker setting need to be changed the key code display on the
screen will need to be given to the Striker technician.
Note:

All option screens entered use F4 & F5 to scroll to next specific
option and press F6 to enter. Again f4 & F5 are used to change
the perimeter and F6 to Enter/ESC
NOTE, USE THE ESC KEY TO GO BACK TO THE PREVIOUS SCREEN

F-8
HQR1112
ISSUE: 01/2017
Feeder settings
Factory set

Language
Factory set

There are levels of password on the striker plant:
c) Operator level ‐ these allow operator to set plant to
Time and Date
Able to be adjust for different time zones by the operator
d) optimum running condition. Operator code is 1234.
Factory setting – these can only be changed on connection
with factory technician.

Note:

If a Striker setting need to be changed the key code display on the
screen will need to be given to the Striker technician.

Note:

All option screens entered use F4 & F5 to scroll to next specific
option and press F6 to enter. Again f4 & F5 are used to change
the perimeter and F6 to Enter/ESC
NOTE, USE THE ESC KEY TO GO BACK TO THE PREVIOUS SCREEN

F-9
HQR1112
ISSUE: 01/2017
OPTIONS: 8. Low Pressure Time, This is the

1. Water pump, If FITTED isdisplayed impactor hydraulic presser, if the
the water pump will start with the presser drops and is not re‐charged
main conveyor or if NOT FITTED is with in this time the LOW
displayed it will not operate No pass HYDRAULIC PRESSER fault is
code is required to change this displayed and the feeder will stop.
setting. The timer is factory set.
2. Stacker, If FITTED is displayed, 9. Product conveyor sensor, If FITTED
stacker will have to be started in the is displayed a conveyor belt under
plant screen, If NOT FITTED is speed is being used and the feeder
displayed the stacker cannot be will stop if the product conveyor
started; No Pass Code is required to becomes jammed, If NOT FITTED is
this setting. displayed the function is disabled;
3. Re‐Cycle Conveyor, if fitted is Striker Pass Code is required to
displayed, Re‐Cycler will have to be change this setting.
started in the plant screen, If NOT 10. Machine Type, If FITTED is displayed
FITTED is displayed the Re‐cycler the auto zero function will be
cannot be started, Factor set. available from the plant screen, if
4. Side Conveyor, If FITTED is NOT FITTED is displayed the function
displayed, stacker will have to be will not be available. (Striker Pass
started in the plant screen, If NOT Code protected)
FITTED is displayed the stacker
cannot be started; No Pass Code is 11. Radio Type, This is Factory set to
required to this setting. suite the type of remote control
5. Link Options, Only used when used. (Striker Pass Code protected)
interlocking machines together, If
STOP FEEDER is displayed the feeder Delay Timers
will stop and restart in conjunction These are is Factory set, (Striker Pass Code
with the machine is connected to, If protected)
OFF is displayed there will be no
interlocks between the machines, The PRE‐START is the time between the
Operator pass Code is required to button being pressed to start the function
change the setting (1234). and the function starting.
6. Feeder Restart Time, Only applies
when the LINK OPTION is being The RUNNING is a timer that starts after a
used, and is the time between the function has been started and must time out
downstream machines feeder before the next function can be started.
starting and this feeder starting,
Operator pass Code is required to
change the timer (1234).
7. Allow Feed Delay Time, Only applies
when the LINK OPTION is being
used, and starts counting down after
this feeder has started and has to
time out before the machine that
feeds this machine can start its
feeder, Operator pass Code is
required to change the timer (1234).


F-10
HQR1112
ISSUE: 01/2017
Feeder settings
1. Feeder Cut out SP, when the % off
engine load reaches the set point
the feeder will cut out, No Pass Code
is required to change this setting.

2. Feeder Cut Out Time, The % of
engine load has to be over the set
point for this time before the feeder
will cut out; No Pass Code is
required to change this setting.

3. Feeder Cut in SP, the feeder will re‐
start once the % of engine load has
dropped below this set point, No
Pass Code is required to change this
setting.

4. Feeder Cut in Time, The % of engine
load has to be below the set point
for this time before the feeder will
re‐start; No Pass Code is required to
change this setting.

5. Feeder High Speed Percentage, Sets
the maximum feeder seed, this is
Factory set. (Striker Pass Code
protected)

6. Feeder Low Speed Percentage, Sets
the minimum feeder seed, this is
Factory set. (Striker Pass Code
protected)

Clutch Settings
All these options are Factory set and assist in
gentle starting of the impactor. (Striker Pass
Code protected)

Language
This is Factory set. (Striker Pass Code
protected)

Time and date
This can be set to suite different time zones
No pass code is required to change this
setting.


F-11
HQR1112
ISSUE: 01/2017

Use F4 & F5 to scroll through the faults

Use F5 & F6 to scroll through the faults


F-12
HQR1112
ISSUE: 01/2017
6.8.1 Important Notes: General 12. Ensure that careless use of

mechanical shovels does not
For long and reliable service from Striker damage unit.
Crushing Plant, correct operation and 13. Where hydraulics are installed use
rigorous maintenance is essential. Points of only recommended fluids.
special importance are listed here in 14. Inspect track chains for cracked or
summarised form. We stress that the missing rollers and renew as
operator must familiarise himself with all necessary.
aspects of plant operation described in this 15. Control the throughput so as to keep
manual: all units well fed but not overloaded.
1. Before machine operation, release Beware of 'tramp iron' or other
all devices used to secure plant foreign material in feed.
during transit, fit and secure such 16. Do not over lubricate bearings. Refer
devices before machine travelling is to applicable lubrication chart for
undertaken. lubricant and colour code details.
2. Always replace vee belts in matched
sets. Ensure that vee belts seat Lubrication
correctly in grooves. 17. Use only recommended lubricants or
3. Always maintain correct tension and their strictest equivalents.
alignment of all belts and chain 18. The permissible temperature of
drives. roller bearings on crushers and
4. Keep all belt drives free from oil or breakers is up to 71C Temperatures
grease. Keep clean with water, in excess of 82C indicates some
naphtha or petrol. Do NOT use belt undesirable cause which must be
dressing on vee belts. traced and remedied.
5. Ensure that flywheel keys are
secure. Conveyors
6. Do not run any machine at a speed 19. Check carrying belt alignment and
faster than recommended. tension.
7. Ensure that plant or unit is mounted 20. Tension carrying belt by means of
level on both planes and jacks or adjustable tail shaft bearings. Head
supports are mounted on level shaft bearings are adjustable to
ground ‐ pack with wood where facilitate drive tensioning and belt
required. alignment only.
8. Before shutting down always allow
units to clear of material. This Mobiles
applies particularly to feed hoppers, 21. Check tyre pressures (plate on
when in arctic conditions material chassis), connect and test brakes,
may freeze causing difficulty on and release parking brake(s) before
starting. travelling.
9. Always maintain a bed of material in 22. Ensure that brake and light systems
feeder to cushion the impact of function efficiently before travelling
material when recharging. is undertaken.
10. No attempt must be made to 23. If dust is particularly heavy extend
increase hopper capacity by fitting the engine air intake by a suitable
extension plates. pipe to place outside the dust zone.
11. On feeder hoppers not fitted with a All clutches (including Power take‐
grid, keep feed size within the off) must be engaged with a firm
machines capabilities. and steady movement.

F-13
HQR1112
ISSUE: 01/2017
6.9.1 Engine Pre‐Start‐Up Inspection and Pre‐Start‐Up Inspection:

Operating Requirement  Operator to carry out the engine
pre‐start‐up inspection as
Read the manuals: recommended in the Operation and
 Operator must fully understand the Maintenance manual.
engine Operational and
Maintenance manual. This is the first  Operator to warm up the engine
book that every Operator must read before starting. The engine is fitted
and it is very helpful to every with heater at the engine jacket
Operator. The Operator will find this water (require AC power), heater at
manual break up into a few sections the lube oil pan (require AC power)
(Safety section, Product Information and also heater at the air inlet
section, Operation section, manifold (require DC power). There
Maintenance section, Warranty is a heater’s temperature control
section, Reference Information box fitted to the engine and the
section and Index section). (Please Operator can view the temperature
see literature number: SEBU7772‐ reading for both the jacket water
02). and lube oil from the two digital
meters at the box’s front cover.
 Operator must fully understand the Operator to remove the heaters
Cold Weather Recommendation for (Jacket Water and Oil Pan) from the
All Caterpillar Machines Guide. small generator set when the engine
is ready for startup.
Service/Maintenance Interval:
 Operator must service/maintain the  Operator also to ensure no pre‐
engine according to the Caterpillar loading during engine start. This is
recommended maintenance an important criterion that the
interval. Please refer to the Operator must check prior to
Maintenance section in Operation starting in the cold weather.
and Maintenance manual (Please
see literature number: SEBU7772‐ Operator also requires carrying out the
02). following to ensure the engine will be
working in good condition.
 Operator must use the correct fluids Diesel Fuel:
(such as Lube Oil, Coolant, Diesel  Operator to ensure there is no
Fuel and etc) that recommended by contamination/sediment/jelling/wat
Caterpillar (Please see literature er in the diesel fuel tank and also the
number: SEBU6251‐10 – Caterpillar fuel that going into the engine.
Commercial Diesel Engine Fluids
Recommendations).  Operator must always monitor the
fuel supply into the engine. Drain
 Operator must always use genuine the water/sediment from the
Caterpillar parts that source from collecting bowl at the diesel fuel
the Caterpillar dealer. water separator. Please refer to the
Operation and Maintenance manual.


F-14
HQR1112
ISSUE: 01/2017
Lube Oil:
 Operator to ensure no water / icing
formed in the engine lube oil
system. Any water or icing going
thru the lube oil system will also
cause damage to engine.
 Operator requires checking lube oil

level with the dipstick provided
regularly.
Exhaust System:
 Operator to ensure there is no water
/ icing formed in the exhaust system
(including the exhaust muffler, tail
pipe and etc). Any icing or water into
the exhaust system will eventually
goes into the engine and causes
damage to the engine.

Cooling System:
 Operator to ensure the water in the
radiator is not icing.

Air Inlet System:
/ icing formed in the engine air inlet
system. Any water or icing formed
or go into the air inlet will causes

 Operator also requires checking the
air filter service indicator and
carrying out the servicing whenever
necessary. Please refer to the

Battery:
 Operators to ensure the batteries
are in fully charged condition for
engine starting.

NOTE:

Whenever a question arises regarding the
machine, the Caterpillar guides or the
Operation and Maintenance manual, the
Operator shall consult the Caterpillar
dealer for latest available information.

F-15
HQR1112
SECTION : Shut Down Crusher
ISSUE: 01/2017
Table of Contents

7.1.1 Safety Information G-2
7.2.1 Shut Down G-2

G-1
HQR1112
SECTION : Shut Down Crusher
ISSUE: 01/2017
7.1.1 Safety Information

7.2.1 Shut Down

Procedure:
1. Take note of all safety warnings.
2. Stop the feeder and exit feeder page
by pressing F1 (ESC).
3. Press F4 when the chamber is
completely empty from material,
stop the crusher.
4. Press F3 to the main conveyor.
5. Press F2 to stop stacker (If option
fitting)
6. Reduce the engine RPM to idle for at
least 5 minute
7. Switch off the ignition.
8. Isolate the machine when not in use.

Notice:

Make sure the operator has read and
understood this manual and the preceding
sections before shutting off the machine.

G-2
HQR1112
SECTION : Maintenance
ISSUE:01/2017
Table of Contents

8.1.1 Safety Information H-3
8.2.1 General Information H-3
8.3.1 Tensioning the Main Conveyor Belt H-4

8.3.2 Tracking the Conveyor Belts H-4
8.4.1 Adding Fuel H-7
8.4.2 Emptying the fuel filter water trap H-7

8.4.3 Changing the Fuel Filters H-7

8.4.4 Checking oil levels H-8

8.4.5 Draining engine oil H-8

8.4.6 Changing Oil Filter H-8

8.4.7 Air Cleaner H-8

8.5.1 Electrical Safety Instructions H-9

8.5.2 Check Battery H-9

8.5.3 Battery Removal H-10

8.5.4 Battery Installation H-10

8.6.1 Track Maintenance H-11

8.6.2 Tensioning the tracks H-11

8.6.3 Slacking the tracks H-12

8.7.1 Hydraulic System H-12

8.7.2 Hydraulic oil H-13

8.7.3 Changing hydraulic oil H-14

8.7.4 Changing the return line filter H-14


H-1
HQR1112
ISSUE:01/2017
8.8.1 Feeder Mechanism H-15

8.9.1 Drive Belts H-16

8.10.1 Maintenance schedules H-19

8.11.1 Engine Pre‐Start‐Up Inspection and Operating Requirement H-32


H-2
HQR1112
ISSUE:01/2017
8.1.1 Safety Information Read and understand all service and

operation procedures before performing
maintenance or operating the machine.

WARNING

Make sure all relevant PPE equipment is
8.2.1 General Information used as required by the job conditions. Do
not wear anything loose as this may get
Maintenance should only be carried out caught on moving parts.
after all safety rules throughout the manual
are read and observed. Ensure the work area is free from obstacles.
Keep body parts and loose clothing away
Regular maintenance is imperative as from moving parts and nip points.
breakdown caused by insufficient
maintenance could cause high repair costs. All machinery must be OFF and isolated
before any cleaning, adjusting or such is
The life and reliability of our machinery carried out.
depends on regular and proper
maintenance. Before performing maintenance or repairs
please remember to:
Consult Striker Crushing or your dealer if
your machinery is operated in extreme 1. Turn off all power and control to
climate conditions as maintenance schedules relieve all pressure.
may vary. 2. Stop the engine.
3. Implement lock out procedure.
The machine has been designed to facilitate 4. Allow the machine to cool down
easy routine maintenance. It may be before beginning.
necessary, when conducting maintenance to
remove items such as guard doors which are
all fitted with captive nuts and bolts. Please
ensure these are replaced before the
machine is restarted. DANGER

For maintenance instructions and schedules Never work equipment that isn’t supported
for the Impactor Crusher, Tracks and Engine correctly.
see the supplementary accompanying
manuals.


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Keep all parts in good condition and properly 8.3.1 Tensioning the Main Conveyor

installed. Fix any damage and replace worn Belt
or broken parts immediately.
Procedure:
Warning 1. Take note of all safety warnings.
Disconnect the remote control receiver 2. Start the engine and the conveyor.
cable and antenna PLC cables & lockout 3. Loosen locknut.
machining cable (‐) before making 4. Tighten the belt by adjusting both
adjustments on electrical systems or welding belt adjusters evenly until slippage
on machine. stops.
5. Re‐tighten locknut.
A minimum of 2 people should be present at
all times during maintenance.

8.3.2 Tracking the Conveyor Belts

Procedure:
2. Have the appropriate conveyor
running.
3. Look through the viewing apertures
to observe the belt alignment at the
head and tail drum and observe the
way the belt is running.


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Conveyor Belt Tracking Guidelines Training or Tracking a Conveyor belt

Tracking of a conveyor belt is not an exact Before attempting to track a conveyor it
science. To maintain a well trained conveyor should be pointed out that the Head and Tail
belt the basic principles of alignment should Pulleys should be Square to the frame and
be considered. Start at the basics and work each other. Attempts to track a conveyor
up the adjustments as suggested in this with the Head or Tail pulley can result in
document. Stretching of one edge of the belt. Once an
edge is stretched the belt is in effect longer
Safety on one side than the other side. Tracking will
therefore be very difficult.
The following Procedure can be dangerous if
not carried out in the correct manner. Such Knocking the Idlers
a procedure should only be carried out by
suitably trained personnel. Once you have established the Pulleys are
Appropriate JSA should be completed and square the belt can be trained in a given
lock out procedures should be followed as direction by use of the carry and return
per site Inductions. rollers.
This is called Knocking of the rollers and
The Basics follows the same principle as Handlebars on
a Bicycle. When you hit one side of the idler
1. Check that the Head and Tail Drums frame the belt will be driven in that direction
are set up with their shafts square to that the roller is moved.
the main Conveyor frame. The basic rule is that the belt will steer in the
2. Check that the Head and tail drums direction of the roller it touches first.
are square and parallel to each
other. Note:
3. Check the head and tail drums to
ensure they are free from Dirt build Return idlers are used to train the belt
up. with no load condition. Trough idlers are
4. Check that all Carry roller and return used to train the belt in loaded condition.
roller frames are square to the
frame. The Procedure
5. Check all the carry and return rollers
to ensure they are free from Dirt. 1. Determine where along the length
6. Check to ensure all the rollers are of the conveyor the belt is running
free to rotate. off and if it is the top side or the
7. Check there are no Rocks jammed return side or both.
up in the frame area and hindering 2. To help determine the run off Look
the belt natural travel path. along the conveyor in the direction
8. Check the Head Scraper and the V of travel.
plough return scraper to ensure they 3. Mark the frame with Chalk where
are worn evenly and have good the run off begins. Now check the
contact with the belt. nearest Idler frame to the mark and
9. Check the belt is tensioned correctly. mark it also.
10. Check the alignment of the conveyor MOVING OF THE IDLERS SHOULD BE
frame CARRIED OUT WITH THE PLANT STOPPED
AND LOCKED OUT.

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4. This idler frame should now be Additional Troubleshooting

moved. When moving the idler
frame you should also adjust the If by following the above procedure there is
idler frames at either side of this still difficulty with the tracking of the belt
one. The movements should be in then Additional trouble shooting may be
small increments say 2mm at any required:
one time. The plant can now be 1. The conveyor belt runs to one side for
started. Observe the belt over a the full Length of the conveyor.
number of revolutions to determine  The load is not centrally placed on
if the movement of the rollers is the conveyor.
successful.  The structure is bent or crooked.
 Some idlers are worn out or sticking.
If the conveyor belt is still running our  Some idlers are loose in their frames
repeat steps 2 to 4 again. 2. The Conveyor belt runs true when empty
but deviates when a load is applied.
Please see the diagram below that will  The feed onto the conveyor is not
assist. central to the conveyor.
 The idler heights are different on the
If the idler is as per the diagram please note conveyor causing un equal contact.
the direction of travel of the belt.  The tension of the belt is in
adequate.
By Moving the idler in the direction of A will  The conveyor is not level.
cause the belt to track towards the direction 3. One section of the belt runs to one side
of “a” along the whole length of the conveyor

By Moving the idler in the direction of B will  Belt Splice is not square
cause the belt to track towards the direction
 One section has worn or stretched
of “b”
edge.

 Crooked or bowed belt. If the belt is
Please see the diagram below that will assist.
new this may correct itself. If the

deviation is too great then the belt
If the idler is as per the diagram please note
should be replaced.
the direction of travel of the belt.
4. Belt has erratic action and follows no
By Moving the idler in the direction of A will
certain path whilst attempting to track.
 The belt is too stiff to train
of “a”
 The belt is too thick for the head or

tail drum Wrap. This should be
By Moving the idler in the direction of B will
checked with the belt supplier.
of “b”  The ultimate cure in this case is to fit
training idlers.
5. Belt runs off track only at the head or tail
A a area.
 Check the pulley lagging for wear.
Direction of the  Check the pulleys for material build
Belt up.

 Return rollers out of alignment.

B b  Worn belt scrappers

Idler Frame

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6. Belt runs off but only on certain days.
 Check environmental conditions. It Warning:
may be necessary to fit wind
deflectors on the side of the Diesel fuel is highly flammable.
conveyor.
 Check the material % moisture Never mix other fuels to diesel fuel as this
content. If this varies the Scrapers can cause fire or explosion.
may be in effective on certain days.
Do not carry out maintenance on the fuel
8.4.1 Adding Fuel system around open flames, sources of
sparks such as welding or near anyone
Notice: smoking.

Do not fill the fuel tank to it’s full capacity. 8.4.2 Emptying the fuel filter water trap
Keep an eye on the gauge at the side.
Room for expansion must be allowed. If 1. Take note of all safety warnings.
fuel happens to spill, clean up immediately 2. To allow water to drain, unscrew the
to prevent damage to the machine and water bung at the bottom of the
environment. water trap.
3. When pure diesel starts to drain out,
tighten the drain bung.

8.4.3 Changing the Fuel Filters

Procedure:
2. Fuel filters are to be unscrewed
using a commercial tool and spin off.
Procedure: Make sure all escaping fuel is
1. Take note of all safety warnings. caught.
2. Make sure area surrounding the 3. Clean the seal of the filter carrier, if
filler cap is clean. necessary.
3. Remove the filler cap. 4. Apply a small amount of oil to
4. Fill the tank with diesel up to the top rubber gasket of the new fuel filter
level of the gauge. cartridge.
5. Replace the filler cap. 5. Fuel filter cartridge must be
tightened firmly.
6. Fuel must be re‐primed using the
prime pump on engine.
7. Refer to filter manufacture.

WARNING

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8.4.4 Checking Oil Levels 8.4.6 Changing Oil Filter

Procedure: Procedure:
Notice: 1. Take note of all safety warnings.
2. Oil filters are to be unscrewed using
If the engine is warm, switch the machine a commercial tool and spin off.
off and wait 5 minutes before restarting. Make sure all escaping oil is caught.
3. Clean the seal of the filter carrier, if
1. Take note of all safety warnings. necessary.
2. Make sure the machine is on level 4. Apply a small amount of oil to
ground. rubber gasket of the new oil filter
3. Remove the dipstick. cartridge.
4. Wipe the dipstick with a clean, non‐ 5. Oil filter cartridge must be tightened
fibrous cloth. firmly.
5. Insert the dipstick back in,
completely and pull out again. 8.4.7 Air Cleaner
6. Check the oil level on the dipstick. If
required, top up to the maximum Cleaning the Air Filter Elements: Filter
level. DO NOT OVER FILL. Cartridge

Notice: Notice:
The oil level should never drop below the
“Minimum” mark. Air cleaner restrictions must always be
obeyed.
8.4.5 Draining Engine Oil
Procedure:
Procedure: 1. Take note of all safety warnings.
1. Take note of all safety warnings. 2. Empty Pre Cleaner.
2. Run the engine until warm. 3. Undo the clip fasteners.
3. Make sure the machine is on level 4. Remove the hood.
ground. 5. Remove outer element and inspect,
4. Open the oil drain gate valve. change as required (follow
5. To drain the oil, unscrew the drain manufactory guidelines)
bung on the sump, draining oil into
an appropriate container.
Insert bung and re‐tighten.

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Clean by: Only a skilled electrician or an instructed

1. Wash according to manufacturer’s person under the supervision of a skilled
instructions. electrician may work on the electrical
system or equipment of the machine. All
2. Remove inner element and inspect, electrical work must be carried out in
change as required (follow accordance with electrical engineering rules
manufactory guidelines) and regulations
3. Check seal and sealing surface and
replace if necessary. Battery isolator ON Starter Isolator OFF
4. Install cartridges, replace the hood
and do up the clip fasteners. Allows system to power up but will not allow
the starter to engage allowing for engine
Warning: diagnostics.
Battery isolator ON Starter Isolator ON
Filter cartridge must never be cleaned with Normal operation
hot fluids or petrol.
Battery Isolation OFF Starter isolation OFF
Total machine isolation

WARNING
WARNING

8.5.1 Electrical Safety Instructions
8.5.2 Check Battery
Warning:
Battery leads must be disconnected before
Machine must be switched off immediately any electrical maintenance is carried out.
if malfunction occurs in the electrical
system. Batteries contain sulphuric acid and
electrolytes which can produce explosive

gases or cause burns. Avoid contact with
Check the machine and electrical parts for
eyes, skin or clothing.
the presence of power before any work

begins.

All power supplied to the machine must be
OFF before beginning any work. The battery
or power line must be disconnected or de‐
energised.

Parts to be worked on must be grounded
and live parts insulated to prevent an
Procedure:
electrocution hazard.
Notice:
When working with electricity, all tools must
be insulated. Distilled water should only be used
immediately before starting the engine in
All electrical equipment must be inspected cold weather to avoid freezing
on a regular basis.

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1. Notice must be taken of all safety 8.5.4 Battery Installation

warnings.
2. Electrical connections are required
to be clean and tight. A coating of
petroleum jelly will protect them
from corrosion.
3. Remove the battery filler plugs. The
electrolyte level should be between
6mm and 9mm from the top of cells.
4. Fill up with distilled water if
necessary to manufacture Procedure:
recommendations. 1. Take note of all safety warnings.
2. Switch OFF electrical circuits
8.5.3 Battery Removal 3. Place batteries onto the machine.
4. Fit the batteries retaining frame.
1. Take notice of all safety warnings. 5. Tighten the bolts to the batteries
2. Switch OFF all electrical circuits. retaining frame.
3. Disconnect the ground lead from the 6. Connect the positive lead to battery
battery (‐). one (+).
4. Disconnect the positive lead from 7. Connect link lead between battery
the battery (+). one (‐) and battery two (+).
5. Loosen the bolts from the battery Connect the negative lead from the battery
retaining frame. two (‐).
6. Remove the batteries retaining
frame. Warning:
7. Remove the batteries from the
machine. When installing the battery, the positive
lead (+) must be connected first. The
machine is negative earth. Please observe
correct polarity.

WARNING

WARNING
Warning:

Disconnect the battery leads before carrying
out any electrical work.
Batteries contain sulphuric acid, electrolyte
which can produce explosive gases or cause
severe burns.
Avoid contact with skin, eyes or clothing

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8.6.1 Track Maintenance 8.6.2 Tensioning The Tracks

Checking the track tension The track will require tensioning if the sag is
greater than 15mm.
Every track is fitted with a grease chamber
and grease fitting on the end. Grease is
pumped into or release out the chamber
when tightening or slacking the track.

Procedure:
1. Take notice of all safety warnings.
2. Remove the aperture cover on the
side of the track frame by loosening
Procedure: the two screws.
1. Take notice of all safety warnings. 3. The grease fitting and grease gun
2. The machine is to be driven a adaptor must be clean and free of
minimum of 2 metres in a forward dirt. Connect the grease gun to the
direction. fitting. Add grease until the track
3. Take measurements are of the top tension reaches between 5mm –
part of the track, on the longest part 15mm.
of unsupported track. 4. Replace the aperture cover.
5. Drive the machine forward 50
This sag, on the track must be between 5mm metres and backwards and repeat
and 15mm. the above procedure if the track
slackens.

WARNING
Warning:

Take care when loosening the grease fitting
as the track tensioner is pressurised. Refer to
Strickland Manual Supplementary Section
17. Note:

For further information refers to the
Strickland Manual.


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8.6.3 Slacking The Tracks
Warning:
If the sag is less than 5mm the track will
need to be slackened. If the track fails to slacken after the grease
fitting has been loosened, do not attempt to
remove the tracks or disassemble the track
tensioner. The grease may be expelled if the
grease fitting is loosened and the tracks are
run a short distance in both directions.

Qualified fitters are to carry out the above
procedures only, involving grease contained
at high pressures.
Procedure:
1. Take notice of all safety warnings. 8.7.1 Hydraulic System
2. Remove the aperture cover on the
side of the track frame by loosening Notice:
the two screws.
3. Loosen the grease fitting to expel When maintenance or repairs are carried
the grease by turning anti‐clockwise out on the hydraulic system, attention must
using gradual increments. Do not be paid to cleanliness to avoid
loosen too quickly. contamination. For major repairs, contact
4. When the correct track tension has your Striker Crushing dealer.
been obtained, tighten the grease

fitting by turning clockwise. Clean

away any traces of grease. Do not
Notice:
over tighten the grease fitting.

5. Replace aperture cover.
The breather on the top of hydraulic tank

must be kept clean to allow the hydraulic
system to breathe.

Hydraulic Tank Breather

WARNING Notice:

When re‐filling the hydraulic system on a
regular basis, all components and hoses
should be inspected for leaks. Repairs should
be made immediately, before re‐operating
the machine.

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8.7.2 Hydraulic Oil

Adding hydraulic fluid

The system requires oil when the oil drops
below the red line on the indicator.

Hydraulic Fill Point

Procedure:
1. Take note of all safety procedures.
2. Make sure the machine is on level
ground.
3. Make sure all cylinders are extended
where possible.
Hydraulic tank components’ 4. Implement the lock‐out procedure.
5. The tank must be filled between the
1. Return line filters Low and High lines on the level
2. Filler fitting indicator. (See “Lubricants and
3. Tank access cover plate Fluid” section)
4. Hydraulic oil level indicator
5. Suction filter
6. Drain bung

Hydraulic Fill Point

Notice:

Do not overfill the hydraulic tank as this will
cause leakage from the breathers.


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8.7.3 Changing Hydraulic Oil 13. The tank can now be re‐filled with
hydraulic fluid through the quick
release filler coupling to halfway
between the Low and k lines on the
level indicator. Ensure all tank ball
valves are open.
14. The engine needs running to
circulate the oil. Operate the
controls to purge any air in the
system.
Procedure: 15. Stop the engine and fill the system
Notice: as required.

A suitable container is to be placed on the 8.7.4 Changing The Return Line Filter
ground to catch the full capacity of the oil in
the tank.

2. Hydraulic oil must be at ambient
temperature.
3. Ensure all hydraulic cylinder and
valves are not in operation mode.
4. Make sure all cylinders are
retracted. Procedure:
5. Ensure the ball valve on the drain 1. Take note of all safety warnings.
plug is in the closed position. 2. Clean the filter cover.
6. Remove the drain bung to drain the 3. Remove the filter cover by
tank open ball valve unscrewing the bolts.
7. Once the tank is empty remove the 4. Using the lifting handles remove the
tank inspection cover. filter element and discard.
8. Remove both suction filters by 5. Ensure filter cover is clean.
unscrewing them from the suction 6. Put new filter on ensuring the seal
pipes. rings are in the correct position.
9. The tank needs to be flushed out 7. Replace the filter cover and tighten
using clean hydraulic oil, taking securely.
extreme care to remove dirt and
foreign matter.
10. Fit new suction strainers to the
suction pipes.
11. Replace tank inspection cover,
making sure that the correct seal
and sealant are used.
12. Change the return line filter
elements by removing the return
line filter housing lids. Ensure the
lids are replaced securely.


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8.8.1 Feeder Mechanism

Tensioning of the new bolts is to be done as per
recommended tensioning sequencing as per Table 1.
The recommended tension and parts are as per Table2.

Table 1

18
15
9
7
1
4 20
6
10 16
13 12
17 5
3
2
8
11
14
19

Hardware Part Numbers & Tension

Table 2

Part Number Description Qty. Req’d
0320‐0081 Bolt – 20mm X 80mm Gde. 10.9 20
0320‐0082 Nut – 20mm Gde 10.9 40
0320‐0011 Washer – 20mm H/T Flat 40
Pre Tension 300Nm 1st Pass 528Nm nd
2 Pass 528Nm
Tension Tension

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8.9.1 Drive Belts 5. If required tension is met, lock

engine down with top lock nut.
Part of the machine daily checks is the
driven belt tension. A special tool is provided
for this.

There are two types of belts which can be
fitted, either single or banded belts and the
tool supplied will only suit the type of belt
fitted at time of delivery.

Note:

Do not over tension belts as this could
cause damage to both the engine and the
crusher.
Ensure both adjustment rods are equal
and the engine is level.

Procedure:
1. Take note of all safety warnings
2. Access drive belt through hinged
cover plate.
3. Check tension meets required
measurement.
4. If measurement is satisfactory
resecure cover plate

New drive belts and over a period of time all
drive belts will stretch and require additional
adjustments to ensure required
measurements are met.

Procedure:
2. Release top lock nut.
3. Raise engine on threaded rods.
4. Check tension.

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Shafts are not Shafts are not in Shafts are parallel and Correct
installation both
parallel to one correct alignment in alignment but

another. although they appear pulleys are not in shafts and pulleys
parallel when seen alignment. are parallel and in
from above. alignment.

The dotted lines emphasise the faults by indicating the correct position
Fig 2

Fig 3


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Drive Belts tension

Single belts

INPUT DRIVE DRIVEN
Pulley Diameter 355 1000
Belt type SPC 8000
BELT DEFLECTION 29mm
MIN. DEFLECTION FORCE AT INSTALLATION 5.5kgf
MAX. DEFLECTION FORCE AT INSTALLATION 6kgf
MIN DEFLECTION FORCE AT RETENSIONING 4.5kgf
MAX DEFLECTION FORCE AT RETENSIONING 5kgf

Banded belts

INPUT DRIVE DRIVEN
Pulley Diameter 335 1000
Belt type SPC 8000/4
BELT DEFLECTION 29mm
MIN. DEFLECTION FORCE AT INSTALLATION 6kgf
MAX. DEFLECTION FORCE AT INSTALLATION 6.5kgf
MIN DEFLECTION FORCE AT RETENSIONING 5kgf
MAX DEFLECTION FORCE AT RETENSIONING 5.5kgf

Note:

Tension figures given are per banded
belt

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8.10.1 Maintenance Schedules

MAINTENANCE SCHEDULE ‐HQR1112
INTIAL 200 EVERY 250 EVERY 500 EVERY 1000

COMPARTMENT OIL TYPE DAILY 40 HOURS 100 HOURS
HOURS HOURS HOURS HOURS
Check &
Impact Crusher Visual Repack
Ep2 10 G Record
Bearing Inspection Bearing
Temp.
Check &
Visual Repack
All Conveyors Ep2 4‐5 G Record
Inspection Bearing
Temp.
Service‐Oil Service‐Oil
Check Oil
Change & Change &
Grizzly Feeder Meropa 460 Levels
Replace Replace
Breathers
Breather Breather
Mobil DTE
Premium Fluid 24(VG‐ CHANGE OIL
Couplings 32)/DTE(VG‐ AND FILTER
46)
Engine Engine
Cat Engine 15w‐40 Inspect Belts Service Refer Service Refer

Cat Manual Cat Manual
Titan Gear
Funk Gearbox Change Oil Change Oil
Hyp 85/140
Check Oil
Strickland Tracks 80w‐90 Change Oil Change Oil
Levels
Check
Service, Service‐Oil
Check Oil Clean/Replac Condition Of
Hydraulic System Renolin B68 Filter Change Change And
Level e Breather All Fitting
Oil Filter
And Hose.
Check &
Visual Repack
Recycle Screen Ep2 12‐14 G Record
Inspection Bearing
Temp.

Note:

CAT engine servicing to be completed by an approved CAT service agent.

All oil compartment to be SOS sample at every service interval.

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IMPACT CRUSHER DAILY PRE‐START CHECK SHEET ‐ Refer Data Sheet For Oils / Additional Info ‐HQR1112
Asset Number Inspected By:

Asset Description Signature Of Inspector
Hour Meter Reading hrs Start Time Of Inspection
Date Finish Time Of Inspection

Item Inspection Type Pass Fail Notes
Vibrating Feeder (External Ground Level Inspection) ‐ Machine Isolated
Oil Level On Site Glass
Feeder Motor Leaks/Wear on Hydraulic Piping
Side Walls/Rear Wall Cracking / Wear
Underside of Feeder Cracking / Wear
Breather Fitted / Leaks
Springs Fitted / Signs of collapse or cracking
Grizzly Securing Bolts Present / Signs of Breakage
Vibrating Feeder (Internal Inspections from Platform)
Grizzly Bars Even / Uneven Wear
Feeder Floor Wear / Signs Of Damage
Feeder Wings Liner Condition
Vibrating Feeder ‐ Machine Running ‐ Restricted Operations
Feeder Sides Leakage / Loose Components
Feeder Underside Leakage / Loose Plates and Bolts
Internal Feeder / Grizzly Loose Items
Feeder Motor / Gearing Leaks from Hydraulics / Unusual Noises
Feeder Fines Chute ‐ Machine Isolated ‐ Inspection from under Vibrating Feeder
By pass chute Flop gate Condition / Fitted
By pass chute side Condition / Breakages / Deformation
Under Feeder Chute Cracking/Wear
Feeder Fines Chute ‐ Restricted Operations ‐ Inspect From under Vibrating Feeder
Chute Liner Wear / Signs Of Damage
Feeder Chute Present / Signs of Breakage
Discharge Hopper ‐ Machine Isolated ‐ Inspection from Impact crusher
All Liners Condition / Fitted
Hopper Rock ledge Condition / Breakages / Deformation
Securing Bolts All Present (Tightened)
Discharge Hopper ‐ Restricted Operations ‐ Inspect From Impact Crusher
All Liner Wear / Signs Of Damage
Impact Arm Top/Bottom Wear / Signs Of Damage
Hopper Skirt Rubber clamps Condition/Wear
Impact Crusher (External Inspection) ‐ Machine Isolated
Impact Top Assembly Tight / Fitted
Rotor Assembly Secure / Fitted
Lid Assembly Secure / Fitted/Hydraulic Cylinder
Bottom Assembly Tight / Fitted
Top/Centre/Bottom Hydraulic Leaks/Wear on Hydraulic Piping
Fixed Locking Tight / Fitted
Duct Curtains Wear/Damage

Hinged Inspection Door Tight / Fitted

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Impact Crusher ‐ Restricted Operations Inspection
Top/Side/Bottom Liner Craking/Wear
Gap between the lower edge impact plate Check /Increase/Decrease
Top/Centre/Bottom Arm Craking/Wear
Rotor Check direction
Base Bearings Free movement / Audible Noises
Base Bearings Check Temperatures and Record in Notes
Forward Conveyor ‐ All round Inspection ‐ Machine Isolated
Rock Discharge Area Under Crusher Clear from debris / Skirts OK / Liner Plates OK
Belt Signs of Wear / Rips / Repairs coming undone
Main Skirts Signs of Wear / Open Areas
Rollers (where accessible) Free Rolling / No Flat Spots / Fitted
Grease Lines Fitted / Damage
Belt Scraper Fitted / Condition of Rubber
Hydraulic Motors Leaks / Pipework Condition
Head Pulley Visual Condition of Lagging
Forward Conveyor ‐ Restricted Operations
Belt Tracking to be Central
Rollers Free moving / Unusual Noises
Bearings Audible Noises
Bearings Check Temperatures and Record in Notes
Hydraulic Motors Signs of Leaking
Head Pulley Signs of Belt Slipping
Oversize Conveyor ‐ All round Inspection ‐ Machine Isolated
Rock Discharge Area Under Screen Clear from debris / Skirts OK / Liner Plates OK
Oversize Conveyor ‐ Restricted Operations
Return Conveyor ‐ All round Inspection ‐ Machine Isolated
Discharge Hopper Clear from debris / Skirts OK / Liner Plates OK

Guards All Present (Tightened/Loose)

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Return Conveyor ‐ Restricted Operations
Side Conveyor (Where Fitted) ‐ All Round Inspection ‐ Machine Isolated
Side Conveyor ‐ Restricted Operations
Fines Conveyor (Where Fitted) ‐ All Round Inspection ‐ Machine Isolated
belt Signs of Wear / Rips / Repairs coming undone
Fines Conveyor ‐ Restricted Operations
Recycle Screen (External Inspection) ‐ Machine Isolated
Feed Tray Tight / Fitted/Material build up
Hook Mesh Clamp Secure / Fitted
Motor Cover Secure / Fitted
Side Body Welding/loose bolts
Wire Mesh Tight / Fitted
Recycle Screen ‐ Restricted Operations Inspection
Rock flowing down Inspect level/Shaft
Movement Screen Free movement / uneven distribution of material
Mechanism heat/Excessive
Spring Check/Tight/build up materials
Bearings Free movement / Audible Noises


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Engine ‐ Machine Isolated ‐ Inspection From Platforms
Engine Oil Level In Normal Operation Level
Engine Coolant Level In Normal Operation Level
Radiator Fan Blade Condition / Draws from Outside
Alternator Belts Fitted / Tension / Squealing
Water Pump Belt Fitted / Tension / Squealing
Air Cleaners (Inner / Outer) Dust / Fitted
Exhaust Condition of Pipework
Hydraulic Fluid Level Above danger level
Hydraulic Cooler Fans Operational when powered / Intakes clear
Air Intake Condition of Pipework
Electrical Wiring Broken Wires / Damage from Heat
Engine ‐ Restricted Operations
Rev Range Engine runs freely through Rev Range
Oil Leaks Check for weeps
Premium Fluid Coupling ‐ Machine Isolated ‐ Access From Engine Platform
Oil Level When shut down should be on site glass
Pipework Signs of wear / leaks
Condition of 74cc Pumps Attachment / Signs of Leaks
Condition of Hydraulic Piping Signs of wear / leaks
General Machine Inspection
Battery Box Battery Charge / Visual Condition
Hydraulic Pipework / PVG Valves Visual condition / Leaks
Control Panel Doors secure / Screen OK
Tracks Damage to Growsers / Chain
Ladders Secure / Fitted
Walkways Clear of material / debris
Guarding of Conveyors Fitted / clear of material build up

Additional Requirements During Pre‐Start Completed

 All bearings to be greased every 8 hours of operation (20 manual pumps per bearing)

 Check fire extinguishers and dates for last check (if not in date inform supervisor)

 Remove any build‐up under tail drums

 Remove any build‐up conveyor rollers and guards

 Any skirts showing signs of damage to be replaced (Weekly Preventative Maintenance)

 All guards fitted, securing bolts/locks in place

Oil Specifications ‐ For Top Ups Where Required Bearing Temperature Ranges ‐ Record After 10min Run

Premium fluid couplings ‐Mobil DTE 24(VG‐32)/DTE(VG‐46) Impact Crusher Bearing (L) °C
Crusher Feeder Gears ‐ CLP 460 Impact Crusher Bearing ( R) °C
Engine Oil ‐ 15W‐40 Recycle Screen Bearing (L) °C
Track Gear Units ‐ 80W‐90 Recycle Screen Bearing ( R) °C
Approved Radiator Coolant To Be Used ONLY

Conveyor Bearing FR °C
Conveyor Bearing FL °C
Conveyor Bearing RR °C

Conveyor Bearing RL °C

H-23
HQR1112
ISSUE:01/2017

IMPACT CRUSHER WEEKLY PRE‐START CHECK SHEET ‐ Refer Data Sheet For Oils / Additional Info ‐HQR1112


Breather Fitted / Leaks
Springs Fitted / Signs of collapse or cracking
Feeder Floor Wear / Signs Of Damage
Feeder Sides Leakage / Loose Components
Feeder Underside Leakage / Loose Plates and Bolts
Internal Feeder / Grizzly Loose Items
By pass chute Flop gate Condition / Fitted
Rotor Shaft Free movement
Blow bar Condition/Adjust
Cylinder Hinge Check and apply grease
Belt Signs of Wear / Damage
Belt Scraper Rubber wear/adjust


H-24
HQR1112
ISSUE:01/2017
Rollers Free moving / Unusual Noises/material build up
Belt Tracking to be Central/Wear
Discharge Hopper Clear from debris / Skirts OK / Liner Plates OK
Belt Tracking to be Central/wear


H-25
HQR1112
ISSUE:01/2017

Feed Tray Tight / Fitted
Hook Mesh Clamp Secure / Fitted
Motor Cover Secure / Fitted
Side Body Welding crack/Damage
Rock flowing down Inspect level/Shaft
Rubber buffer Wear/damage
Movement Screen Free movement / Leaks on Hydraulics
Spring Check/Tight
Radiator Fan Blade Condition / Draws from Outside
Air Intake Condition of Pipework
Electrical Wiring Broken Wires / Damage from Heat
General Machine Inspection
Battery Box Battery Charge / Visual Condition
Hydraulic Pipework / PVG Valves Visual condition / Leaks
Tracks Damage to Growsers / Chain
Ladders Secure / Fitted
Walkways Clear of material / debris
Guarding of Conveyors Fitted / clear of material build up

Additional Requirements During Pre‐Start Completed

 All bearings to be greased every 8 hours of operation (20 manual pumps per bearing)

 Remove any build‐up under tail drums

 Any skirts showing signs of damage to be replaced (Weekly Preventative Maintenance)

 All guards fitted, securing bolts/locks in place




Conveyor Bearing RL °C

H-26
HQR1112
ISSUE:01/2017

IMPACT CRUSHER MONTHLY PRE‐START CHECK SHEET ‐ Refer Data Sheet For Oils / Additional Info ‐HQR1112


Grizzly Securing Bolts Present / Signs of Breakage
Feeder gearbox Clear breather if replace
Feeder Sides Wear/Damage
Internal Feeder / Grizzly Wear/Damage
Hydraulic Pressure Filter indicator if required
Grease Line Fitting/apply
Base Bearings Check Temperatures and Record in Notes

Head Pulley Signs of Belt Slipping/Wear

H-27
HQR1112
ISSUE:01/2017

Rollers Free moving / Unusual Noises/Material build up
Head Pulley Signs of Belt Slipping/Wear
Wire Mesh Wear/Damage/Change
Side body Crack/damage
Movement Screen Free movement / Leaks on Hydraulics
Spring Check/Tight


H-28
HQR1112
ISSUE:01/2017
Radiator Check cooler cores(if required)
Alternator Belts Fitted / Tension / Squealing
Water Pump Belt Fitted / Tension / Squealing
Battery electrolite Check the level
Condition of Hydraulic Piping Signs of wear / leaks



Conveyor Bearing RL

°C

H-29
HQR1112
ISSUE:01/2017

LUBE LIST ‐ HQR1112
Bil Item New Lube Spec Qty
1 Feeder Gearbox oil Caltex Meropa 460 2
2 Track Drive Gearbox oil Caltex Thuban GL5 EP 80W90 2
3 Hydraulic oil Caltex Rando HD68 2
4 Engine oil Caltex Delo 400 15W40 2
5 Engine Coolant Caltex Extended life coolant Premix 1
6 Grease points Caltex Lipex EP2 grease 23
7 Premium fluid couplings Mobil DTE 24(VG-32)/DTE(VG-46) 1


H-30
HQR1112
ISSUE:01/2017
LUBRICATION & MAINTENANCE SCHEDULES IMPACTORS
MACHINE SERVICE HOURS
COMPARTMENT OIL TYPE DAILY 40 100 EVERY250 EVERY 500 EVERY1000
ENGINES
Check
Oil&
Inspect &
CATERPILLAR ENGINE Levels & Service & Service & Oil Sample refer
Adjust "V"
(Refer CAT Manual) Clean Air Oil Sample CAT engine manual
Belts
Filter
Elements
15W‐40
HYDRAULICS
Service,
Check condition of
Filter Clean/
HYDRAULIC SYSTEM Check Oil all fittings and hoses Service, Filter change & Oil
change replace
(Refer STRIKER Manual) Levels remove all rock Sample
& Oil breathers
build up
Sample
RENOLIN B
68
VIBRATING FEEDER
INITIAL OIL
TWIN SHAFT OIL SAMPLE OIL CHANGE AND SAMPLE
CHANGE
RENOLIN
460
TWIN EXCITER FEEDER
INSPECT
Check for GREASE 5
TWIN EXCITERS GREASE
noise GRAMS
LINES
EP 2
TRACKS
Check Oil
Strickland tracks Change Oils
Levels
80W‐90
CONVEYORS
Check and
SIDE CONVEYOR (IF Visual
5 GRAMS record Re pack bearings
FITTED) inspection
EP#2 temps
Check and
Visual
PRODUCT CONVEYORS 5 GRAMS record Re pack bearings
inspection
EP#2 temps


H-31
HQR1112
ISSUE:01/2017



H-32
HQR1112
ISSUE:01/2017
Lube Oil:

regularly.
Exhaust System:

Cooling System:

Air Inlet System:


Battery:
engine starting.

NOTE:


H-33
HQR1112
SECTION : Trouble Shooting
ISSUE: 01/2017
Table of Contents

9.1.1 Trouble Shooting Table I-2

I-1
HQR1112
ISSUE: 01/2017

TROUBLE SHOOTING ‐ HQR1112
TITLE PROBLEM CAUSE REMEDY

1. Too much load on belt. 1. Reduce load on belt.
Drive drum turns but conveyor
2. Incorrectly tensioned belt. 2. Tension belt.
belt does not move
3. Worn belt. 3. Replace belt.
1. Load is not centrally placed. 1. Knocking one side of the idler frame
2. Structure is bent or crooked. 2. Ensure structure is straight line.
3. Some idler rollers are worn out. 3. Replace new rollers.
Conveyor belt completely 4. Material jam. 4. Remove material jam

stopped. 5. Motor burn. 5. Replace new motor or rewind back.
6. Lanyard switch or Emergency 6. Release emergency stop and Restart the
stop. conveyor.
7. Drive coupling failure. 7. Replace new Coupling.
1. Conveyor is not level. 1. Ensure Conveyor is on level ground
2. Head and tail are miss‐ 2. Use the drum adjustment to ensure drums
ALL alignment are parallel.
CONVEYORS Belts are tracking off 3. Belts are not being fed evenly; 3. Ensure Conveyor is fed more evenly.
material is tending to be fed to
one side of conveyor.
4. Bearing Failure. 4. Replace new bearing.
Material spillage. 1. Skirting rubbers not adjusted. 1. Adjust skirting rubbers.

1. Bearing lacking grease. 1. Follow greasing procedure.
Drum pulley noisy bearing 2. Incorrectly aligned bearing. 2. Align bearing.

3. Bearing is damaged. 3. Replace bearing.
1. Pull core switch not function. 1. Both Product conveyor and Feeder will stop.
LH/RH Lanyard
2. Clear code and restart function.
1. Drum pulley lagging worn off. 1. Check Drum pulley lagging everyday
2. Materials build up on drum 2. Check and clean it.
Belts run off track only at the pulley.
Head or tail area. 3. Return rollers out alignment. 3. Check the rollers are worn.
4. Belt Scrapers are worn. 4. Check rubber scraper everyday.
1. Press 'E' Stops. 1. Check and release all 'E' stops.
2. Stackers 'E' Stops. 2. Check Stacker if fitted check 'E' stops
Emergency stop Fault
3. Remarks OK fault on screen. 3. Check the system voltage as a flat battery
may register the same fault.
1. Show on Screen. 1. From the main screen F6 diagnostics.
2. F2 engine information.
Engine Fault 3. F6 engine diagnostics.
4. Rectify the noted fault.
5. Retry start sequence.
1. Low oil level. 1. Fill up hydraulic oil level correct level.
Hydraulic oil low
IMPACTOR 2. Check the float switch and switch contacts.
CRUSHER
1. Low oil level. 1. Check KPTO cooler core for blockage and fan
operation.
Clutch Temperature High 2. Fill up correct oil level with engine
3. Clean cooler core with high pressure water.
1. Blockage oil flow 1. Change KTPO filter and oil.
Clutch Pressure High 2. Check Sensor for correct temp. range/
calibration
1. Radio Receiver no function. 1. Check condition of remote battery.
2. Check that remote is switched on.
Radio Stop Fault
3. Check that remote stop button isreleased.
4. Check aerial connection on remotereceiver.


I-2
HQR1112
ISSUE: 01/2017
TROUBLE SHOOTING ‐ HQR1112
TITLE PROBLEM CAUSE REMEDY

1. Low oil level. 1. Check hydraulic oil coolers for blockageand
fan operation.
2. Fill up the oil level correct level.
Hydraulic oil Temperature
Warning 3. Check operational pressures of bothvalve
groups.
4. Clean out cooler core with high
IMPACTOR pressurewater.
CRUSHER 1. Low oil level. 1. Check hydraulic oil level, fill to required.
2. Clean out cooler core with high
pressurewater.
Hydraulic oil Temperature High 3. Clean hydraulic oil tank down.
4. Restart machine.
5. Check cooler fan operation.
1. Bearing lacking lubricate. 1. Follow greasing procedure.
Screen noisy bearing 2. Incorrectly aligned bearing. 2. Align bearing correctly.
3. Bearing is damaged. 3. Replace new bearing.
1. Conveyor belt Wedge or rubbing 1. Clear obstruction, adjust and align conveyor
against fixed parts. belt.
Screening noise when conveyor
2. Belt scraper too tightly placed 2. Re‐adjust conveyor belt scraper.
belt is running.
against conveyor belt
1. Out of specification product that 1. Daily inspection of wire cloth before start‐up.
Worn in wire cloth. does not meet size
requirements.
1. Top deck load too light. 1. Select wire cloth with smaller openings to
increase load.
Screen Spillage 2. Stroke is too long. 2. Reduce stroke length.
3. Screen speed too fast. 3. Set it run slower.
4. Stroke angle too steep. 4. Set it run at more shallow angle.
1. Screen is overloaded. 1. Check plug weight placement and spring on
Decks overflowing screen is feed end.
dead on feed end 2. Increase rpm.
3. Reduce feed.
1. Screen not laterally (side to side) 1. Inspect the level screen.
RECYCLE level.
SCREEN Rock flowing down one side 2. Feed is on one side of screen 2. Check in feed conveyor.
screen. only.
3. Broken impulse shaft 3. Replace shaft.
1. Rpm too high. 1. Decrease rpm but stay within stroke speed
Rock moves across screen too range.
fast. 2. Stroke angle too flat. 2. Increase stroke angle.
3. Screen base not level. 3. Level screen.
1. Wire cloth wire too heavy. 1. Use smaller gauge wire.
2. Insufficient water spray. 2. Spray more water, if possible.
Decks blinded with clay.
3. Feed material has too much clay. 3. Clean feed material before screening. Install a
ball tray.
1. Screen basket not level. 1. Level the screen basket.
2. Incorrect motor or shaft rpm. 2. Inspect the motor plate before install and
start.
3. Unbalanced sheaves due to dirt. 3. Clean sheaves.
4. Loose or misaligned weights. 4. Check counterweight bolts, number and
Excessive Vibration
position of plug weight
5. Screen not properly supported 5. Brace Structure.
or support not braced enough.
6. If using coil spring fatigued, 6. Replace Springs.
sagging springs bottoming out.


I-3
HQR1112
SECTION : Risk Assessments
ISSUE: 01/2017
Table of Contents
10.1.1 Risk Assessments Table J-2

J-1
HQR1112
ISSUE: 01/2017

Probability: A = Common B = Likely C = Possible D = Unlikely E = Practically Impossible
Consequence: Range 1 ‐ 5 Larger number = Lower Consequences
Risk Rank: (H)igh = 1‐6 (M)edium = 7‐15 (L)ow = 16‐25
Consequence
People Prod. Equip. Environ. Public Risk

Potential Hazards Prob. Action to Eliminate / Reduce Risks
Safety Losses Damage Impact Relations Rank
1. Crushing hazard from Ensure adequate lifting capacity of crane.

machine falling during Observe appropriate safe work procedure
transportation and lifting. associated with lifting load. Ensure
D 1 4 1 4 2 7M
adequate supervision and instructions are
provided to installation crew. Use lifting
plugs where provided.
2. Pinching points during Follow safety precautions and consult
positioning of parts for supervisor.
C 2 4 5 5 5 13M
assembly.

3. Slipping and falling or Appropriate hydraulic torque wrench
bruising from bolt should be used for bolt tightening. Belting
tightening. Sprain and strain with sledgehammer to tighten or loosen
C 3 5 5 4 5 13 = M
and flying debris from nuts should be avoided where practicable.
belting with sledge hammer.

4. Electrical hazards. Ensure electrical power is isolated where
practicable during installation and
D 1 4 5 3 3 7 = M
maintenance. Ensure the electrical wiring
system is effectively earthed.
5. Operator error or D 3 4 4 5 5 17 = L Ensure the plant is suitable for the task and
unfamiliarity with current copy of the Instruction Manual is with the
work practices or suitability plant. Read and understand manuals
of plant. before commencing work.
6. Appropriate personal D 4 4 5 5 5 21 = L Clothing which might catch or tangle in
protective equipment and control levers and mechanical parts is
clothing. unsuitable and should not be worn. Wear a
helmet, protective goggles, safety boots,
mask, gloves and hearing protection where
necessary.
7. Slips, trips and falls from Ensure floor, steps and handrails are kept
poor housekeeping. C 3 5 5 5 5 13 = M clear of obstacles.

8. Controls and mechanical Carry out pre‐operational checks to ensure
failure of plant. D 5 1 3 5 5 7 = M guards are in place and safety controls are
operational.
9. Machine stops without Ensure the battery is fully charged or
warning due to flat battery D 5 1 4 5 5 16=l replace prior to use of remote
10. Machine is in close proximity Use a spotter near the plant if there is a
to another machine or blind spot to ensure the unit clears other
D 3 1 1 3 3 6=H
building and could clash plant and equipment.
during movement
11. Starting the engine on the Only trained operators to carry out this
machine to carry out set up, task. Check that there are no isolation tags
plant or track functions on the machine. Have a good look around
D 3 3 3 5 5 10=M
could cause injury to co the machine to ensure the area is clear and
workers damage to free of personnel.
equipment and electrical
12. Moving track machine, Ensure that all personnel are clear of the
forward reverse or left or intended area of movement. Ensure no
right could cause injury to co power lines or cables in the air or on the
D 3 1 1 3 3 6‐H
workers damage to ground are in the way. Move any
equipment and electrical equipment that might be in the way.
hazard.
13. Moving the machine over Check suitability of area to be operated in.
uneven ground, unstable Stay at least 10m away from natural slopes
ground or operating near of more than 5 degrees. Stay at least 10m
D 3 1 1 3 3 6=H
retaining walls or natural away from retaining walls.
slopes.
14. Positioning of track machine Ensure there are no overhead or low
for operation can cause power lines in the area that the loading
possible electrical and takes place. Check ground for suitability
C 4 2 1 5 5 10=M
equipment damage to for operation of the loading equipment.
equipment being used to
feed the machine
15. Starting engine and Only trained operators to be used
operating functions on
machine by unsafe / D 2 1 2 5 5 7=M
incompetent operators
16. Operating belt magnet. Control the speed of the magnet to
Material discharge from C 1 5 5 5 3 7=M prevent steel being flung away from the
height. area around the plant.

J-2
HQR1112
ISSUE: 01/2017

Probability: A = Common B = Likely C = Possible D = Unlikely E = Practically Impossible
Consequence: Range 1 ‐ 5 Larger number = Lower Consequences
Risk Rank: (H)igh = 1‐6 (M)edium = 7‐15 (L)ow = 16‐25
Consequence
People Prod. Equip. Environ. Public Risk

Potential Hazards Prob. Action to Eliminate / Reduce Risks
Safety Losses Damage Impact Relations Rank
17. Starting crusher possible fly Ensure crusher is empty before operation.
rock hazard and 4 Ensure the feeder is empty before
D 5 4 5 5 16=L
entanglement operation ensures any safety grids are in
place before operation.
18. Crushing material. Ensure suitable dust suppression is used.
 Dust hazard to area Operators and co workers to wear
surrounding the appropriate safety equipment masks etc,
operation. asses wind direction and surrounding areas
 Stability of machine for other risks.
 Noise hazard to area Ensure unit is stable on ground whilst
surrounding the B 2 5 5 2 2 6=M crushing.
operation Proper ear protection to be worn, assess
 Pollution hazard to area beyond operation for risks.
local creeks and Ensure no run off from lubrication and
water ways fauna refueling find their way into waterways.
and flora Avoid operation in areas of obvious value
for flora and fauna.
19. Refueling the machine, Avoid spillage of fuel by ensuring person
pollution hazard refueling is alert and responsible. Have an
D 5 5 5 1 1 10=M
action plan in place to deal with any
spillage that occurs.
20. Fuel loss due to ruptured Check fuel lines for condition as part of
fuel lines, pollution hazard regular maintenance. Ensure fire
and fire hazard to operators extinguishers are appropriately placed and
C 3 4 4 1 1 6=M
and co workers, hazard to in serviceable condition. Have an action
creeks, waterway and fauna plan in place to deal with any spillage that
and flora. occurs.
21. Re filling hydraulic oil in the Avoid spillage of oil by ensuring person
machine is a potential refilling is alert and responsible. Have an
C 3 4 4 1 1 6=M
pollution hazard action plan in place to deal with any
spillage that occurs.
22. Oil loss due to ruptured fuel 6=M Check oil lines for condition as part of
lines Pollution hazard and regular maintenance. Ensure fire
fire hazard to Operators and extinguishers are appropriately place and
C 3 4 4 1 1
co workers, hazard to creeks, in serviceable condition. Have an action
waterway and fauna and plan in place to deal with any spillage that
flora occurs.
23. Loading and unloading the Only certified operators to be used
machine for transport Ensure there are no overhead or low
Unsafe/Incompetent power lines in the area that the loading or
operator unloading takes place. Check ground for
 Possible electrical and suitability for operation of
D 1 4 1 4 2 7=M
equipment damage to loading/unloading the equipment.
operator and equipment Check suitability of area to be operated in.
 Unstable ground Stay at least 10m away from natural slopes
of more than 5 degrees. Stay at least 10m
away from retaining walls.
24. Transportation of machine Ensure machine is correctly chained to
from one site to another. float, discuss best practice with float
Machine not chained down driver. Ensure machine is properly clean
properly and material or D 1 3 1 4 3 8=M removing and material, which may
tools falling of machine on dislodge during transport. Secure any tools
public roadways or remove before transport

J-3
HQR1112
SECTION : Parts List
ISSUE: 01/2017


K-1
HQR1112
ISSUE: 01/2017

Master List
11.1 HQR1112 Track Impact Crusher GA
K-3
11.2 1005‐0006 Primary Feeder GA
K-102
11.3 1011‐1029 Hydraulic Tank Assembly
K-114
11.4 1013‐0130 ‐ Main Conveyor GA
K-124
11.5 1013‐0141 ‐ Transfer Conveyor Assembly
K-159
11.6 1013‐0146 Return Conveyor Assembly
K-173
11.7 1013‐0150 ‐ Fines Conveyor Assembly
K-195
11.8 1013‐9001 Side Conveyor GA
K-219
11.9 1015‐0012 ‐ Engine Canopy Assembly
K-235
11.10 1016‐9001 Fuel Tank GA
K-262
11.11 1018‐0007 ‐ Discharge Hopper Assembly
K-268
11.12 1019‐0036 Fines Chute Assembly
K-283
11.13 1019‐0041 Fines Chute Lower Section
K-293
11.14 1019‐0198 Transfer Discharge Chute Assembly
K-297
11.15 1035‐9001 Magnet Hydraulic Drive GA
K-305
11.16 1042‐0001 ‐ 1112 Impactor GA
K-313
11.17 1042‐0006 ‐ Impactor ‐ Base
K-321
11.18 1042‐0011 ‐ 1112 Impactor ‐ Fixed
K-339
11.19 1042‐0016 ‐ 1112 Impactor ‐ Hinged
K-347
11.20 1042‐0021 Impact Arm ‐ Bottom
K-365
11.21 1042‐0026 Impact Arm ‐ Centre
K-369
11.22 1042‐0031 Impact Arm ‐ Top
K-373
11.23 1043‐1208 LFM1200 Feeder Mechanism
K-377
11.24 1045‐1002 Screen Section Assembly
K-395
11.25 1045‐1007 Screen Box Assembly
K-409
11.26 1142‐0001 Bearing Housing 516‐613 Open & Fixed
K-426
11.27 1142‐0006 Bearing Housing 516‐613 Close & Fixed
K-430
11.28 1142‐0011 Bearing Housing 516‐613 Close & Floating

K-434

K-2
HQR1112
ISSUE: 01/2017

Table Of Contents
Section 1 – HQR1112 Track Impact Crusher GA

11.1.1 General Arrangement
K-5
11.1.2 Chassis, Tracks And Conveyor Support
K-6
11.1.3 Main Conveyor & Discharge Hopper
K-8
11.1.4 Removable Sub‐Chassis
K-10
11.1.5 Hydraulic Tank Assembly
K-12
11.1.6 Fuel Tank Assembly
K-14
11.1.7 Conveyor Guards
K-16
11.1.8 Fines Chute
K-18
11.1.9 Impact Crusher
K-20
11.1.10 Engine Canopy
K-22
11.1.11 Platform Supports
K-24
11.1.12 Control Panel
K-26
11.1.13 Battery Box Assembly
K-28
11.1.14 Access Walkways Assembly
K-34
11.1.15 Oil Cooler , Cooler Mount & Beacon
K-38
11.1.16 Hopper Wing Supports & Feeder Spring Mount
K-40
11.1.17 Primary Feeder & Compression Spring
K-43
11.1.18 Dust Cover Assembly
K-45
11.1.19 Hopper Wings Assembly
K-47
11.1.20 Step Ladder Assembly
K-50
11.1.21 Handrails Assembly
K-56
11.1.22 Pulley Assembly
K-59
11.1.23 Pulley Guard Assembly
K-61
11.1.24 Hydraulic Control Valve & Manifold
K-64
11.1.25 Hydraulic Control Valve
K-66
11.1.26 Dust Suppression Manifold
K-68
11.1.27 Lifting Bracket
K-70
11.1.28 Side Conveyor Assembly
K-72

11.1.29 Magnet Kit Assembly
K-74

K-3
HQR1112
ISSUE: 01/2017

11.1.30 Water Pump Assembly
K-76
11.1.31 Screen Support Assembly
K-78
11.1.32 Transfer Conveyor Assembly
K-80
11.1.33 Guards Assembly
K-82
11.1.34 Screen Section Assembly
K-84
11.1.35 Fire Suppression & Emergency Stop Switch
K-87
11.1.36 Emergency Stop Switch
K-90
11.1.37 Support Frame Assembly
K-92
11.1.38 Return Conveyor Assembly
K-94
11.1.39 Extension Piece Assembly
K-96

11.1.40 Optional ‐ Stacker Outlet
K-98

K-4
GENERAL ARRANGEMENT 02/01022016
K-5
CHASSIS, TRACKS & CONVEYOR SUPPORT 02/01022016
K-6
CHASSIS, TRACKS & CONVEYOR SUPPORT 02/01022016
ItemNo Part No Part Description Qty Drawing ItemNo Part No Part Description Qty Drawing
1 0002-1002 CHASSIS 1
2 8500-3841 TRACKS 1
3 0002-0009 CONVEYOR SUPPORT 4
4 0020-3050 CONVEYOR SUPPORT LEG 2
BG2 0316-0045 BOLT 8
BG3 0316-0050 BOLT 8
W11 0316-0004 FLAT WASHER 32
N11 0316-0002 NYLOCK NUT 16
K-7
MAIN CONVEYOR & DISCHARGE HOPPER 02/01022016
K-8
MAIN CONVEYOR & DISCHARGE HOPPER 02/01022016
5 1013-0130 MAIN CONVEYOR ASSEMBLY 1
6 1018-0007 DISCHARGE HOPPER ASSEMBLY 1
BF5 0312-0040 BOLT 8
BG1 0316-0042 BOLT 8
BG2 0316-0045 BOLT 8
W11 0316-0004 FLAT WASHER 32
N11 0316-0002 NYLOCK NUT 16
K-9
REMOVABLE SUB-CHASSIS 02/01022016
K-10
REMOVABLE SUB-CHASSIS 02/01022016
7 0002-1008 REMOVABLE SUB-CHASSIS - RH 1 BH6 0320-0065 BOLT 20
8 0002-1015 REMOVABLE SUB-CHASSIS - LH 1 BH7 0320-0070 BOLT 2
9 0002-1043 REMOVABLE SUB-CHASSIS 2 W11 0316-0004 FLAT WASHER 16
10 0002-1050 MAGNET SUPPORT - BRACE 1 W13 0320-0009 FLAT WASHER 48
11 0002-1057 MAGNET SUPPORT - BRACE 1 W14 0320-0012 SPRING WASHER 4
12 0020-0997 HEAD SUPPORT - 1430 2 N11 0316-0002 NYLOCK NUT 8
13 0251-4016 TURNBUCKLE 2 N13 0320-0005 NYLOCK NUT 22
BG3 0316-0050 BOLT 8
BH5 0320-0060 BOLT 4
K-11
HYDRAULIC TANK ASSEMBLY 02/01022016
K-12
HYDRAULIC TANK ASSEMBLY 02/01022016
14 1011-1029 HYDRAULIC TANK GA 1
BH6 0320-0065 BOLT 8
W13 0320-0009 FLAT WASHER 10
W14 0320-0012 SPRING WASHER 6
N13 0320-0005 NYLOCK NUT 2
K-13
FUEL TANK ASSEMBLY 02/01022016
10
K-14
15 1016-9001 FUEL TANK 1 W7 0310-0005 FLAT WASHER 4
16 0016-9029 FUEL TANK SLIDE RAIL 1 W11 0316-0004 FLAT WASHER 12
17 0016-9030 FUEL TANK SIDE RAIL 1 W40 0315-0901 FLAT WASHER 4
18 0042-4392 SPINDLE PROCTECTOR COVER 1 N7 0310-0001 NYLOCK NUT 2
19 0002-1400 LOCKING BRACKET 2 N11 0316-0002 NYLOCK NUT 8
20 0260-0216 RUBBER MOUNT 4
BE4 0310-0030 BOLT 2
BG2 0316-0045 BOLT 4
BG9 0316-0090 BOLT 4
11
K-15
CONVEYOR GUARDS 02/01022016
12
K-16
CONVEYOR GUARDS 02/01022016
21 0006-1052 SIDE GUARD - RH 1 W10 0312-0012 SPRING WASHER 4
22 0006-1059 SIDE GUARD - LH 1
23 0006-1066 TAIL DRUM GUARD - RH 1
24 0006-1073 TAIL DRUM GUARD - LH 1
BE6 0310-0040 BOLT 8
BF6 0312-0045 BOLT 4
13
K-17
FINES CHUTE 02/01022016
14
K-18
FINES CHUTE 02/01022016
25 1019-0036 FINES CHUTE ASSEMBLY 1
BF4 0312-0035 BOLT 13
BF6 0312-0045 BOLT 4
N9 0312-0002 NYLOCK NUT 17
15
K-19
IMPACT CRUSHER 02/01022016
16
K-20
IMPACT CRUSHER 02/01022016
26 1042-0001 IMPACT CRUSHER 1
27 0018-2092 DUST CURTAIN 2
BG5 0316-0060 BOLT 10
BJ5 0324-0100 BOLT 6
W11 0316-0004 FLAT WASHER 20
W15 0324-0003 FLAT WASHER 12
N11 0316-0002 NYLOCK NUT 10
N16 0324-0001 HEX NUT 12
17
K-21
ENGINE CANOPY 02/01022016
18
K-22
ENGINE CANOPY 02/01022016
28 1015-0012 ENGINE CANOPY GA 1 N13 0320-0005 NYLOCK NUT 4
29 0009-0102 TAKE UP ROD 2
30 0009-0109 TAKE UP ROD LOCATOR 4
31 0009-0118 TAKE UP ROD PROTECTOR 4
32 0030-5013 PIN 2
33 0029-0751 PIN WASHER 2
SP03 0399-6308 SPLIT PIN 2
BH8 0320-0075 BOLT 4
19
K-23
PLATFORM SUPPORTS 02/01022016
20
K-24
PLATFORM SUPPORTS 02/01022016
34 0008-4008 PLATFORM SUPPORT 1 W9 0312-0006 FLAT WASHER 20
35 0008-4015 PLATFORM SUPPORT 1 W10 0312-0012 SPRING WASHER 4
36 0007-3050 PLATFORM SUPPORT 1 W11 0316-0004 FLAT WASHER 4
37 0007-3056 PLATFORM SUPPORT 1 W12 0316-0009 SPRING WASHER 4
38 0007-2578 PLATFORM SUPPORT 1 N9 0312-0002 NYLOCK NUT 8
39 0007-2577 PLATFORM SUPPORT 1
40 0006-1045 PLATFORM SUPPORT 2
BF5 0312-0040 BOLT 12
BG1 0316-0042 BOLT 4
21
K-25
CONTROL PANEL 02/01022016
22
K-26
CONTROL PANEL 02/01022016
41 8800-1000 CONTROL PANEL 1
42 0260-0001 DOOR LOCK 1
43 0260-0224 GAS STRUT 2
BB1 0305-0017 BOLT 4
BG1 0316-0042 BOLT 4
23
K-27
BATTERY BOX ASSEMBLY 02/01022016
24
K-28
42 0260-0001 DOOR LOCK 1 BG1 0316-0042 BOLT 6
44 0002-1393 SUPPORT BRACKET 1 W2 0305-0005 FLAT WASHER 4
45 0008-2010 BATTERY BOX 1 W5 0308-0005 FLAT WASHER 8
46 0008-2016 DOOR PANEL 1 W11 0316-0004 FLAT WASHER 8
47 0260-0101 HINGE STRAP 2 W12 0316-0009 SPRING WASHER 4
48 0260-0102 HINGE - LH 1 N2 0305-0001 NYLOCK NUT 4
49 0260-0103 HINGE - RH 1 N5 0308-0003 NYLOCK NUT 8
BB1 0305-0017 BOLT 4 N11 0316-0002 NYLOCK NUT 2
BD2 0308-0025 BOLT 8
25
K-29
26
K-30
50 0008-2005 ACCESS RUBBER CLAMP 1 BE2 0310-0025 BOLT 2
51 0008-4085 BATTERY CLAMP 2 W3 0306-0004 FLAT WASHER 18
52 0120-0004 BATTERY 2 W5 0308-0005 FLAT WASHER 4
53A 0112-3237 PROPORTIONAL VALVE 1 W6 0308-0004 SPRING WASHER 4
53B 0112-3246 PROPORTIONAL VALVE 1 W7 0310-0005 FLAT WASHER 8
54 5900-0008 BUZZER 1 N3 0306-0003 NYLOCK NUT 9
55 0008-4106 BATTERY LOCKING HOOK 4 N7 0310-0001 NYLOCK NUT 6
BC2 0306-0030 BOLT 9
BD1 0308-0020 BOLT 4
27
K-31
28
K-32
56 0008-2004 ISOLATOR BRACKET 2 W7 0310-0005 FLAT WASHER 2
57 5900-0009 LIGHTER FLUSH MOUNT 1 W8 0310-0004 SPRING WASHER 2
58 5102-0003 BATTERY MASTER SWITCH 2 N1 0303-0001 NYLOCK NUT 3
59 5102-0006 INSULATOR 2 N2 0305-0001 NYLOCK NUT 8
BAP1 0305-0008 BOLT 3
BB2 0305-0025 BOLT 8
BE2 0310-0020 BOLT 2
29
K-33
ACCESS WALKWAYS ASSEMBLY 02/01022016
DETAIL D DETAIL E
DETAIL F
DETAIL G
30
K-34
60 0007-1021 HYDRAULIC TANK PLATFORM 1 W9 0312-0006 FLAT WASHER 26
61 0007-1014 ENGINE SIDE PLATFORM 1 N9 0312-0002 NYLOCK NUT 21
62 0007-0701 REMOVABLE DOOR PANEL 2
63 0007-1006 SIDE ACCESS PLATFORM 1
BF4 0312-0035 BOLT 2
BF6 0312-0045 BOLT 2
BF7 0312-0052 BOLT 1
BFC1 0312-0036 BOLT - C/SUNK 14
BFC2 0312-0047 BOLT - C/SUNK 4
31
K-35
32
K-36
42 0260-0001 DOOR LOCK 1 W2 0305-0005 FLAT WASHER 4
47 0260-0101 HINGE STRAP 2 W5 0308-0005 FLAT WASHER 8
48 0260-0102 HINGE - LH 1 N2 0305-0001 NYLOCK NUT 4
49 0260-0103 HINGE - RH 1 N5 0308-0003 NYLOCK NUT 8
64 0007-0607 DOOR PANEL 1
65 0007-0101 DOOR STAYS 2
UB1 0301-0100 U-BOLT 2
BB1 0305-0017 BOLT 4
BD2 0308-0025 BOLT 8
33
K-37
OIL COOLER , COOLER MOUNT & BEACON 02/01022016
34
K-38
OIL COOLER , COOLER MOUNT & BEACON 02/01022016
66 0011-1011 COOLER MOUNT 1 W5 0308-0005 FLAT WASHER 16
67 0115-0001 OIL COOLER 2 W7 0310-0005 FLAT WASHER 8
68 5900-0017 BEACON 1 W11 0316-0004 FLAT WASHER 4
69 0010-9092 BEACON SUPPORT 1 W13 0320-0009 FLAT WASHER 8
70 0010-9099 BEACON SUPPORT 1 N5 0308-0003 NYLOCK NUT 8
BD3 0308-0030 BOLT 8 N7 0310-0001 NYLOCK NUT 4
BE4 0310-0030 BOLT 4 N11 0316-0002 NYLOCK NUT 2
BG3 0316-0050 BOLT 2 N13 0320-0005 NYLOCK NUT 4
BH4 0320-0055 BOLT 4
35
K-39
HQR 1112R TRACK IMPACT CRUSHER
ISSUE:
HOPPER WING SUPPORTS &
02/01022016
FEEDER SPRING MOUNT
36
K-40
ISSUE:
02/01022016
FEEDER SPRING MOUNT
71 0002-1029 SIDE WING SUPPORT - LH 1 BGC1 0316-0047 BOLT - C/SUNK 8
72 0002-1036 SIDE WING SUPPORT - RH 1 BGC2 0316-0055 BOLT - C/SUNK 16
73 0002-1022 SIDE WING SUPPORT - REAR 1 BH4 0320-0055 BOLT 6
74 0002-1071 REAR WING SUPPORT - LH 1 BH5 0320-0060 BOLT 2
75 0002-1064 REAR WING SUPPORT - RH 1 BH6 0320-0065 BOLT 20
76 0002-1092 WING LOCK WEDGE 4 W11 0316-0004 FLAT WASHER 16
77 0002-1099 WING LOCK WEDGE 2 W13 0320-0009 FLAT WASHER 50
78 0002-1085 FEEDER SPRING MOUNT - REAR 1 W14 0320-0012 SPRING WASHER 6
79 0002-1078 FEEDER SPRING MOUNT - FRONT 2 N11 0316-0002 NYLOCK NUT 16
37
K-41
ISSUE:
02/01022016
FEEDER SPRING MOUNT
N13 0320-0005 NYLOCK NUT 22
38
K-42
PRIMARY FEEDER & COMPRESSION SPRING 02/01022016
39
K-43
PRIMARY FEEDER & COMPRESSION SPRING 02/01022016
80 1005-0006 PRIMARY FEEDER ASSEMBLY 1
81 0190-0101 COMPRESSION SPRING 11
82 0005-1143 TRAVEL BRACKET 4
BF6 0312-0045 BOLT 8
40
K-44
DUST COVER ASSEMBLY 02/01022016
41
K-45
DUST COVER ASSEMBLY 02/01022016
83 0005-2610 RUBBER CLAMP RH 1
84 0005-2603 RUBBER CLAMP LH 1
85 0167-0007 RUBBER 1.5m
BG5 0316-0060 BOLT 6
W11 0316-0004 FLAT WASHER 12
N11 0316-0002 NYLOCK NUT 6
42
K-46
HOPPER WINGS ASSEMBLY 02/01022016
43
K-47
86 0004-1116 SIDE WING - LH 1 95 0030-4830 PIVOT PIN 4
87 0004-1109 SIDE WING - RH 1 96 0030-3018 PIVOT PIN 2
88 0004-1102 REAR WING 1 97 0030-4820 PIVOT PIN 2
89 0002-1120 UPPER SUPPORT ARM 2 98 0029-0532 PIN WASHER 6
90 0002-1113 LOWER SUPPORT ARM 2 99 0030-9022 COLLAR 6
91 0002-1169 SUPPORT BRACKET 2 100 0110-0257 CYCLINDER 2
92 0002-1127 LOCK WEDGE 2 101 0110-0267 CYCLINDER 1
93 0030-3016 PIVOT PIN 2 102 0018-0298 HYDRAULIC CYLINDER 2
94 0030-3015 PIVOT PIN 2 103 0030-9001 PIN MOUNT COLLAR 2
44
K-48
104 0030-9008 LOCK PIN 2 N3 0306-0003 NYLOCK NUT 6
105 0260-0214 GRIP CLIP 2 N11 0316-0002 NYLOCK NUT 8
SP03 0399-6308 SPLIT PIN 6
BC10 0306-0110 BOLT 6
BE7 0310-0050 BOLT 12
BG4 0316-0056 BOLT 8
W11 0316-0004 FLAT WASHER 16
45
K-49
STEP LADDER ASSEMBLY 02/01022016
46
K-50
106 0007-3091 STEP LADDER UPPER SECTION 1 BF5 0312-0040 BOLT 2
107 0007-3084 STEP LADDER LOWER SECTION 1 BG1 0316-0042 BOLT 2
108 0007-2768 LOCKING PLATE 2 BG2 0316-0045 BOLT 2
109 0007-3077 SUPPORT ARM MOUNT 1 BH7 0320-0070 BOLT 1
110 0007-3070 SUPPORT ARM 1 W7 0310-0005 FLAT WASHER 8
111 0007-4858 SUPPORT ARM LOCK 1 W9 0312-0006 FLAT WASHER 4
112 0007-4927 PIVOT SUPPORT 1 W10 0312-0012 SPRING WASHER 2
113 0030-9015 LOCKING PIN 2 W11 0316-0004 FLAT WASHER 8
BE4 0310-0030 BOLT 4 W13 0320-0009 FLAT WASHER 2
47
K-51
N11 0316-0002 NYLOCK NUT 4
N13 0320-0005 NYLOCK NUT 1
48
K-52
49
K-53
108 0007-2768 LOCKING PLATE 2 BE4 0310-0030 BOLT 8
109 0007-3077 SUPPORT ARM MOUNT 1 BF5 0312-0040 BOLT 2
112 0007-4927 PIVOT SUPPORT 1 BG1 0316-0042 BOLT 2
113 0030-9015 LOCKING PIN 2 BG2 0316-0045 BOLT 2
114 0007-2478 STEP LADDER UPPER SECTION 1 BH7 0320-0070 BOLT 1
115 0007-2485 STEP LADDER LOWER SECTION 1 W7 0310-0005 FLAT WASHER 16
116 0007-2492 EXTENSION STEP LADDER 1 W9 0312-0006 FLAT WASHER 4
117 0007-2583 SUPPORT ARM 1 W10 0312-0012 SPRING WASHER 2
118 0007-4857 SUPPORT ARM LOCK 1 W11 0316-0004 FLAT WASHER 8
50
K-54
N11 0316-0002 NYLOCK NUT 4
N13 0320-0005 NYLOCK NUT 1
51
K-55
HANDRAILS ASSEMBLY 02/01022016
52
K-56
119 0007-2007 HANDRAIL 1 BD7 0308-0070 BOLT 16
120 0007-2453 ACCESS GATE 1 BF4 0312-0035 BOLT 10
121 0007-0248 ACCESS GATE 1 BG1 0316-0042 BOLT 3
122 0007-2028 HANDRAIL 1 BG8 0316-0080 BOLT 3
123 0007-2012 HANDRAIL 1 W3 0306-0004 FLAT WASHER 16
124 0007-2019 HANDRAIL 1 W5 0308-0005 FLAT WASHER 32
125 0007-0164 HINGE BRACKET 4 W9 0312-0006 FLAT WASHER 20
126 0007-0118 HINGE 4 W11 0316-0004 FLAT WASHER 6
BC1 0306-0020 BOLT 16 W12 0316-0009 SPRING WASHER 6
53
K-57
N3 0306-0003 NYLOCK NUT 16
N5 0308-0003 NYLOCK NUT 16
N9 0312-0002 NYLOCK NUT 10
54
K-58
PULLEY ASSEMBLY 02/01022016
55
K-59
PULLEY ASSEMBLY 02/01022016
127 0140-1001 DRIVE PULLEY 1
128 0140-0357 DRIVE PULLEY 1
129 0145-5006 TAPER LOCK 1
130 0145-3512 TAPER LOCK 1
131 0141-8000 DRIVE BELT 8
56
K-60
PULLEY GUARD ASSEMBLY 02/01022016
57
K-61
47 0260-0101 HINGE STRAP 3 139 0006-1031 SUPPORT BRACKET 1
48 0260-0102 HINGE - LH 2 140 0260-0104 HINGE 1
49 0260-0103 HINGE - RH 1 BC1 0306-0020 BOLT 4
132 0006-1423 DRIVE PULLEY COVER 1 BD2 0308-0025 BOLT 12
133 0006-1430 DRIVE PULLEY COVER 1 BE3 0310-0025 BOLT 19
134 0006-1438 DRIVE PULLEY COVER 1 BF4 0312-0035 BOLT 7
135 0015-4002 INSPECTION HATCH 1 BF7 0312-0052 BOLT 2
136 0006-1038 COVER PLATE 1 W3 0306-0004 FLAT WASHER 4
58
K-62
N5 0308-0003 NYLOCK NUT 12
59
K-63
HYDRAULIC CONTROL VALVE & MANIFOLD 02/01022016
60
K-64
HYDRAULIC CONTROL VALVE & MANIFOLD 02/01022016
140 0008-3001 VALVE COVER PLATE 1 BE5 0310-0035 BOLT 4
PROPORTIONAL VALVE
141A 0112-3236 1 W5 0308-0005 FLAT WASHER 6
(STANDARD / RECYCLE-KIT)
PROPORTIONAL VALVE
141B 0112-3244 1 W6 0308-0004 SPRING WASHER 2
(SIDE CONVEYOR)
142 4100-0005 CONTROL VALVE 1 W7 0310-0005 FLAT WASHER 8
143 4100-0010 CONTROL VALVE 1 N5 0308-0003 NYLOCK NUT 4
144 4102-0002 CASE DRAIN MANIFOLD 2 N7 0310-0001 NYLOCK NUT 4
BD2 0308-0025 BOLT 2
BD6 0308-0060 BOLT 2
BD7 0308-0070 BOLT 2
61
K-65
HYDRAULIC CONTROL VALVE 02/01022016
62
K-66
HYDRAULIC CONTROL VALVE 02/01022016
145 4100-0001 CONTROL VALVE SINGLE SPOOL 2 W3 0306-0004 FLAT WASHER 2
146 5900-0025 CONTROL STATION 1 W4 0306-0008 SPRING WASHER 2
147 5120-0017 GREEN PUSH BUTTON 1 W5 0308-0005 FLAT WASHER 4
148 0118-0281 PRESSURE SWITCH 1 W7 0310-0005 FLAT WASHER 2
149 0118-0280 DC MOTOR 1 W8 0310-0004 SPRING WASHER 2
BCP1 0306-0010 BOLT - PAN HEAD 2 N5 0308-0003 NYLOCK NUT 4
BD6 0308-0060 BOLT 2
BD7 0308-0070 BOLT 2
BE3 0310-0025 BOLT 2
63
K-67
DUST SUPPRESSION MANIFOLD 02/01022016
64
K-68
DUST SUPPRESSION MANIFOLD 02/01022016
150 0010-0003 SUPPRESSION SYSTEM MANIFOLD 1 BE5 0310-0035 BOLT 4
151 0301-0003 FITTING - HEX PLUG 2 W7 0310-0005 FLAT WASHER 8
152 0301-0037 FITTING - HEX PLUG 1 N7 0310-0001 NYLOCK NUT 4
153 0301-0005 FITTING - HEX NIPPLE 7
154 0301-0002 FITTING - 90° ELBOW 4
155 0301-0022 FITTING - VALVE 3
156 0301-0001 FITTING - SWAGE 4
157 0301-0008 HOSE CLAMP 4
158 0301-0009 HOSE 30m
65
K-69
LIFTING BRACKET 02/01022016
66
K-70
LIFTING BRACKET 02/01022016
159 0020-5134 LIFTING BRACKET - LH 1
160 0020-5127 LIFTING BRACKET - RH 1
161 0020-5015 LIFTING BRACKET CENTER BRACE 1
BG1 0316-0042 BOLT 8
BH3 0320-0050 BOLT 14
W13 0320-0009 FLAT WASHER 14
67
K-71
SIDE CONVEYOR ASSEMBLY 02/01022016
68
K-72
SIDE CONVEYOR ASSEMBLY 02/01022016
162 1013-9001 SIDE CONVEYOR 1 W7 0310-0005 FLAT WASHER 28
163 1019-0041 FINES CHUTE LOWER SECTION 1 W9 0312-0006 FLAT WASHER 24
164 0006-4162 TAIL GUARD 1 W11 0316-0004 FLAT WASHER 12
165 0020-3036 TAIL SUPPORT 1 N7 0310-0001 NYLOCK NUT 14
BF4 0312-0035 BOLT 4 N11 0316-0002 NYLOCK NUT 6
BF5 0312-0040 BOLT 8
BG2 0316-0045 BOLT 4
BG4 0316-0056 BOLT 2
69
K-73
MAGNET KIT ASSEMBLY 02/01022016
70
K-74
MAGNET KIT ASSEMBLY 02/01022016
13 0251-4016 TURNBUCKLE 2 N9 0312-0002 NYLOCK NUT 4
166 1035-9001 MAGNET KIT 1 N11 0316-0002 NYLOCK NUT 10
167 0019-9001 DISCHARGE CHUTE 1
168 0002-0106 PIVOT BRACKET 2
BF5 0312-0040 BOLT 4
BG4 0316-0056 BOLT 8
BG8 0316-0080 BOLT 2
W11 0316-0004 FLAT WASHER 20
71
K-75
WATER PUMP ASSEMBLY 02/01022016
72
K-76
WATER PUMP ASSEMBLY 02/01022016
169 1000-0151 WATER PUMP GA 1
BE5 0310-0035 BOLT 4
73
K-77
SCREEN SUPPORT ASSEMBLY 02/01022016
74
K-78
SCREEN SUPPORT ASSEMBLY 02/01022016
170 0020-4009 SCREEN SUPPORT 1 BG2 0316-0045 BOLT 8
171 0020-4002 SCREEN SUPPORT 1 BH3 0320-0050 BOLT 16
172 0020-5036 LIFTING BRACKET 1 BH5 0320-0060 BOLT 8
173 0020-5029 LIFTING BRACKET 1 BH6 0320-0065 BOLT 8
174 0020-4039 PIVOT SUPPORT 1 W11 0316-0004 FLAT WASHER 8
175 0020-4087 SUPPORT LUG 2 W12 0316-0009 SPRING WASHER 8
176 0030-4907 PIN 2 W13 0320-0009 FLAT WASHER 48
177 0029-0750 PIN WASHER 2 W14 0320-0012 SPRING WASHER 16
SP03 0399-6308 SPLIT PIN 2 N13 0320-0005 NYLOCK NUT 16
75
K-79
TRANSFER CONVEYOR ASSEMBLY 02/01022016
76
K-80
TRANSFER CONVEYOR ASSEMBLY 02/01022016
178 1013-0140 TRANSFER CONVEYOR ASSEMBLY 1 BG2 0316-0045 BOLT 12
179 0020-4025 SUPPORT FRAME 1 W11 0316-0004 FLAT WASHER 24
180 0020-4024 LOCKING PLATE 2 N11 0316-0002 NYLOCK NUT 12
181 0012-2666 CARRIAGE SHAFT 4
182 0012-2672 CARRIAGE WHEEL 4
183 0142-0105 BEARING 4
184 0012-2679 RETAINING PLATE 4
185 0110-0256 CYLINDER 1
BEC1 0310-0021 BOLT - C/SUNK 4
77
K-81
GUARDS ASSEMBLY 02/01022016
78
K-82
186 0006-4727 TAIL GUARD 1 W8 0310-0004 SPRING WASHER 8
187 0006-4736 UNDER GUARD 1 N5 0308-0003 NYLOCK NUT 2
188 4100-0007 CONTROL VALVE 1
BD6 0308-0060 BOLT 1
BD7 0308-0070 BOLT 1
BE4 0310-0030 BOLT 4
BE5 0310-0035 BOLT 4
79
K-83
SCREEN SECTION ASSEMBLY 02/01022016
80
K-84
17 0029-0750 PIN WASHER 2 197 0030-3007 PIN 2
189 1045-1002 SCREEN SECTION GA 1 198 0029-0532 PIN WASHER 6
190 0020-4086 SUPPORT LUG 2 199 0110-0321 CYLINDER 2
191 0020-1062 RAISE & LOWER OUTER SUPPORT 2 SP02 0399-6305 SPLIT PIN 6
192 0020-1056 RAISE & LOWER INNER SUPPORT 2 SP03 0399-6308 SPLIT PIN 2
193 0008-3002 OUTLET BRACKET 1 BE5 0310-0035 BOLT 2
194 0030-3009 PIN 2 BH6 0320-0065 BOLT 8
195 0030-4910 PIN 2 W7 0310-0005 FLAT WASHER 4
196 0030-3012 PIN 2 W13 0320-0009 FLAT WASHER 16
81
K-85
N13 0320-0005 NYLOCK NUT 8
82
K-86
ISSUE:
FIRE SUPPRESSION &
02/01022016
EMERGENCY STOP SWITCH
83
K-87
ISSUE:
FIRE SUPPRESSION &
02/01022016
200 0250-0001 FIRE EXTINGUISHER 1 209 5124-1111 TURNBUCKLES 1
201 0250-0002 MOUNT BRACKET 1 BBP1 0305-0030 BOLT 4
202 5120-0002 E-STOP SWITCH - PUSH BUTTON 2 BC2 0306-0030 BOLT 4
203 0020-2058 E-STOP SWITCH MOUNT BRACKET 1 BE4 0310-0030 BOLT 4
204 5120-0021 E-STOP SWITCH - TRIP WIRE 1 BG2 0316-0045 BOLT 2
205 0251-0016 CABLE CLAMP 4 W2 0305-0005 FLAT WASHER 4
206 5120-0024 END SPRING 1 W3 0306-0004 FLAT WASHER 8
207 5001-0100 TRIP WIRE 12m W7 0310-0005 FLAT WASHER 8
208 0310-1007 EYE BOLT 5 W11 0316-0004 FLAT WASHER 4
84
K-88
ISSUE:
FIRE SUPPRESSION &
02/01022016
N11 0316-0002 NYLOCK NUT 2
85
K-89
EMERGENCY STOP SWITCH 02/01022016
86
K-90
EMERGENCY STOP SWITCH 02/01022016
161 5120-0002 E-STOP SWITCH - PUSH BUTTON 2 BC2 0306-0030 BOLT 4
162 0020-2058 E-STOP SWITCH MOUNT BRACKET 1 BG2 0316-0045 BOLT 2
163 5120-0021 E-STOP SWITCH - TRIP WIRE 1 W2 0305-0005 FLAT WASHER 4
164 0251-0016 CABLE CLAMP 4 W3 0306-0004 FLAT WASHER 8
165 5120-0024 END SPRING 1 W11 0316-0004 FLAT WASHER 4
166 5001-0100 TRIP WIRE 12m N2 0305-0001 NYLOCK NUT 4
167 0310-1007 EYE BOLT 4 N3 0306-0003 NYLOCK NUT 4
168 5124-1111 TURNBUCKLES 1 N11 0316-0002 NYLOCK NUT 2
BBP1 0305-0030 BOLT 4
87
K-91
SUPPORT FRAME ASSEMBLY 02/01022016
88
K-92
SUPPORT FRAME ASSEMBLY 02/01022016
177 0029-0750 PIN WASHER 2 N13 0320-0005 NYLOCK NUT 12
195 0030-4910 PIN 2
199 0110-0321 CYLINDER 1
210 0020-4093 SUPPORT FRAME 1
SP03 0399-6308 SPLIT PIN 2
BH4 0320-0055 BOLT 8
BH5 0320-0060 BOLT 4
W13 0320-0009 FLAT WASHER 24
89
K-93
RETURN CONVEYOR ASSEMBLY 02/01022016
90
K-94
RETURN CONVEYOR ASSEMBLY 02/01022016
106 0260-0214 GRIP CLIP 1 213 0030-2415 PIN 1
146 4100-0001 CONTROL VALVE SINGLE SPOOL 1 SP03 0399-6308 SPLIT PIN 2
177 0029-0750 PIN WASHER 2 BD6 0308-0060 BOLT 1
181 0012-2666 CARRIAGE SHAFT 2 BD7 0308-0070 BOLT 1
182 0012-2672 CARRIAGE WHEEL 2 BEC1 0310-0021 BOLT - C/SUNK 2
183 0142-0105 BEARING 2
184 0012-2679 RETAINING PLATE 2
195 0030-4910 PIN 2
212 1013-0146 RETURN CONVEYOR GA 1
91
K-95
EXTENSION PIECE ASSEMBLY 02/01022016
92
K-96
EXTENSION PIECE ASSEMBLY 02/01022016
214 0004-1256 EXTENSION PIECE 1 W13 0320-0009 FLAT WASHER 3
215 0026-6617 LINER 1 N9 0312-0002 NYLOCK NUT 11
217 0030-3908 PIN 2
218 029-0741 PIN WASHER 2
SP02 0399-6305 SPLIT PIN 2
BFC4 0312-0042 BOLT - C/SUNK 11
BHC1 0320-0062 BOLT - C/SUNK 3
93
K-97
OPTIONAL - STACKER OUTLET 02/01022016
94
K-98
95
K-99
193 0008-3002 STACKER OUTLET BRACKET 1 227 0118-0237 HYD COUPLER 1
219 4000-0101 BULKHEAD 1 228 4000-0247 NIPPLE REDUCER 3
220 4000-0501 45° SWIVEL ELBOW 1 229 0118-1115 HOSE 1
221 4000-0802 STRAIGHT SWIVEL 1 230 0013-5239 BRACKET SOCKET 1
222 0118-0230 HYD COUPLER 1 231 5900-0005 DEUTSCHE HOUSING 1
223 4000-0244 NIPPLE REDUCER 1 232 0118-2278 VALVE BLOCK 1
224 4000-0803 STRAIGHT SWIVEL 2 233 4000-0452 SWIVEL TEE 1
225 4000-0102 BULKHEAD 2 234 4000-0313 90° SWIVEL ELBOW 2
226 4000-0502 45° SWIVEL ELBOW 2 235 0118-2277 VALVE COIL 1
96
K-100
236 4104-0005 TEST POINT 1
237 0118-2276 RELIEF VALVE 1
BAP1 0305-0008 BOLT - PAN 4
BD2 0308-0025 BOLT 2
97
K-101
HQR1112
ISSUE: 01/2017

Section 2 – 1005‐0006 Primary Feeder GA

K-103
11.2.2 Feeder Outlet & Liners Assembly
K-104
11.2.3 Grizzly & Clamps Assembly
K-106
11.2.4 Feeder Mechanism Assembly
K-108
11.2.5 Drive Components Assembly
K-110

11.2.6 Blanking Plates Assembly
K-112

K-102
1005-0006 PRIMARY FEEDER GA ISSUE:
K-103
FEEDER OUTLET & LINERS ASSEMBLY 02/01022016
K-104
FEEDER OUTLET & LINERS ASSEMBLY 02/01022016
1 0005-1001 PRIMARY FEEDER 1 N11 0316-0002 NYLOCK NUT 42
2 0005-1008 FEEDER OUTLET 1 N13 0320-0005 NYLOCK NUT 28
3 0026-5001 FEEDER DEFLECTOR LINER - LH 1
4 0026-5008 FEEDER DEFLECTOR LINER - RH 1
5 0026-5015 FEEDER FLOOR LINER 1
BGC1 0316-0047 BOLT 42
BH4 0320-0055 BOLT 28
W11 0316-0004 FLAT WASHER 42
W13 0320-0009 FLAT WASHER 28
K-105
GRIZZLY & CLAMPS ASSEMBLY 02/01022016
K-106
GRIZZLY & CLAMPS ASSEMBLY 02/01022016
6 0005-5112 GRIZZLY CARTRIDGE 30-50 1
7 0005-0007 GRIZZLY CLAMP 4
BJ3 0324-0080 BOLT 4
BJB1 0324-0202 BOLT 4
W15 0324-0003 FLAT WASHER 16
N16 0324-0001 HEX NUT 8
K-107
FEEDER MECHANISM ASSEMBLY 02/01022016
K-108
FEEDER MECHANISM ASSEMBLY 02/01022016
8 1043-1208 FEEDER MECHANISM GA 1
BHB3 0320-0101 BOLT 16
W21 0320-0011 FLAT WASHER 32
NB15 0320-0082 HEX NUT 32
K-109
DRIVE COMPONENTS ASSEMBLY 02/01022016
K-110
9 0143-1501 COUPLING 1 BGH1 0316-0035 BOLT - CAP HEAD 6
10 0143-1502 COUPLING 1 W3 0306-0004 FLAT WASHER 2
11 0143-1503 COUPLING ELEMENT 1 W4 0306-0008 SPRING WASHER 2
12 0145-2002 TAPER LOCK 1 W9 0312-0006 FLAT WASHER 4
13 0013-6915 COUPLING COVER 1 W10 0312-0012 SPRING WASHER 4
14 0111-0802 MOTOR 1 W11 0316-0004 FLAT WASHER 6
15 0013-6922 COUPLING COVER PLATE 1 W12 0316-0009 SPRING WASHER 6
BC1 0306-0020 BOLT 2
BF8 0312-0055 BOLT 4
K-111
BLANKING PLATES ASSEMBLY 02/01022016
10
K-112
16 0026-5022 BLANKING PLATE - TOP 1
17 0026-5029 BLANKING PLATE - BOTTOM 1
BGC1 0316-0047 BOLT - C/SUNK 12
11
K-113
HQR1112
ISSUE: 01/2017

Section 3 – 1011‐1029 Hydraulic Tank Assembly

K-115
11.3.2 Suction Filter
K-116
11.3.3 Fluid Level Gauge, Air Filter & Return Filter
K-118
11.3.4 Inspection Door & Oil Seal
K-120

11.3.5 Hydraulic Fitting
K-122

K-114
1011-1029 HYDRAULIC TANK ASSEMBLY ISSUE:
K-115
SUCTION FILTER 01/01022016
K-116
SUCTION FILTER 01/01022016
1 0011-9043 HYDRAULIC TANK 1
2 0116-0005 SUCTION FILTER 2
3 0116-0004 SUCTION FILTER 1
K-117
1011-1029 HYDRAULIC TANK ASSEMBLY
ISSUE:
FLUID LEVEL GAUGE, AIR FILTER & RETURN
01/01022016
FILTER
K-118
1011-1029 HYDRAULIC TANK ASSEMBLY
ISSUE:
FLUID LEVEL GAUGE, AIR FILTER & RETURN
01/01022016
FILTER
6 0116-0006 RETURN FILTER HOUSING 2
7 0119-0900 FLUID LEVEL GAUGE 1
8 0116-0012 AIR FILTER 2
9 4000-0722 FITTING - MALE PLUG 2
BE4 0310-0030 BOLT 8
K-119
INSPECTION DOOR & OIL SEAL 01/01022016
K-120
INSPECTION DOOR & OIL SEAL 01/01022016
10 0011-9008 INSPECTION DOOR 2
11 3005-0024 OIL SEAL 2
BF7 0312-0052 BOLT 12
K-121
HYDRAULIC FITTING 01/01022016
K-122
HYDRAULIC FITTING 01/01022016
12 4000-0331 FITTING - 90° ELBOW 4
13 4000-1100 FITTING - 45° FLANGE ELBOW 2
14 0118-0833 FITTING - BALL VALVE 4
K-123
HQR1112
ISSUE: 01/2017

Section 4 – 1013‐0130 ‐ Main Conveyor GA

K-125
11.4.2 Frames Assembly
K-126
11.4.3 Take Up Support Assembly
K-128
11.4.4 Skirt Cover Assembly
K-130
11.4.5 Vee Scraper
K-132
11.4.6 Idler Frames & Rollers
K-134
11.4.7 Idler Frames, Rollers & Guard
K-136
11.4.8 Impact Bars & Impact Plate
K-139
11.4.9 Drums & Bearing Housings
K-141
11.4.10 Drive Components & Belt Assembly
K-143
11.4.11 Skirt Clamps & Inspection Hatches
K-145
11.4.12 Head Scrapper & Dust Suppression Components
K-149
11.4.13 Canvas Cover Bracket
K-151
11.4.14 Dust Cover Guards
K-153
11.4.15 Dust Cover
K-155

11.4.16 Speed Sensor
K-157

K-124
1013-0130 - MAIN CONVEYOR GA ISSUE:
K-125
FRAMES ASSEMBLY 01/01022016
K-126
FRAMES ASSEMBLY 01/01022016
1 0013-5183 CONVEYOR TAIL FRAME 1
2 0013-5169 CONVEYOR MIDDLE FRAME 1
3 0013-5177 CONVEYOR HEAD FRAME 1
4 0013-1502 BEARING SUPPORT 2
BG1 0316-0042 BOLT 4
BG2 0316-0045 BOLT 8
W11 0316-0004 FLAT WASHER 20
N11 0316-0002 NYLOCK NUT 8
K-127
TAKE UP SUPPORT ASSEMBLY 01/01022016
K-128
TAKE UP SUPPORT ASSEMBLY 01/01022016
5 0013-1000 TAKE UP SUPPORT 1 N11 0316-0002 NYLOCK NUT 4
6 0013-2049 TAKE UP SUPPORT 2
7 0013-2043 TAKE UP OUTER SLEEVE 2
8 0013-2743 TAKE UP ROD 2
9 0013-2736 TAKE UP ROD KEEP PLATE 4
BG2 0316-0045 BOLT 8
W11 0316-0004 FLAT WASHER 12
K-129
SKIRT COVER ASSEMBLY 01/01022016
K-130
SKIRT COVER ASSEMBLY 01/01022016
10 0013-6116 SKIRT COVER - LH 1
11 0013-6123 SKIRT COVER - RH 1
12 0013-0037 SKIRT COVER 2
BF4 0312-0035 BOLT 12
BF5 0312-0040 BOLT 8
N9 0312-0002 NYLOCK NUT 20
K-131
VEE SCRAPER 01/01022016
K-132
13 0013-3501 VEE SCRAPER 1
14 0013-3502 CLAMP PLATE 2
15 0013-3503 COUPLING PLATE 3
16 0167-0012 SKIRT RUBBER 1.4 m
BF6 0312-0045 BOLT 8
BF7 0312-0052 BOLT 6
N9 0312-0002 NYLOCK NUT 14
K-133
IDLER FRAMES & ROLLERS 01/01022016
10
K-134
17 0031-1223 IDLER FRAME 3 BE5 0310-0035 BOLT 8
18 0031-1206 IDLER FRAME 10 BF4 0312-0035 BOLT 52
19 0031-0303 SIDE GUIDE BRACKET 4 W7 0310-0005 FLAT WASHER 16
R1 0152-0191 ROLLER 10 W9 0312-0006 FLAT WASHER 104
R2 0150-0186 ROLLER 16 N7 0310-0001 NYLOCK NUT 8
R4 0150-0841 ROLLER 8
R5 0155-1850 ROLLER 4
BD1 0308-0020 BOLT 4
11
K-135
IDLER FRAMES, ROLLERS & GUARD 01/01022016
12
K-136
20 0031-0104 RETURN ROLLER BRACKET 8 R6 0152-1296 ROLLER 4
21 0013-8008 PACKER PLATE 2 R7 0152-0596 ROLLER 2
22 0013-8015 PACKER PLATE 2 BD1 0308-0020 BOLT 2
23 0031-0602 ROLLER BRACKET 2 BE5 0310-0035 BOLT 4
24 0031-2012 RETURN ROLLER FRAME - VEE 1 BF4 0312-0035 BOLT 12
25 0031-0601 RETAINER PLATE 4 BF6 0312-0045 BOLT 8
26 0031-0304 SIDE GUIDE BRACKET 2 BF8 0312-0055 BOLT 8
27 0013-6001 RETURN IDLER GUARD 2 W5 0308-0005 FLAT WASHER 8
R5 0155-1850 ROLLER 2 W7 0310-0005 FLAT WASHER 8
13
K-137
N9 0312-0002 NYLOCK NUT 28
14
K-138
IMPACT BARS & IMPACT PLATE 01/01022016
15
K-139
IMPACT BARS & IMPACT PLATE 01/01022016
28 0018-2071 IMPACT PLATE 1
29 0159-0100 IMPACT BAR 7
30 0159-0105 'T' BOLT 21
16
K-140
DRUMS & BEARING HOUSINGS 01/01022016
17
K-141
DRUMS & BEARING HOUSINGS 01/01022016
31 0014-1203 TAIL DRUM 1 N10 0312-0004 HEX NUT 2
32 0014-1204 HEAD DRUM 1 N13 0320-0005 NYLOCK NUT 8
33 1142-0011 BEARING HOUSING (FLOAT) 2
34 1142-0006 BEARING HOUSING (FIXED) 1
BF8 0312-0055 BOLT 2
BH9 0320-0080 BOLT 4
BH10 0320-0090 BOLT 4
W13 0320-0009 FLAT WASHER 16
18
K-142
DRIVE COMPONENTS & BELT ASSEMBLY 01/01022016
19
K-143
DRIVE COMPONENTS & BELT ASSEMBLY 01/01022016
36 0145-3003 TAPER LOCK 1 BE5 0310-0035 BOLT 3
37 0143-0030 COUPLING 1 BG6 0316-0065 BOLT 4
38 0145-3001 TAPER LOCK 1 BH10 0320-0090 BOLT 1
39 0013-6901 COUPLING COVER 1 W7 0310-0005 FLAT WASHER 7
40 0013-2001 TORQUE ARM 1 W8 0310-0004 SPRING WASHER 7
42 0013-6908 COUPLING COVER PLATE 1 W13 0320-0009 FLAT WASHER 2
43 0166-0005 CONVEYOR BELT 24 m N11 0316-0002 NYLOCK NUT 4
20
K-144
SKIRT CLAMPS & INSPECTION HATCHES 01/01022016
21
K-145
44 0026-1339 SKIRT CLAMP 3 53 0169-0007 DUST COVER CLIP 8
45 0026-1346 SKIRT CLAMP 1 54 3023-0001 BLIND RIVET 16
46 0026-1353 SKIRT CLAMP 1 55 0167-0010 SKIRT RUBBER 8m
47 0026-1360 SKIRT CLAMP 1 BE4 0310-0030 BOLT 18
48 0026-1367 SKIRT CLAMP 1 BFC2 0312-0047 BOLT - C/SUNK 18
49 0026-1375 SKIRT CLAMP 1 W7 0310-0005 FLAT WASHER 18
50 0026-1332 SKIRT CLAMP 1 W8 0310-0004 SPRING WASHER 18
51 0013-6813 INSPECTION PLATE 7
22
K-146
23
K-147
44 0026-1339 SKIRT CLAMP 3 53 0169-0007 DUST COVER CLIP 8
45 0026-1346 SKIRT CLAMP 1 54 3023-0001 BLIND RIVET 16
46 0026-1353 SKIRT CLAMP 1 55 0167-0010 SKIRT RUBBER 8m
47 0026-1360 SKIRT CLAMP 1 BE4 0310-0030 BOLT 18
48 0026-1367 SKIRT CLAMP 1 BFC2 0312-0047 BOLT - C/SUNK 18
49 0026-1375 SKIRT CLAMP 1 W7 0310-0005 FLAT WASHER 18
50 0026-1332 SKIRT CLAMP 1 W8 0310-0004 SPRING WASHER 18
24
K-148
1013-0130 - MAIN CONVEYOR GA
ISSUE:
HEAD SCRAPPER & DUST SUPPRESSION
01/01022016
COMPONENTS
25
K-149
1013-0130 - MAIN CONVEYOR GA
ISSUE:
HEAD SCRAPPER & DUST SUPPRESSION
01/01022016
COMPONENTS
56 0013-3019 HEAD SCRAPER 1 65 0301-0001 FITTING - SWAGE 1
57 0169-0210 RUBBER BLADE 6 UB1 0107-0050 U-BOLT 2
58 0149-0001 TENSIONER 2 BF4 0312-0035 BOLT 4
59 0013-4002 SPRAY BAR SUPPORT - LH 1 BF5 0312-0040 BOLT 4
60 0013-4001 SPRAY BAR SUPPORT - RH 1 BFC2 0312-0047 BOLT - C/SUNK 12
61 0010-9036 SPRINKLER BAR 1 W9 0312-0006 FLAT WASHER 24
62 0349-0008 CLIP EYELET AND THREADED BALL 2 W10 0312-0012 SPRING WASHER 4
63 0349-0011 NOZZLE 2 N9 0312-0002 NYLOCK NUT 16
64 0301-0002 FITTING - 90 ELBOW 1
26
K-150
CANVAS COVER BRACKET 01/01022016
27
K-151
CANVAS COVER BRACKET 01/01022016
66 0013-8715 CANVAS COVER BRACKET 4
BF4 0312-0035 BOLT 8
28
K-152
DUST COVER GUARDS 01/01022016
29
K-153
DUST COVER GUARDS 01/01022016
67 0013-7537 DUST COVER GUARD 1
BE4 0310-0030 BOLT 28
30
K-154
DUST COVER 01/01022016
31
K-155
DUST COVER 01/01022016
73 N/A DUST COVER KIT 1
32
K-156
SPEED SENSOR 01/01022016
33
K-157
SPEED SENSOR 01/01022016
74 1013-8120 SPEED SENSOR 1
34
K-158
HQR1112
ISSUE: 01/2017

Section 5 – 1013‐0141 ‐ Transfer Conveyor Assembly

K-160
11.5.2 Conveyor & Take Up Frame
K-161
11.5.3 Vee Scraper
K-163
K-165
11.5.5 Drums & Bearing Housing
K-167
11.5.6 Conveyor Belt & Skirt Covers
K-169

11.5.7 Hydraulic Motor Assembly
K-171

K-159
1013-0141 - TRANSFER CONVEYOR
ISSUE:
ASSEMBLY
01/01022016
GENERAL ARRANGEMENT
K-160
ISSUE:
ASSEMBLY
01/01022016
CONVEYOR & TAKE UP FRAME
K-161
ISSUE:
ASSEMBLY
01/01022016
CONVEYOR & TAKE UP FRAME
1 0012-2659 CONVEYOR 1
2 0012-1015 TAKE UP FRAME 2
N14 0320-0008 HEX NUT 4
K-162
ISSUE:
ASSEMBLY
01/01022016
VEE SCRAPER
K-163
ISSUE:
ASSEMBLY
01/01022016
VEE SCRAPER
3 0013-3678 VEE SCRAPER 1 N9 0312-0002 NYLOCK NUT 6
4 0027-1614 CLAMP PLATE 2
6 0167-0005 SKIRT RUBBER 0.7M
BE6 0310-0040 BOLT 4
BF7 0312-0052 BOLT 6
K-164
ISSUE:
ASSEMBLY
01/01022016
IDLER FRAMES & ROLLERS
K-165
ISSUE:
ASSEMBLY
01/01022016
IDLER FRAMES & ROLLERS
7 0031-0501 IDLER FRAME 6 W7 0310-0005 FLAT WASHER 16
9 0031-0344 SIDE GUIDE BRACKET 2 N7 0310-0001 NYLOCK NUT 8
R2 0155-1850 ROLLER 4
BD1 0308-0020 BOLT 4
BE4 0310-0030 BOLT 4
BE5 0310-0035 BOLT 4
BF4 0312-0035 BOLT 24
K-166
ISSUE:
ASSEMBLY
01/01022016
DRUMS & BEARING HOUSING
K-167
ISSUE:
ASSEMBLY
01/01022016
DRUMS & BEARING HOUSING
10 0014-4800 TAIL DRUM 1
11 0014-4797 HEAD DRUM 1
12 0142-9010 BEARING HOUSING 4
BG5 0316-0060 BOLT 8
W11 0316-0004 FLAT WASHER 16
N11 0316-0002 NYLOCK NUT 8
K-168
ISSUE:
ASSEMBLY
01/01022016
CONVEYOR BELT & SKIRT COVERS
10
K-169
ISSUE:
ASSEMBLY
01/01022016
CONVEYOR BELT & SKIRT COVERS
13 0012-2178 SKIRT COVER - LH 1 BE5 0310-0035 BOLT 20
14 0012-2171 SKIRT COVER - RH 1 BF3 0312-0030 BOLT 2
15 0027-1593 CLAMP PLATE 4 BF5 0312-0040 BOLT 3
16 0027-1607 CLAMP PLATE 1 W7 0310-0005 FLAT WASHER 37
17 0012-2686 SPILLAGE BRACKET 1 W8 0310-0004 SPRING WASHER 37
18 0166-4011 CONVEYOR BELT 8M W9 0312-0006 FLAT WASHER 8
19 0167-0007 SKIRT RUBBER 5.0m W10 0312-0012 SPRING WASHER 2
20 0166-4011 DUST CURTAIN 1 N9 0312-0002 NYLOCK NUT 3
BE3 0310-0025 BOLT 17
11
K-170
ISSUE:
ASSEMBLY
01/01022016
HYDRAULIC MOTOR ASSEMBLY
12
K-171
ISSUE:
ASSEMBLY
01/01022016
HYDRAULIC MOTOR ASSEMBLY
21 0111-4001 HYDRAULIC MOTOR 1 W7 0310-0005 FLAT WASHER 4
25 0145-2501 TAPER LOCK 1 N9 0312-0002 NYLOCK NUT 2
26 0145-2506 TAPER LOCK 1 N13 0320-0005 NYLOCK NUT 1
BE5 0310-0035 BOLT 4
BH10 0320-0090 BOLT 1
13
K-172
HQR1112
ISSUE: 01/2017

Section 6 – 1013‐0146 Return Conveyor Assembly

K-174
11.6.2 Truss Assembly
K-175
11.6.3 Idler Frame & Rollers
K-177
11.6.4 Vee Scrapper
K-181
11.6.5 Drums & Bearings
K-183
11.6.6 Drive Unit & Conveyor Belt
K-185
11.6.7 Skirt Covers
K-187
11.6.8 Guard & Covers
K-189
11.6.9 Slide Rail Support & Guard
K-191

11.6.10 Discharge Chute
K-193

K-173
1013-0146 RETURN CONVEYOR ASSEMBLY ISSUE:
K-174
TRUSS ASSEMBLY 01/01022016
K-175
1 0012-2219 HEAD TRUSS 1
2 0012-2226 TAIL TRUSS 1
BG2 0316-0045 BOLT 8
W11 0316-0004 FLAT WASHER 16
N11 0316-0002 NYLOCK NUT 8
K-176
IDLER FRAME & ROLLERS 01/01022016
K-177
3 0031-0501 IDLER FRAME 14 N7 0310-0001 NYLOCK NUT 4
R1 0150-0275 ROLLER 28
R2 0155-1850 ROLLER 2
BD1 0308-0020 BOLT 2
BE5 0310-0035 BOLT 4
BF4 0312-0035 BOLT 56
W9 0312-0006 FLAT WASHER 112
K-178
K-179
6 0031-0104 RETURN ROLLER BRACKET 6 N7 0310-0001 NYLOCK NUT 4
7 0006-4120 RETURN IDLER GUARD 2 N9 0312-0002 NYLOCK NUT 20
R2 0155-1850 ROLLER 2
R3 0152-0545 ROLLER 3
BD1 0308-0020 BOLT 2
BE4 0310-0035 BOLT 4
BF4 0312-0030 BOLT 20
K-180
VEE SCRAPPER 01/01022016
K-181
VEE SCRAPPER 01/01022016
11 0167-0005 SKIRT RUBBER 0.7m
BE6 0310-0040 BOLT 4
BF7 0312-0052 BOLT 6
K-182
DRUMS & BEARINGS 01/01022016
10
K-183
DRUMS & BEARINGS 01/01022016
12 0014-0551 HEAD DRUM 1 W11 0316-0004 FLAT WASHER 12
13 0014-0550 TAIL DRUM 1 W13 0320-0009 FLAT WASHER 8
14 0012-2533 BEARING KEEPER - LH 1 W15 0324-0003 FLAT WASHER 4
15 0012-2540 BEARING KEEPER - RH 1 N11 0316-0002 NYLOCK NUT 6
16 0142-9210 BEARING HOUSING 2 N13 0320-0005 NYLOCK NUT 4
17 0142-9010 BEARING HOUSING 2 N16 0324-0001 HEX NUT 6
18 0910-0025 TAKE UP - ROD 2
BG2 0316-0045 BOLT 6
BH6 0320-0065 BOLT 4
11
K-184
DRIVE UNIT & CONVEYOR BELT 01/01022016
12
K-185
DRIVE UNIT & CONVEYOR BELT 01/01022016
19 0145-2506 TAPER LOCK 2 BG6 0316-0065 BOLT 4
20 0143-0025 COUPLING 1 BH10 0320-0090 BOLT 1
24 0012-2150 COUPLING COVER PLATE 1 W13 0320-0009 FLAT WASHER 2
25 0166-4011 CONVEYOR BELT 20m N11 0316-0002 NYLOCK NUT 4
BCE1 0310-0021 BOLT - C/SUNK 3
13
K-186
SKIRT COVERS 01/01022016
14
K-187
SKIRT COVERS 01/01022016
11 0167-0005 SKIRT RUBBER 18m BFC1 0312-0036 BOLT - C/SUNK 36
26 0006-4115 SKIRT COVER 1 W7 0310-0005 FLAT WASHER 72
27 0006-4100 SKIRT COVER 2 W8 0310-0004 SPRING WASHER 72
28 0006-4086 SKIRT COVER 1
29 0006-4108 SKIRT COVER 1
30 0006-4093 SKIRT COVER 1
31 0012-2268 CLAMP PLATE 2
32 0012-2275 CLAMP PLATE 10
BE3 0310-0025 BOLT 72
15
K-188
GUARD & COVERS 01/01022016
16
K-189
GUARD & COVERS 01/01022016
33 0012-2547 BEARING GUARD 2
34 0006-4730 TAIL GUARD 1
35 0006-4739 UNDER TAIL GUARD 1
36 0006-4742 UPPER TAIL GUARD 1
BE4 0310-0030 BOLT 20
17
K-190
SLIDE RAIL SUPPORT & GUARD 01/01022016
18
K-191
SLIDE RAIL SUPPORT & GUARD 01/01022016
37 0020-0092 SLIDE RAIL SUPPORT 1
38 0006-4733 SIDE GUARD 1
BE3 0310-0025 BOLT 4
BF4 0312-0035 BOLT 18
N9 0312-0002 NYLOCK NUT 18
19
K-192
DISCHARGE CHUTE 01/01022016
20
K-193
DISCHARGE CHUTE 01/01022016
TRANSFER DISCHARGE CHUTE

39 1019-0198 1
ASSEMBLY
BE3 0310-0025 BOLT 6
21
K-194
HQR1112
ISSUE: 01/2017

Section 7 – 1013‐0150 ‐ Fines Conveyor Assembly

K-196
11.7.2 Truss & Take‐Up Support
K-197
11.7.3 Idler Frame & Roller
K-199
11.7.4 Vee Scraper
K-203
11.7.5 Drum & Bearing Assembly
K-205
11.7.6 Head Scraper
K-207
11.7.7 Drive Components
K-209
11.7.8 Clamp Plate Assembly
K-211
11.7.9 Tail Guards Assembly
K-215

11.7.10 Under Guard Assembly
K-217

K-195
1013-0150 - FINES CONVEYOR ASSEMBLY ISSUE:
K-196
TRUSS & TAKE-UP SUPPORT 01/01022016
K-197
TRUSS & TAKE-UP SUPPORT 01/01022016
1 0012-2002 CONVEYOR TRUSS 1 W11 0316-0004 FLAT WASHER 20
2 0013-1000 TAKE UP SUPPORT 1 W12 0316-0009 SPRING WASHER 4
3 0012-2009 TAKE UP SUPPORT 2 N11 0316-0002 NYLOCK NUT 8
4 0013-2046 TAKE UP SLEEVE 2
5 0013-2743 TAKE UP ROD 2
6 0013-2736 TAKE UP ROD KEEP PLATE 4
BG1 0316-0042 BOLT 8
BG2 0316-0045 BOLT 4
K-198
IDLER FRAME & ROLLER 01/01022016
K-199
7 0031-1206 IDLER FRAME 5 W9 0312-0006 FLAT WASHER 40
R2 0150-0841 ROLLER 5
R3 0155-1850 ROLLER 2
BD1 0308-0020 BOLT 2
BE5 0310-0035 BOLT 4
BF4 0312-0035 BOLT 20
K-200
K-201
9 0031-0104 RETURN ROLLER BRACKET 2 W9 0312-0006 FLAT WASHER 16
11 0013-6001 RETURN IDLER GUARD 1 N9 0312-0002 NYLOCK NUT 8
R3 0155-1850 ROLLER 2
R4 0152-1296 ROLLER 1
BD1 0308-0020 BOLT 2
BE5 0310-0035 BOLT 4
BF4 0312-0035 BOLT 8
K-202
K-203
13 0027-4185 CLAMP PLATE 2
15 0167-0005 SKIRT RUBBER 1.4 m
BE6 0310-0040 BOLT 6
BF7 0312-0052 BOLT 6
K-204
DRUM & BEARING ASSEMBLY 01/01022016
10
K-205
DRUM & BEARING ASSEMBLY 01/01022016
16 0014-1203 TAIL DRUM 1 W14 0320-0012 SPRING WASHER 2
17 0014-1204 HEAD DRUM 1 N10 0312-0004 HEX NUT 2
18 1142-0011 BEARING HOUSING (FLOAT) 2 N13 0320-0005 NYLOCK NUT 6
BF8 0312-0055 BOLT 2
BH8 0320-0075 BOLT 4
BH9 0320-0080 BOLT 4
W13 0320-0009 FLAT WASHER 14
11
K-206
HEAD SCRAPER 01/01022016
12
K-207
HEAD SCRAPER 01/01022016
21 0166-0005 CONVEYOR BELT 13m
22 0013-3019 HEAD SCRAPER 1
23 0169-0210 RUBBER BLADE 6
24 0149-0001 TENSIONER 2
BF5 0312-0040 BOLT 4
BFC2 0312-0047 BOLT - C/SUNK 12
N9 0312-0002 NYLOCK NUT 16
13
K-208
DRIVE COMPONENTS 01/01022016
14
K-209
25 0145-3003 TAPER LOCK 1 BG6 0316-0065 BOLT 4
26 0143-0030 COUPLING 1 BH10 0320-0090 BOLT 1
28 0013-6901 COUPLING COVER 1 W8 0310-0004 SPRING WASHER 7
29 0013-2001 TORQUE ARM 1 W11 0316-0004 FLAT WASHER 8
31 0013-6908 COUPLING COVER PLATE 1 N11 0316-0002 NYLOCK NUT 4
BE5 0310-0035 BOLT 3
15
K-210
CLAMP PLATE ASSEMBLY 01/01022016
16
K-211
32 0012-2065 FRONT PLATE 1 W8 0310-0004 SPRING WASHER 10
34 0027-1948 CLAMP PLATE 4 W10 0312-0012 SPRING WASHER 2
35 0006-4724 INSPECTION HATCH 5
36 0167-0007 SKIRT RUBBER 4m
BE3 0310-0025 BOLT 10
BF5 0312-0040 BOLT 2
BFC4 0312-0042 BOLT - C/SUNK 12
17
K-212
18
K-213
34 0027-1948 CLAMP PLATE 4
BE3 0310-0025 BOLT 10
19
K-214
TAIL GUARDS ASSEMBLY 01/01022016
20
K-215
TAIL GUARDS ASSEMBLY 01/01022016
37 0006-4709 TAIL GUARD 1
38 0006-4712 TAIL GUARD COVER PLATE 1
BE4 0310-0030 BOLT 8
21
K-216
UNDER GUARD ASSEMBLY 01/01022016
22
K-217
UNDER GUARD ASSEMBLY 01/01022016
39 0006-4715 UNDER GUARD 1 W7 0310-0005 FLAT WASHER 9
40 0006-4721 SWING GUARD LOCK 1 W8 0310-0004 SPRING WASHER 9
41 0006-4718 SWING GUARD 1 N5 0308-0003 NYLOCK NUT 16
42 0260-0101 HINGE STRAP 4
43 0260-0103 HINGE RH 2
44 0260-0102 HINGE LH 2
BD2 0308-0025 BOLT 16
BE4 0310-0030 BOLT 9
23
K-218
HQR1112
ISSUE: 01/2017

Section 8 – 1013‐9001 Side Conveyor GA

K-220
11.8.2 Truss Assembly
K-221
11.8.3 Vee Scraper Assembly
K-223
K-225
11.8.5 Drums & Bearing Units
K-227
11.8.6 Conveyor Belt, Skirt & Return Roller Cover
K-229
11.8.7 Drive Components
K-231

11.8.8 Head Scrapper & Cylinder
K-233

K-219
1013-9001 SIDE CONVEYOR GA ISSUE:
K-220
K-221
1 0012-1162 HEAD TRUSS 1 W10 0312-0012 SPRING WASHER 2
2 0012-1155 TAIL TRUSS 1 W13 0320-0009 FLAT WASHER 4
3 0012-1015 TAKE-UP SUPPORT 2 N14 0320-0008 HEX NUT 4
4 0012-1043 TRANSPORT BRACKET 1
5 0030-3912 PIVOT PIN 2
6 0029-0642 PIN WASHER 2
SP02 0399-6305 SPLIT PIN 2
BF4 0312-0035 BOLT 2
K-222
VEE SCRAPER ASSEMBLY 01/01022016
K-223
VEE SCRAPER ASSEMBLY 01/01022016
7 0012-1169 VEE SCRAPER 1
BE6 0310-0040 BOLT 12
N7 0310-0001 NYLOCK NUT 12
K-224
K-225
11 0031-0104 RETURN ROLLER BRACKET 2 N9 0312-0002 NYLOCK NUT 4
12 0031-0651 IDLER FRAME 6
R1 0150-0291 ROLLER 12
R2 0152-0697 RETURN ROLLER 1
BE5 0310-0035 BOLT 24
BF4 0312-0035 BOLT 4
N7 0310-0001 NYLOCK NUT 24
K-226
DRUMS & BEARING UNITS 01/01022016
K-227
DRUMS & BEARING UNITS 01/01022016
13 0014-0651 HEAD DRUM 1
14 0014-0658 TAIL DRUM 1
15 0142-9010 PILLOW BLOCK 4
BG5 0316-0060 BOLT 8
W11 0316-0004 FLAT WASHER 16
N11 0316-0002 NYLOCK NUT 8
K-228
1013-9001 SIDE CONVEYOR GA
ISSUE:
CONVEYOR BELT, SKIRT & RETURN ROLLER
01/01022016
COVER
10
K-229
1013-9001 SIDE CONVEYOR GA
ISSUE:
CONVEYOR BELT, SKIRT & RETURN ROLLER
01/01022016
COVER
16 0012-1064 SKIRT COVER - RH 1 25 0166-3001 CONVEYOR BELT 10m
17 0012-1057 SKIRT COVER - LH 1 BE3 0310-0025 BOLT 16
18 0012-1071 INSPECTION COVER 4 BF3 0312-0030 BOLT 22
19 0012-1078 SKIRT COVER 2 W7 0310-0005 FLAT WASHER 16
20 0012-1085 SKIRT COVER - RH 1 W8 0310-0004 SPRING WASHER 16
21 0012-1086 SKIRT COVER - LH 1 W9 0312-0006 FLAT WASHER 26
22 0012-1092 SKIRT COVER 1 W10 0312-0012 SPRING WASHER 18
23 0012-1099 SKIRT COVER 1 N9 0312-0002 NYLOCK NUT 4
24 0006-4078 RETURN IDLER GUARD 1
11
K-230
12
K-231
27 0145-2505 TAPER LOCK 1 W8 0310-0004 SPRING WASHER 4
30 0012-1050 TORQUE ARM 1 N9 0312-0002 NYLOCK NUT 4
31 0111-1601 MOTOR 1 N13 0320-0005 NYLOCK NUT 1
BE3 0310-0025 BOLT 4
BFC5 0312-0060 BOLT 4
BH10 0320-0090 BOLT 1
13
K-232
HEAD SCRAPPER & CYLINDER 01/01022016
14
K-233
HEAD SCRAPPER & CYLINDER 01/01022016
10 0167-0005 RUBBER 0.7m
32 0012-1120 HEAD SCRAPPER 1
33 0012-1127 CLAMP PLATE 1
34 0149-0001 TENSIONER 2
35 0110-0256 HYDRAULIC CYLINDER 1
BF5 0312-0040 BOLT 4
BF6 0312-0045 BOLT 4
15
K-234
HQR1112
ISSUE: 01/2017

Section 9 – 1015‐0012 ‐ Engine Canopy Assembly

K-236
11.9.2 Engine Sub Frame & Cover Plate
K-237
11.9.3 Pressure Filter & Clutch Support
K-239
11.9.4 Engine, Clutch & Pump
K-241
11.9.5 Circuit Breaker & Frame Assembly
K-244
11.9.6 Air Cleaner Fitting Assembly
K-246
11.9.7 Exhaust Fitting Assembly
K-248
11.9.8 Rear Door Assembly
K-250
11.9.9 Door Panels Assembly
K-252
11.9.10 Radiator Cover & Inspection Hatch
K-256
11.9.11 Clutch Door
K-258

11.9.12 Clamp Plate & Turbo Precleaner
K-260

K-235
1015-0012
1015-0012 - 1112- ENGINE CANOPY
ISSUE:
ASSEMBLY
01/01022016
GENERAL ARRANGEMENT
K-236
1015-0012 - 1112
1015-0012 - ENGINE CANOPY
ISSUE:
ASSEMBLY
01/01022016
ENGINE SUB FRAME & COVER PLATE
K-237
1015-0012 - 1112
ISSUE:
ASSEMBLY
01/01022016
ENGINE SUB FRAME & COVER PLATE
1 0009-1015 ENGINE SUB FRAME 1
2 0009-2031 COVER PLATE 1
BF2 0312-0025 BOLT 2
BF4 0312-0035 BOLT 13
K-238
1015-0012 - 1112
ISSUE:
ASSEMBLY
01/01022016
PRESSURE FILTER & CLUTCH SUPPORT
K-239
1015-0012
- 1112
ISSUE:
ASSEMBLY
01/01022016
PRESSURE FILTER & CLUTCH SUPPORT
7 0009-2017 COVER PLATE 1 W8 0310-0004 SPRING WASHER 12
8 0009-0011 PRESSURE FILTER SUPPORT 1 W9 0312-0006 FLAT WASHER 8
9 0116-0031 PRESSURE FILTER 2 W11 0316-0004 FLAT WASHER 16
10 0009-1022 CLUTCH SUPPORT 2 N9 0312-0002 NYLOCK NUT 4
BF5 0312-0040 BOLT 4
BG1 0316-0042 BOLT 4
BG3 0316-0050 BOLT 4
K-240
1015-0012 - 1112
ISSUE:
ASSEMBLY
01/01022016
ENGINE, CLUTCH & PUMP
K-241
1015-0012 - 1112
ISSUE:
ASSEMBLY
01/01022016
11 0101-0001 ENGINE 1 BH4 0320-0055 BOLT 12
12 0113-0741 PUMP 2 BQ4 0313-0011 BOLT 8
13 0102-0012 CLUTCH 1 BQ5 0311-0002 BOLT 6
14 0009-1049 FUEL FILTER SUPPORT 1 W3 0306-0004 FLAT WASHER 4
15 5120-0001 SOLENOID 1 W5 0308-0005 FLAT WASHER 4
BCP2 0306-0031 BOLT - PAN HEAD 2 W10 0312-0012 SPRING WASHER 14
BD3 0308-0030 BOLT 2 W11 0316-0004 FLAT WASHER 16
BG3 0316-0050 BOLT 4 W13 0320-0009 FLAT WASHER 24
BG4 0316-0056 BOLT 4 N3 0306-0003 NYLOCK NUT 2
K-242
1015-0012 - 1112
ISSUE:
ASSEMBLY
01/01022016
N11 0316-0002 NYLOCK NUT 8
N13 0320-0005 NYLOCK NUT 12
K-243
1015-0012 - 1112
ISSUE:
ASSEMBLY
01/01022016
CIRCUIT BREAKER & FRAME ASSEMBLY
K-244
1015-0012 - 1112
ISSUE:
ASSEMBLY
01/01022016
CIRCUIT BREAKER & FRAME ASSEMBLY
16 0015-4502 CANOPY MAIN FRAME 1 W2 0305-0005 FLAT WASHER 2
17 0015-4508 CANOPY SUB FRAME 1 W9 0312-0006 FLAT WASHER 8
18 0015-4651 CLUTCH COVER 1 W11 0316-0004 FLAT WASHER 20
19 0009-3127 MOUNT BRACKET 1 N9 0312-0002 NYLOCK NUT 4
20 5111-0080 CIRCUIT BREAKER 1 N11 0316-0002 NYLOCK NUT 10
BBP1 0305-0030 BOLT - PAN HEAD 2
BF4 0312-0035 BOLT 4
BG1 0316-0042 BOLT 8
BG9 0316-0090 BOLT 2
10
K-245
1015-0012
1015-0012 - 1112- ENGINE CANOPY
ISSUE:
ASSEMBLY
01/01022016
AIR CLEANER FITTING ASSEMBLY
DETAIL C
11
K-246
1015-0012 - 1112- ENGINE CANOPY
1015-0012
ISSUE:
ASSEMBLY
01/01022016
AIR CLEANER FITTING ASSEMBLY
21 0101-2001 AIR CLEANER MOUNT 1 BE5 0310-0035 BOLT 2
22 0107-0022 T-BOLT CLAMP 1 W7 0310-0005 FLAT WASHER 10
23 0107-0027 RUBBER REDUCER 1 W8 0310-0004 SPRING WASHER 2
24 0107-0021 T-BOLT CLAMP 1 N7 0310-0001 NYLOCK NUT 4
25 0107-0005 RUBBER INSERT 1
26 0107-0010 FITTING - 90° BEND PIPE 1
27 0107-0017 T-BOLT CLAMP 2
28 0107-0003 FITTING RUBBER 45° 1
BE4 0310-0030 BOLT 4
12
K-247
1015-0012 - 1112- ENGINE CANOPY
1015-0012
ISSUE:
ASSEMBLY
01/01022016
EXHAUST FITTING ASSEMBLY
13
K-248
1015-0012
1015-0012 - 1112- ENGINE CANOPY
ISSUE:
ASSEMBLY
01/01022016
EXHAUST FITTING ASSEMBLY
29 0107-0018 LAP JOINT CLAMP 4
30 0107-0127 FLEXIBLE EXHAUST PIPE 1
31 0107-0004 FITTING - 90° BEND PIPE 2
32 0107-0023 CLAMP MUFFLER 2
33 0107-0024 MUFFLER 1
34 0107-0001 RAIN CAP 1
BE4 0310-0030 BOLT 4
14
K-249
1015-0012 - 1112- ENGINE CANOPY
1015-0012 ISSUE:
ASSEMBLY
01/01022016
REAR DOOR ASSEMBLY
DETAIL F
15
K-250
1015-0012 - 1112- ENGINE CANOPY
1015-0012
ISSUE:
ASSEMBLY
01/01022016
REAR DOOR ASSEMBLY
35 0015-4615 REAR DOOR 1
36 0260-0100 HINGE 3
37 0260-0205 CATCH WITH PLATE 2
38 0260-0223 GAS STRUT 2
39 3023-0001 BLIND RIVET 8
BC8 0306-0073 BOLT 24
N3 0306-0003 NYLOCK NUT 24
16
K-251
1015-0012 - 1112- ENGINE CANOPY
1015-0012
ISSUE:
ASSEMBLY
01/01022016
DOOR PANELS ASSEMBLY
17
K-252
1015-0012 - 1112
ISSUE:
ASSEMBLY
01/01022016
40 0015-4703 DOOR PANEL SUPPORT 1 BD7 0308-0070 BOLT 12
41 0015-4601 DOOR PANEL 2 BE3 0310-0025 BOLT 4
43 0260-0102 HINGE - LH 3 W5 0308-0005 FLAT WASHER 24
44 0260-0103 HINGE - RH 3 W7 0310-0005 BOLT 8
45 0260-0101 HINGE STRAP 6 N2 0305-0001 NYLOCK NUT 12
46 0260-0001 DOOR LOCK 3 N5 0308-0003 NYLOCK NUT 24
BD2 0308-0025 BOLT 12
18
K-253
1015-0012 - 1112- ENGINE CANOPY
1015-0012
ISSUE:
ASSEMBLY
01/01022016
19
K-254
1015-0012 - 1112
ISSUE:
ASSEMBLY
01/01022016
40 0015-4703 DOOR PANEL SUPPORT 1 BD7 0308-0070 BOLT 12
41 0015-4601 DOOR PANEL 2 BE3 0310-0025 BOLT 4
43 0260-0102 HINGE - LH 3 W5 0308-0005 FLAT WASHER 24
44 0260-0103 HINGE - RH 3 W7 0310-0005 BOLT 8
45 0260-0101 HINGE STRAP 6 N2 0305-0001 NYLOCK NUT 12
46 0260-0001 DOOR LOCK 3 N5 0308-0003 NYLOCK NUT 24
BD2 0308-0025 BOLT 12
20
K-255
1015-0012 - 1112- ENGINE CANOPY
1015-0012
ISSUE:
ASSEMBLY
01/01022016
RADIATOR COVER & INSPECTION HATCH
21
K-256
1015-0012 - 1112- ENGINE CANOPY
1015-0012
ISSUE:
ASSEMBLY
01/01022016
RADIATOR COVER & INSPECTION HATCH
47 0015-4009 INSPECTION HATCH 1 W9 0312-0006 FLAT WASHER 16
48 0260-0104 HINGE 1 W10 0312-0012 SPRING WASHER 16
49 0015-4425 RADIATOR COVER 1 N3 0306-0003 NYLOCK NUT 4
BC1 0306-0020 BOLT 4
BE3 0310-0026 BOLT 1
BF11 0312-0075 BOLT 16
22
K-257
1015-0012
1015-0012 - 1112- ENGINE CANOPY
ISSUE:
ASSEMBLY
01/01022016
CLUTCH DOOR
23
K-258
1015-0012 - 1112- ENGINE CANOPY
1015-0012 ISSUE:
ASSEMBLY
01/01022016
CLUTCH DOOR
50 0015-4658 DOOR PANEL - LH 1
51 0015-4665 DOOR PANEL - RH 1
BE3 0310-0025 BOLT 8
24
K-259
1015-0012 - 1112
ISSUE:
ASSEMBLY
01/01022016
CLAMP PLATE & TURBO PRECLEANER
25
K-260
1015-0012 - 1112- ENGINE CANOPY
1015-0012
ISSUE:
ASSEMBLY
01/01022016
CLAMP PLATE & TURBO PRECLEANER
52 0027-1614 CLAMP PLATE 2
53 0167-0005 SKIRT RUBBER 0.8M
54 0116-0116 TURBO PRECLEANER 1
BE5 0310-0035 BOLT 4
26
K-261
HQR1112
ISSUE: 01/2017

Section 10 ‐ 1016‐9001 Fuel Tank GA

K-263

11.10.2 Fuel Tank Assembly
K-264

K-262
1016-9001 FUEL TANK GA ISSUE:
K-263
K-264
1 0016-9001 FUEL TANK 1 W9 0312-0006 FLAT WASHER 36
4 0016-9022 DROP TUBE 3
5 0105-0001 FUEL CAP 1
6 0105-0003 ADAPTOR 1
7 0105-0002 STRAINER 1
8 0016-9036 BLANKING PLATE 1
BF4 0312-0035 BOLT 36
K-265
K-266
10 0301-0007 PLUG 1
K-267
HQR1112
ISSUE: 01/2017

Section 11– 1018‐0007 ‐ Discharge Hopper Assembly

K-269
11.11.2 Hopper, Door & Support Legs
K-270
11.11.3 Liners
K-272
11.11.4 Impact Arm Plate
K-277
11.11.5 Impact Liners Assembly
K-279

11.11.6 Skirt Clamps Assembly
K-281

K-268
1018-0007-
1018-0007 - 1112 DISCHARGE HOPPER
ISSUE:
ASSEMBLY
01/01022016
GENERAL ARRANGEMENT
K-269
1018-0007-
ISSUE:
ASSEMBLY
01/01022016
HOPPER, DOOR & SUPPORT LEGS
K-270
1018-0007-
ISSUE:
ASSEMBLY
01/01022016
HOPPER, DOOR & SUPPORT LEGS
1 0018-2003 DISCHARGE HOPPER 1 N11 0316-0002 NYLOCK NUT 8
2 0018-2030 INSPECTION DOOR 1 N13 0320-0005 NYLOCK NUT 2
3 0018-2009 SUPPORT LEG 4 N16 0324-0001 HEX NUT 2
BG2 0316-0045 BOLT 8
BH7 0320-0070 BOLT 2
W11 0316-0004 FLAT WASHER 16
K-271
1018-0007-
ISSUE:
ASSEMBLY
01/01022016
LINERS
K-272
1018-0007-
ISSUE:
ASSEMBLY
01/01022016
LINERS
4 0026-1138 LINER - LH 1 BFC1 0312-0036 BOLT - C/SUNK 32
5 0026-1134 LINER - RH 1 W9 0312-0006 FLAT WASHER 32
7 0026-1126 LINER 2
8 0026-1123 LINER - LH 1
9 0026-1119 LINER - RH 1
10 0026-1102 LINER - ROCK LEDGE 4
K-273
1018-0007-
ISSUE:
ASSEMBLY
01/01022016
LINERS
K-274
1018-0007-
ISSUE:
ASSEMBLY
01/01022016
LINERS
13 0026-1087 LINER 2 22 0026-1044 LINER - LH 1
14 0026-1079 LINER - RH 1 23 0026-1040 LINER - RH 1
15 0026-1083 LINER - LH 1 24 0026-1036 LINER - LH 1
16 0026-1075 LINER - LH 1 25 0026-1032 LINER - RH 1
17 0026-1071 LINER - RH 1 26 0026-1028 LINER - LH 1
18 0026-1064 LINER - RH 1 27 0026-1024 LINER - RH 1
19 0026-1068 LINER - RH 1 28 0026-1020 LINER - LH 1
20 0026-1052 LINER - LH 1 29 0026-1016 LINER - RH 1
21 0026-1048 LINER - RH 1 30 0026-1114 LINER 1
K-275
1018-0007-
ISSUE:
ASSEMBLY
01/01022016
LINERS
31 0026-1011 LINER - LH 1
32 0026-1007 LINER - RH 1
33 0026-1059 LINER 1
34 0026-1055 LINER 1
BFC1 0312-0036 BOLT - C/SUNK 72
N9 0312-0002 NYLOCK NUT 81
K-276
1018-0007-
ISSUE:
ASSEMBLY
01/01022016
IMPACT ARM PLATE
K-277
1018-0007- ISSUE:
ASSEMBLY
01/01022016
IMPACT ARM PLATE
35 0018-2017 IMPACT ARM TOP 1
36 0018-2023 IMPACT ARM BOTTOM 1
BG2 0316-0045 BOLT 4
BGC1 0316-0047 BOLT - C/SUNK 6
W11 0316-0004 FLAT WASHER 14
N11 0316-0002 NYLOCK NUT 10
10
K-278
1018-0007-
ISSUE:
ASSEMBLY
01/01022016
IMPACT LINERS ASSEMBLY
11
K-279
1018-0007-
ISSUE:
ASSEMBLY
01/01022016
IMPACT LINERS ASSEMBLY
37 0026-1143 IMPACT LINER 5 W13 0320-0009 FLAT WASHER 38
38 0026-1142 IMPACT LINER 5 W14 0320-0012 SPRING WASHER 20
39 0026-1003 HOPPER ROCK LEDGE 1 N13 0320-0005 NYLOCK NUT 10
40 0026-1110 LINER - LH 1
41 0026-1106 LINER - RH 1
BH1 0320-0040 BOLT 15
BH3 0320-0050 BOLT 5
BH5 0320-0060 BOLT 8
12
K-280
1018-0007-
ISSUE:
ASSEMBLY
01/01022016
SKIRT CLAMPS ASSEMBLY
13
K-281
1018-0007-
ISSUE:
ASSEMBLY
01/01022016
SKIRT CLAMPS ASSEMBLY
42 0027-1339 SKIRT CLAMP 6
43 0027-1360 SKIRT CLAMP 1
44 0027-1346 SKIRT CLAMP WEDGE 14
45 0260-0214 GRIP CLIP 14
46 0169-0101 APRON SEAL 6m
47 0167-0010 RUBBER 6m
14
K-282
HQR1112
ISSUE: 01/2017

Section 12– 1019‐0036 Fines Chute Assembly

K-284
11.12.2 Flop Gate Assembly
K-285
11.12.3 Inspection Door & Backing Plate
K-287
11.12.4 Clamp Plates & Dust Seal
K-289

11.12.5 Blanking Plate ‐ Optional
K-291

K-283
1019-0036 1112 FINES CHUTE ASSEMBLY ISSUE:
K-284
FLOP GATE ASSEMBLY 01/01022016
K-285
FLOP GATE ASSEMBLY 01/01022016
1 0018-1002 FINES CHUTE 1 BF6 0312-0045 BOLT 4
2 0018-0022 FLOP GATE 1 W5 0308-0005 FLAT WASHER 1
5 0018-0008 HANDLE LOCK 1 N5 0308-0003 NYLOCK NUT 1
6 0018-0029 FLOP GATE HANDLE 1 N7 0310-0001 NYLOCK NUT 1
BD6 0308-0060 BOLT 1 N9 0312-0002 NYLOCK NUT 4
BE5 0310-0035 BOLT 1
BE6 0310-0040 BOLT 2
K-286
INSPECTION DOOR & BACKING PLATE 01/01022016
K-287
INSPECTION DOOR & BACKING PLATE 01/01022016
7 0018-0015 INSPECTION DOOR 1
8 0260-0202 FASTENER ANTILUCE 4
K-288
CLAMP PLATES & DUST SEAL 01/01022016
K-289
CLAMP PLATES & DUST SEAL 01/01022016
9 0018-1010 SIDE ACCESS PANEL - LH 1 W7 0310-0005 FLAT WASHER 58
10 0018-1017 SIDE ACCESS PANEL - RH 1 W8 0310-0004 SPRING WASHER 14
11 0018-1031 CLAMP PLATE - LH 1 N7 0310-0001 NYLOCK NUT 22
12 0018-1024 CLAMP PLATE - RH 1
13 0018-1043 CLAMP PLATE 2
14 0018-1037 CLAMP PLATE 2
15 0166-0005 RUBBER 5m
BE4 0310-0030 BOLT 14
BE7 0310-0050 BOLT 22
K-290
BLANKING PLATE - OPTIONAL 01/01022016
K-291
BLANKING PLATE - OPTIONAL 01/01022016
BE5 0310-0035 BOLT 12
N7 0310-0001 NYLOCK NUT 12
K-292
HQR1112
ISSUE: 01/2017

Section 13– 1019‐0041 Fines Chute Lower Section

K-294

11.13.2 Dust Curtain & Skirt Clamp Assembly
K-295

K-293
1019-0041 FINES CHUTE LOWER SECTION ISSUE:
K-294
DUST CURTAIN & SKIRT CLAMP ASSEMBLY 01/01022016
K-295
DUST CURTAIN & SKIRT CLAMP ASSEMBLY 01/01022016
1 0019-2100 FINES CHUTE 1 W7 0310-0005 FLAT WASHER 6
2 0027-2050 SIDE SKIRT CLAMP 4 N7 0310-0001 NYLOCK NUT 3
3 0027-2043 REAR SKIRT CLAMP 1
4 0027-0001 SKIRT WEDGE 10
6 0019-2115 RUBBER CURTAIN 1
8 0260-0214 GRIP CLIP 10
BE7 0310-0050 BOLT 3
K-296
HQR1112
ISSUE: 01/2017

Section 14– 1019‐0198 Transfer Discharge Chute Assembly

K-298
11.14.2 Discharge Chute & Inspection Hatch
K-299
11.14.3 Clamp Plates
K-301

11.14.4 Skirt Clamp
K-303

K-297
1019-0198 TRANSFER DISCHARGE CHUTE
ISSUE:
ASSEMBLY
01/01022016
GENERAL ARRANGEMENT
K-298
ISSUE:
ASSEMBLY
01/01022016
DISCHARGE CHUTE & INSPECTION HATCH
K-299
ISSUE:
ASSEMBLY
01/01022016
DISCHARGE CHUTE & INSPECTION HATCH
1 0019-1347 DISCHARGE CHUTE 1
BE6 0310-0040 BOLT 3
K-300
ISSUE:
ASSEMBLY
01/01022016
CLAMP PLATES
K-301
ISSUE:
ASSEMBLY
01/01022016
CLAMP PLATES
BF5 0312-0040 BOLT 8
K-302
ISSUE:
ASSEMBLY
01/01022016
SKIRT CLAMP
K-303
ISSUE:
ASSEMBLY
01/01022016
SKIRT CLAMP
7 0027-1976 SKIRT CLAMP 1
8 0027-1542 SKIRT WEDGE 2
9 0260-0214 GRIP CLIP 2
K-304
HQR1112
ISSUE: 01/2017

Section 15– 1035‐9001 Magnet Hydraulic Drive GA

K-306
11.15.2 Frame, Magnet, Drum & Bearing Assembly
K-307
11.15.3 Bracket & Motor Assembly
K-309

11.15.4 Guards Assembly
K-311

K-305
1035-9001 MAGNET HYDRAULIC DRIVE GA ISSUE:
K-306
1035-9001 MAGNET HYDRAULIC DRIVE GA
ISSUE:
FRAME,MAGNET,DRUM & BEARING
01/13012016
ASSEMBLY
K-307
1035-9001 MAGNET HYDRAULIC DRIVE GA
ISSUE:
FRAME,MAGNET,DRUM & BEARING
01/13012016
ASSEMBLY
1 0035-9001 MAGNET FRAME 1 W9 0312-0006 FLAT WASHER 4
2 0035-9057 BEARING ADJUSTER 2 W11 0316-0004 FLAT WASHER 16
3 0142-0130 BEARING HOUSING 4 W13 0320-0009 FLAT WASHER 8
4 0035-9050 SUPPORT PLATE 2 N10 0312-0004 HEX NUT 4
5 0035-0002 MAGNET 1 N11 0316-0002 NYLOCK NUT 8
6 0014-0751 HEAD DRUM 1 N13 0320-0005 NYLOCK NUT 4
7 0014-0752 TAIL DRUM 1
BG6 0316-0065 BOLT 8
BH6 0320-0065 BOLT 4
K-308
BRACKET & MOTOR ASSEMBLY 01/13012016
K-309
BRACKET & MOTOR ASSEMBLY 01/15042014
11 0145-1616 TAPERLOCK 1 W11 0316-0004 FLAT WASHER 2
12 0035-9022 TORQUE ARM 1 N9 0312-0002 NYLOCK NUT 4
13 0111-4004 HYDRAULIC MOTOR 1 N11 0316-0002 NYLOCK NUT 1
BC2 0306-0030 BOLT 4
BF8 0312-0055 BOLT 4
BG10 0316-0100 BOLT 1
K-310
K-311
14 0035-9008 SIDE GUARD LH 1
15 0035-9015 SIDE GUARD RH 1
16 0166-9001 BELT 1
17 0320-0001 EYE BOLT 2
BG1 0316-0042 BOLT 6
W11 0316-0004 FLAT WASHER 12
N11 0316-0002 NYLOCK NUT 6
N13 0320-0005 NYLOCK NUT 2
K-312
HQR1112
ISSUE: 01/2017

Section 16– 1042‐0001 ‐ 1112 Impactor GA

K-314
11.16.2 Top Fixed Assembly
K-315
11.16.3 Rotor Assembly
K-317

11.16.4 Lid, Safety & Maintenance Components
K-319

K-313
1042-0001 - 1112 IMPACTOR GA ISSUE:
K-314
TOP FIXED ASSEMBLY 01/01022016
K-315
TOP FIXED ASSEMBLY 01/01022016
1 1042-0006 IMPACTOR BASE GA 1
2 1042-0011 IMPACTOR TOP FIXED GA 1
BG6 0316-0065 BOLT 17
W11 0316-0004 FLAT WASHER 34
N11 0316-0002 NYLOCK NUT 17
K-316
ROTOR ASSEMBLY 01/01022016
K-317
3 201200 BLOW BAR 4 W10 0312-0012 SPRING WASHER 1
4 0042-4329 LIFTING FRAME 1 W11 0316-0004 FLAT WASHER 32
5 200252 BLOW BAR CLAMP - RH 8 N11 0316-0002 NYLOCK NUT 16
6 200251 BLOW BAR CLAMP - LH 8
7 1100-10017 ROTOR LOCK 1
BF5 0312-0040 BOLT 1
BG14 0316-0120 BOLT 16
BJ2 0324-0070 BOLT 2
K-318
1042-0001 - 1112 IMPACTOR GA
ISSUE:
LID, SAFETY & MAINTENANCE
01/01022016
COMPONENTS
K-319
1042-0001 - 1112 IMPACTOR GA
ISSUE:
LID, SAFETY & MAINTENANCE
01/01022016
COMPONENTS
8 1042-0016 IMPACTOR LID GA 1 SP04 0399-1010 SPLIT PIN 2
9 0118-0297 HYDRAULIC CYLINDER 2 BBH2 0305-0070 BOLT - CAP HEAD 2
10 0042-4315 CYLINDER LOCKING BRACKET 2 BD5 0308-0050 BOLT 1
11 0042-4322 SPACER PLATE 1 W2 0305-0005 FLAT WASHER 2
12 5900-0023 LIMIT SWITCH 1 N2 0305-0001 NYLOCK NUT 2
13 5900-0024 LIMIT SWITCH HEAD 1 N6 0308-0002 HEX NUT 1
14 0030-6524 PIN 2
15 0029-1268 WASHER 4
16 0029-1268 SPANNER 1
K-320
HQR1112
ISSUE: 01/2017

Section 17– 1042‐0006 ‐ Impactor ‐ Base

K-322
11.17.2 Inspection Door & Locking Components
K-323
11.17.3 Wear Plates
K-325
11.17.4 Rotor Assembly
K-327
11.17.5 Bearing Housing Assembly
K-329
11.17.6 Spindle & Hydraulic Components
K-335

11.17.7 Impact Arm Assembly
K-337

K-321
1042-0006 - 1112 IMPACTOR - BASE ISSUE:
K-322
1042-0006 - 1112 IMPACTOR - BASE
ISSUE:
INSPECTION DOOR & LOCKING
01/15042014
COMPONENTS
K-323
1042-0006 - 1112 IMPACTOR - BASE
ISSUE:
01/15042014
COMPONENTS
1 0042-2064 CRUSHER BASE 1
2 70070100 INSPECTION DOOR 2
3 1001253 PIN 4
4 10010504 PIN 2
5 0029-0631 PIN WASHER 12
6 0030-1230 TOGGLE BOLT 2
7 0030-1215 TOGGLE NUT 2
SP02 0399-6305 SPLIT PIN 12
K-324
WEAR PLATES 01/15042014
K-325
8 15100 WEAR PLATE 45 W14 0320-0012 SPRING WASHER 8
9 15102 WEAR PLATE 2 N13 0320-0005 NYLOCK NUT 102
10 15103 WEAR PLATE 4
BH4 0320-0055 BOLT 8
BH5 0320-0060 BOLT 98
BH6 0320-0065 BOLT 4
W13 0320-0009 FLAT WASHER 110
K-326
K-327
13 0042-2036 ROTOR SHAFT 1
14 0042-2057 ROTOR 1
15 0042-2001 RING FEEDER SEAL 4
16 0144-0190 RING FEEDER 2
17 0900-0009 KEY STEEL 1
K-328
BEARING HOUSING ASSEMBLY 01/15042014
DETAIL C
DETAIL A
BEARING HOUSING - DRIVE SIVE
DETAIL D
K-329
18 1100-106 OUTER LABYRITH 1 27 1100-114 LIFTING EYE 1
19 1100-107 INNER LABYRITH 1 28 1100-113 GREASE NIPPLE 3
20 1100-109 SPACING RING 2 BGH4 0316-0068 BOLT - CAP HEAD 14
21 1100-102 ADAPTOR SLEEVE 1 W11 0316-0004 FLAT WASHER 14
22 1100-101 BEARING 1 W12 0316-0009 SPRING WASHER 14
23 1100-104 BEARING HOUSING 1 RG30 0316-0033 GRUB SCREW 4
24 1100-108 INNER LABYRITH 1
25 1100-103 SEAL 1
26 1100-105 OUTER LABYRITH 1
K-330
DETAIL C
DETAIL B
BEARING HOUSING - NON DRIVE
DETAIL D DETAIL E
10
K-331
18 1100-106 OUTER LABYRITH 1 28 0300-0152 GREASE NIPPLE 3
19 1100-107 INNER LABYRITH 1 29 1100-110 SHAFT END COVER 1
21 1100-102 ADAPTOR SLEEVE 1 BGH4 0316-0068 BOLT - CAP HEAD 14
22 1100-101 BEARING 1 W11 0316-0004 FLAT WASHER 14
23 1100-104 BEARING HOUSING 1 W12 0316-0009 SPRING WASHER 14
24 1100-108 INNER LABYRITH 1 RG30 0316-0033 GRUB SCREW 4
25 1100-103 SEAL 1
26 1100-105 OUTER LABYRITH 1
27 0320-0001 LIFTING EYE 1
11
K-332
12
K-333
30 0042-4210 BEARING CLAMP 4 W11 0316-0004 FLAT WASHER 12
31 0042-2022 SHAFT SEAL - LH 1 W12 0316-0009 SPRING WASHER 12
32 0042-2029 SHAFT SEAL - RH 1 W13 0320-0009 FLAT WASHER 16
33 0042-2008 SHAFT COVER - TOP 2 W26 0330-0010 SPRING WASHER 4
34 0042-2015 SHAFT COVER - BOTTOM 2 W27 0330-0014 FLAT WASHER 8
35 0142-0497 FELT SEAL 2 N13 0320-0005 NYLOCK NUT 8
BG1 0316-0042 BOLT 12 N18 0330-0005 HEX NUT 4
BH15 0320-0150 BOLT 8 0330-0011 HEX NUT 4
BKB5 0330-0380 BOLT 4
13
K-334
SPINDLE & HYDRAULIC COMPONENTS 01/15042014
14
K-335
SPINDLE & HYDRAULIC COMPONENTS 01/15042014
36 0042-4448 SPINDLE 1 45 0110-0467 HYDRAULIC CYLINDER 2
37 0042-4105 SPINDLE BRACKET 1 BF8 0312-0055 BOLT 4
38 0042-4091 SPINDLE NUT 1 BF13 0312-0110 BOLT 1
39 0042-4399 SPINDLE COVER 1 BH1 0320-0040 BOLT 16
40 0042-4098 NUT LOCKING PLATE 1 W9 0312-0006 FLAT WASHER 26
41 0042-4119 RUBBER BOOT 2 W13 0320-0009 FLAT WASHER 16
42 0042-4035 CYLINDER MOUNT BRACKET 4 W14 0320-0012 SPRING WASHER 16
43 0042-4042 BUSH 4 N9 0312-0002 NYLOCK NUT 21
44 0042-4112 CLAMP PLATE 4
15
K-336
IMPACT ARM ASSEMBLY 01/15042014
16
K-337
46 1042-0021 BOTTOM IMPACT ARM 1
47 0042-4161 END CAP 2
48 0042-4364 PIN 1
49 0042-4126 COVER PLATE 2
50 0042-4357 PIN 1
BF5 0312-0040 BOLT 8
17
K-338
HQR1112
ISSUE: 01/2017

Section 18– 1042‐0011 ‐ 1112 Impactor ‐ Fixed

K-340
11.18.2 Locking Components
K-341
11.18.3 Wear Plates
K-343

11.18.4 Dust Curtains Assembly
K-345

K-339
1042-0011 - 1112 IMPACTOR - FIXED ISSUE:
K-340
LOCKING COMPONENTS 01/01022016
K-341
LOCKING COMPONENTS 01/01022016
1 0042-2043 IMPACTOR TOP FIXED 1 BG5 0316-0060 BOLT 13
2 0042-5007 TOP COVER 1 W9 0312-0006 FLAT WASHER 2
3 0042-4133 LOCKING SEAL 2 W10 0312-0012 SPRING WASHER 2
4 0030-1157 TOGGLE BOLT 4 W11 0316-0004 FLAT WASHER 26
5 0004-3101 PIN 4 N11 0316-0002 NYLOCK NUT 13
6 0029-0631 PIN WASHER 8
7 10010503 LOCKING NUT 4
SP02 0399-6305 SPLIT PIN 8
BF5 0312-0040 BOLT 2
K-342
K-343
WEAR PLATE 01/01022016
8 15100 WEAR PLATE 30 BH3 0320-0050 BOLT 12
11 15121 WEAR PLATE 2 W13 0320-0009 FLAT WASHER 122
12 15122 WEAR PLATE 2 W14 0320-0012 SPRING WASHER 36
BH1 0320-0040 BOLT 18
K-344
DUST CURTAINS ASSEMBLY 01/01022016
K-345
DUST CURTAINS ASSEMBLY 01/01022016
17 0002-1407 CHAIN BRACKET 1 W8 0310-0004 SPRING WASHER 8
18 0002-1414 CHAIN HOLDER 4 W11 0316-0004 FLAT WASHER 20
19 0251-3501 CHAIN LINK - 700mm 16 N11 0316-0002 NYLOCK NUT 10
20 070017A DUST CURTAIN 1
21 070017B DUST CURTAIN 1
BE4 0310-0030 BOLT 8
BG4 0316-0056 BOLT 5
BG6 0316-0065 BOLT 5
K-346
HQR1112
ISSUE: 01/2017

Section 19 – 1042‐0016 ‐ 1112 Impactor ‐ Hinged

K-348
11.19.2 Inspection Door & Locking Components
K-349
11.19.3 Wear Plates
K-351
11.19.4 Spindle Assembly
K-355
11.19.5 Hydraulic Cylinder Assembly
K-357
11.19.6 Impact Arm Assembly
K-359
11.19.7 Impact Arm Lock & Cover
K-361

11.19.8 Accumulator
K-363

K-347
1042-0016 - 1112 IMPACTOR - HINGED ISSUE:
K-348
1042-0016 - 1112 IMPACTOR - HINGED
ISSUE:
01/15042014
COMPONENTS
K-349
1042-0016 - 1112 IMPACTOR - HINGED
ISSUE:
01/15042014
COMPONENTS
1 0042-2050 CRUSHER LID 1 10 0030-1215 TOGGLE NUT 3
2 0042-1233 LOCKING BRACKET 1 SP02 0399-6305 SPLIT PIN 20
3 70072100 INSPECTION DOOR 2
4 1001253 PIN 4
5 10010504 PIN 3
6 0030-3123 PIN 2
9 0029-0631 PIN WASHER 20
K-350
K-351
BH5 0320-0060 BOLT 24
BH6 0320-0065 BOLT 2
W13 0320-0009 FLAT WASHER 26
N13 0320-0005 NYLOCK NUT 26
K-352
K-353
BH3 0320-0050 BOLT 8
BH5 0320-0060 BOLT 24
BH6 0320-0065 BOLT 2
W13 0320-0009 FLAT WASHER 34
K-354
SPINDLE ASSEMBLY 01/15042014
K-355
SPINDLE ASSEMBLY 01/15042014
15 0042-4434 TOP SPINDLE 1 W9 0312-0006 FLAT WASHER 20
16 0042-4441 CENTER SPINDLE 1 N9 0312-0002 NYLOCK NUT 10
17 0042-4105 SPINDLE BRACKET 2
18 0042-4098 NUT LOCKING PLATE 2
19 0042-4091 SPINDLE NUT 2
20 0042-4427 SPINDLE COVER 1
21 0042-4420 SPINDLE COVER CENTRE 1
BF13 0312-0110 BOLT 2
BF8 0312-0055 BOLT 8
K-356
HYDRAULIC CYLINDER ASSEMBLY 01/15042014
10
K-357
HYDRAULIC CYLINDER ASSEMBLY 01/15042014
22 0110-0465 HYDRAULIC CYLINDER 2 W14 0320-0012 SPRING WASHER 32
23 0110-0466 HYDRAULIC CYLINDER 2 N9 0312-0002 NYLOCK NUT 32
24 0042-4035 CYLINDER MOUNT BRACKET 8
25 0042-4042 BUSH 8
26 0042-4112 CLAMP PLATE 8
27 0042-4119 RUBBER BOOT 4
BH1 0320-0040 BOLT 32
W13 0320-0009 FLAT WASHER 32
11
K-358
12
K-359
28 1042-0031 IMPACT ARM - TOP 1
29 1042-0026 IMPACT ARM - CENTRE 1
30 0042-4357 IMPACT ARM - PIVOT PIN 2
31 0042-4126 COVER PLATE 4
BF5 0312-0040 BOLT 16
13
K-360
IMPACT ARM LOCK & COVER 01/15042014
14
K-361
IMPACT ARM LOCK & COVER 01/15042014
33 0042-4161 IMPACT ARM END CAP 4
34 0042-4364 IMPACT ARM CENTER PIN 2
BF5 0312-0040 BOLT 16
15
K-362
ACCUMULATOR 01/15042014
16
K-363
ACCUMULATOR 01/15042014
35 0118-0279 ACCUMULATOR 1
36 0042-2099 ACCUMULATOR BRACKET 1
BF6 0312-0045 BOLT 4
BF8 0312-0055 BOLT 4
17
K-364
HQR1112
ISSUE: 01/2017

Section 20– 1042‐0021 Impact Arm ‐ Bottom

K-366

11.20.2 Impact Arm & Impact Plate
K-367

K-365
1042-0021 IMPACT ARM - BOTTOM ISSUE:
K-366
IMPACT ARM & IMPACT PLATE 01/01022016
K-367
1 0042-4371 BOTTOM IMPACT ARM 1 W27 0330-0014 FLAT WASHER 36
2 90111 IMPACT PLATE 12 W28 0330-0015 SPRING WASHER 36
3 90211 IMPACT PLATE 3 NB15 0320-0082 HEX NUT 6
4 0026-0520 IMPACT PLATE 2 N18 0330-0005 HEX NUT 24
5 0330-0145 STUD BOLT 24 0330-0011 HEX HALT NUT 24
BKB2 0330-0090 BOLT 12
K-368
HQR1112
ISSUE: 01/2017

Section 21– 1042‐0026 Impact Arm ‐ Centre

K-370

K-371

K-369
1042-0026 IMPACT ARM - CENTRE ISSUE:
K-370
K-371
1 0042-4455 CENTER IMPACT ARM 1 W27 0330-0014 FLAT WASHER 30
5 0330-0145 STUD BOLT 18 0330-0011 HEX NUT 18
BKB2 0330-0090 BOLT 12
K-372
HQR1112
ISSUE: 01/2017

Section 22– 1042‐0031 Impact Arm ‐ Top

K-374

K-375

K-373
1042-0031 IMPACT ARM - TOP ISSUE:
K-374
K-375
1 1112-90290 TOP IMPACT ARM 1 W27 0330-0014 FLAT WASHER 42
5 0330-0145 STUD BOLT 30 0330-0011 HEX NUT 30
BKB2 0330-0090 BOLT 12
K-376
HQR1112
ISSUE: 01/2017

Section 23– 1043‐1208 LFM1200 Feeder Mechanism

K-378
11.23.2 Main Frame & Shaft Assembly
K-379
11.23.3 Shaft Assembly
K-383
11.23.4 Gear Assembly
K-387

11.23.5 Cover Assembly
K-389

K-377
1043-1208 LFM1200 FEEDER MECHANISM ISSUE:
K-378
MAIN FRAME & SHAFT ASSEMBLY 01/01022016
K-379
1 0043-2001 MAIN FRAME 1 BJB3 0324-0240 BOLT 6
2 0043-1251 DRIVE SHAFT 1 W10 0312-0012 SPRING WASHER 6
3 0043-5010 IMBALANCED WEIGHT 1 W12 0316-0009 SPRING WASHER 13
4 0043-2201 BEARING HOUSING - LH 1 N17 0324-0002 NYLOCK NUT 6
5 0142-0015 BEARING 1
6 0043-2238 BEARING KEEPER PLATE 1
7 0043-8011 WEIGHT BOLT LOCKER 3
BFH1 0312-0026 BOLT- CAP HEAD 6
BGH4 0316-0068 BOLT - CAP HEAD 13
K-380
K-381
3 0043-5010 IMBALANCED WEIGHT 1 W10 0312-0012 SPRING WASHER 6
6 0043-2238 BEARING KEEPER PLATE 1 N17 0324-0002 NYLOCK NUT 6
7 0043-8011 WEIGHT BOLT LOCKER 3
8 0043-1250 NON-DRIVE SHAFT 1
9 0043-2203 BEARING HOUSING - RH 1
BJB3 0324-0240 BOLT 6
K-382
SHAFT ASSEMBLY 01/01022016
K-383
4 0043-2201 BEARING HOUSING - LH 1 W10 0312-0012 SPRING WASHER 6
10 0043-2286 SPLASHER PLATE 1
11 0043-8006 SPLASHER LOCKING PLATE 1
12 0043-8001 SPLASHER BOLT LOCKER 1
BGB1 0316-0041 BOLT - BLACK 2
K-384
K-385
5 0142-0015 BEARING 1
9 0043-2203 BEARING HOUSING - RH 1
K-386
GEAR ASSEMBLY 01/01022016
10
K-387
GEAR ASSEMBLY 01/01022016
13 0043-2234 SPACING RING 2 BGB4 0316-0066 BOLT 12
14 0043-2267 LOCKING BUSH 2 W10 0312-0012 SPRING WASHER 4
15 0043-9010 GEAR RH 1 W12 0316-0009 SPRING WASHER 12
16 0043-9003 GEAR LH 1
17 0043-8003 GEAR BUSH BOLT LOCKER 6
18 0043-8004 GEAR LOCK PLATE 2
19 0043-8005 GEAR BOLT LOCKER 2
20 0028-1659 KEY STEEL 2
BFB1 0312-0038 BOLT 4
11
K-388
COVER ASSEMBLY 01/01022016
12
K-389
21 0043-6001 OUTER COVER - NON DRIVE 1
22 0119-0005 SIGHT GLASS 1
23 0116-0090 BREATHER 1
24 0301-0007 FITTING - PLUG 1
13
K-390
14
K-391
23 0116-0090 BREATHER 1 BFH2 0312-0031 BOLT- CAP HEAD 24
24 0301-0007 FITTING - PLUG 1 W6 0308-0004 SPRING WASHER 24
25 0043-6003 OUTER COVER - DRIVE SIDE 1 W10 0312-0012 SPRING WASHER 24
26 0142-0390 SPEEDY SLEEVE 1
27 0149-0002 CIRCLIP 1
28 0142-0613 SEAL 1
29 0043-2245 SHAFT SEAL HOUSING 1
30 KEY STEEL 1
BDH2 0308-0031 BOLT- CAP HEAD 6
15
K-392
16
K-393
31 0116-0090 BREATHER 1
BF2 0312-0025 BOLT 28
17
K-394
HQR1112
ISSUE: 01/2017

Section 24– 1045‐1002 Screen Section Assembly

11.24.01
K-396
11.24.02
11.23.7 Fines Conveyor & Support Frame
K-397
11.24.03
11.23.8 Jack Leg Assembly
K-399
11.24.04
11.23.9 Spill Plates
K-401
11.24.05
11.23.10 Clamp Plates
K-403
11.24.06
11.23.11
Screen Box, Spring Mount Base, Compression Spring & Locking

Plate K-405

11.24.07
11.23.12 Jack Legs Assembly
K-407

K-395
1045-1002 SCREEN SECTION ASSEMBLY ISSUE:
K-396
FINES CONVEYOR & SUPPORT FRAME 01/01022016
K-397
FINES CONVEYOR & SUPPORT FRAME 01/01022016
1 1013-0150 FINES CONVEYOR ASSEMBLY 1 SP03 0399-6308 SPLIT PIN 2
3 0020-4125 SUPPORT BRACKET 2
4 0030-4910 PIN 2
5 0029-0750 PIN WASHER 2
6 0030-3002 PIN 2
7 0030-3023 PIN 2
8 0029-0532 PIN WASHER 4
SP02 0399-6305 SPLIT PIN 4
K-398
JACK LEG ASSEMBLY 01/01022016
K-399
JACK LEG ASSEMBLY 01/01022016
7 0030-3023 PIN 2
8 0029-0532 PIN WASHER 4
9 0023-3606 INNER JACK LEG 2
10 0023-3613 JACK LEG PAD 2
11 0010-0271 CYLINDER 2
12 0030-3001 PIN 2
SP02 0399-6305 SPLIT PIN 4
K-400
SPILL PLATES 01/01022016
K-401
SPILL PLATES 01/01022016
13 0012-2380 SPILL PLATE 1
14 0012-2387 SPILL PLATE 1
BE4 0310-0030 BOLT 12
BE6 0310-0040 BOLT 2
K-402
CLAMP PLATES 01/01022016
K-403
CLAMP PLATES 01/01022016
15 0027-1962 CLAMP PLATE 4
16 0027-1600 CLAMP PLATE 2
BE4 0310-0030 BOLT 16
BE5 0310-0035 BOLT 12
N7 0310-0004 NYLOCK NUT 12
K-404
1045-1002 SCREEN SECTION ASSEMBLY
ISSUE:
SCREEN BOX, SPRING MOUNT BASE,
01/01022016
COMPRESSION SPRING & LOCKING PLATE
10
K-405
1045-1002 SCREEN SECTION ASSEMBLY
ISSUE:
SCREEN BOX, SPRING MOUNT BASE,
01/01022016
COMPRESSION SPRING & LOCKING PLATE
18 1045-1007 SCREEN BOX GA ASSEMBLY 1
19 0045-1029 SPRING MOUNT BASE 8
20 0190-0032 COMPRESSION SPRING 8
21 0020-4533 LOCKING PLATE 4
BF5 0312-0040 BOLT 16
BF17 0312-0080 BOLT 8
11
K-406
JACK LEGS ASSEMBLY 01/01022016
12
K-407
JACK LEGS ASSEMBLY 01/01022016
22 0023-3620 JACK LEG 2
23 0030-3023 PIN 2
24 0030-3003 PIN 2
25 0029-0532 PIN WASHER 4
SP02 0399-6305 SPLIT PIN 4
13
K-408
HQR1112
ISSUE: 01/2017

Section 25– 1045‐1007 Screen Box Assembly

11.25.01
K-410
11.25.02
11.23.14 Frame Assembly
K-411
11.25.03
11.23.15 Spring Mount Base & Grease Extension Nipple
K-413
11.25.04
11.23.16 Drive & Counter Weight
K-415
11.25.05
11.23.17 Counter Weight Cover & Clamps
K-417

11.25.06
11.23.18 Hydraulic Motor
K-424

K-409
1045-1007 SCREEN BOX ASSEMBLY ISSUE:
K-410
FRAME ASSEMBLY 01/01022016
K-411
FRAME ASSEMBLY 01/01022016
1 0045-1128 SIDE WALL - RH 1 10 0045-1190 BACKING PLATE - RH 1
2 0045-1121 SIDE WALL - LH 1 11 0020-4590 FRONT SPRING MOUNT - RH 1
3 0045-1141 FRONT PLATE 1 12 0012-4576 REAR SPRING MOUNT - RH 1
4 0045-1134 REAR PLATE 1 13 0045-1183 BACKING PLATE - LH 1
5 0045-1148 TOP DECK FRAME 1 14 0020-4583 FRONT SPRING MOUNT - LH 1
6 0045-1155 BOTTOM DECK FRAME 1 15 0020-4569 REAR SPRING MOUNT - LH 1
7 0045-1225 SHAFT HOUSING 1
8 0045-1169 FEED TRAY 1
9 0045-1162 DISCHARGE TRAY 1
K-412
1045-1007 SCREEN BOX ASSEMBLY
ISSUE:
SPRING MOUNT BASE & GREASE
01/01022016
EXTENSION NIPPLE
K-413
1045-1007 SCREEN BOX ASSEMBLY
ISSUE:
SPRING MOUNT BASE & GREASE
01/01022016
EXTENSION NIPPLE
16 0045-1029 SPRING MOUNT BASE 8 N11 0316-0002 NYLOCK NUT 156
BF4 0312-0035 BOLT 15
BF17 0312-0080 BOLT 8
BG1 0316-0042 BOLT 114
BG2 0316-0045 BOLT 6
BG3 0316-0050 BOLT 36
W11 0316-0004 FLAT WASHER 312
N9 0312-0002 NYLOCK NUT 23
K-414
DRIVE & COUNTER WEIGHT 01/01022016
K-415
17 0045-1043 SCREEN SHAFT 1 26 0145-2509 TAPER LOCK 1
18 0142-0018 BEARING 1 27 0045-1099 GREASE EXTENSION NIPPLE 1
19 0045-1176 OUTER BEARING HOUSING 1 28 0900-0012 KEY STEEL 1
20 0142-0480 OIL SEAL 1 BF7 0312-0052 BOLT 6
21 0045-1267 SPACER 1 BF14 0312-0130 BOLT 3
22 0045-1218 VIBRATOR WEIGHT 1 W9 0312-0006 FLAT WASHER 12
23 0045-1211 ADD-ON VIBRATOR WEIGHT - 20mm 3 W10 0312-0012 SPRING WASHER 6
24 0045-1204 ADD-ON VIBRATOR WEIGHT - 10mm 1 N9 0312-0002 NYLOCK NUT 3
25 0045-1197 ADD-ON VIBRATOR WEIGHT - 6mm 1
K-416
K-417
18 0142-0018 BEARING 1 28 0900-0012 KEY STEEL 1
19 0045-1176 OUTER BEARING HOUSING 1 29 0045-1274 SPACER 1
20 0142-0480 OIL SEAL 1 30 0045-1260 LOCKING PLATE 1
22 0045-1218 VIBRATOR WEIGHT 1 BE5 0310-0035 BOLT 2
23 0045-1211 ADD-ON VIBRATOR WEIGHT - 20mm 3 BF7 0312-0052 BOLT 6
24 0045-1204 ADD-ON VIBRATOR WEIGHT - 10mm 1 BF14 0312-0130 BOLT 3
25 0045-1197 ADD-ON VIBRATOR WEIGHT - 6mm 1 W7 0310-0005 FLAT WASHER 2
27 0045-1099 GREASE EXTENSION NIPPLE 1 W9 0312-0006 FLAT WASHER 12
K-418
10
K-419
COUNTER WEIGHT COVER & CLAMPS 01/01022016
11
K-420
31 0045-1015 SCREEN MESH CLAMP 1 W9 0312-0006 FLAT WASHER 16
33 0045-1239 VIBRATOR WEIGHT COVER 1 N9 0312-0002 NYLOCK NUT 8
34 0045-1253 COVER PLATE 1 N11 0316-0002 NYLOCK NUT 12
35 0045-1477 PACKER 8
36 0045-1484 PACKER 5
BF4 0312-0035 BOLT 8
BG4 0316-0056 BOLT 4
BG13 0316-0152 BOLT 8
12
K-421
13
K-422
31 0045-1015 SCREEN MESH CLAMP 1 BG13 0316-0152 BOLT 8
35 0045-1477 PACKER 8 W8 0310-0004 SPRING WASHER 2
36 0045-1484 PACKER 5 W11 0316-0004 FLAT WASHER 24
37 0045-1232 VIBRATOR WEIGHT COVER 1 N11 0316-0002 NYLOCK NUT 12
38 0045-1092 COVER PLATE 1
39 0510-0010 RUBBER CAP STRIP 10m
BE2 0310-0020 BOLT 2
BG4 0316-0056 BOLT 4
14
K-423
HYDRAULIC MOTOR 01/01022016
15
K-424
HYDRAULIC MOTOR 01/01022016
40 0111-0503 HYDRAULIC MOTOR 1 W9 0312-0006 FLAT WASHER 18
42 0143-1101 COUPLING 1 N9 0312-0002 NYLOCK NUT 8
43 0145-1602 TAPER LOCK 1
44 0143-1103 COUPLING ELEMENT 1
45 0900-0013 KEY STEEL 1
46 0145-1603 TAPER LOCK 1
BF5 0312-0040 BOLT 8
BF7 0312-0052 BOLT 2
16
K-425
HQR1112
ISSUE: 01/2017

Section 26 ‐ 1142‐0001 Bearing Housing 516‐613 Open & Fixed

K-427

11.26.2 Part Assembly
K-428

K-426
1142-0001 BEARING HOUSING 516-613
ISSUE:
OPEN & FIXED
01/01022016
GENERAL ARRANGEMENT
K-427
ISSUE:
OPEN & FIXED
01/01022016
PART ASSEMBLY
K-428
ISSUE:
OPEN & FIXED
01/01022016
PART ASSEMBLY
2 0142-0005 BEARING 1
3 0142-0202 ADAPTOR SLEEVE 1
4 0142-0440 SPACING RING 2
5 0142-0900 LABRYNTH SEAL 2
K-429
HQR1112
ISSUE: 01/2017

Section 27 ‐ 1142‐0006 Bearing Housing 516‐613 Close & Fixed

K-431

K-432

K-430
ISSUE:
CLOSE & FIXED
01/01022016
GENERAL ARRANGEMENT
K-431
ISSUE:
CLOSE & FIXED
01/01022016
PART ASSEMBLY
K-432
ISSUE:
CLOSE & FIXED
01/01022016
PART ASSEMBLY
2 0142-0005 BEARING 1
4 0142-0440 SPACING RING 2
K-433
HQR1112
ISSUE: 01/2017

Section 28 ‐ 1142‐0011 Bearing Housing 516‐613 Close & Floating

K-435

K-436

K-434
ISSUE:
CLOSE & FLOATING
01/01022016
GENERAL ARRANGEMENT
K-435
ISSUE:
CLOSE & FLOATING
01/01022016
PART ASSEMBLY
K-436
ISSUE:
CLOSE & FLOATING
01/01022016
PART ASSEMBLY
2 0142-0005 BEARING 1
K-437
HQR1112
SECTION : Recommended Spare Part
ISSUE: 01/2017
Table of contents
12.1.1 Table of Recommended Spare Parts
L-2

L-1
HQR1112 RECOMMENDED SPARE PART LIST HQR1112
ANCILLARY ITEMS ISSUE : 01/2017
1 0026-1003 HOPPER ROCK LEDGE 1 10 0026-1039 HOPPER LINER 1
2 0026-1007 HOPPER LINER 1 11 0026-1043 HOPPER LINER 1
PL -1-
L-2
27 0026-1106 HOPPER LINER 1 36 0026-5001 FEEDER SIDE LINER 1
PL -2-
L-3
37 0026-5001 FEEDER SIDE LINER 1 46 0112-3245 PROPORTIONAL VALVE 1
38 0026-5008 FEEDER SIDE LINER 1 47 0112-3246 PROPORTIONAL VALVE 1
39 0026-5015 FEEDER FLOOR LINER 1 48 0113-0034 PUMP 1
40 0105-0001 FUEL CAP 1 49 0113-0741 PUMP 2
41 0105-0003 ADAPTOR 1 50 0116-0005 SUCTION FILTER 2
42 0105-0002 STRAINER 1 51 0116-0006 RETURN FILTER 1
43 0111-0321 MOTOR 1 52 0116-0012 AIR FILTER 4
44 0111-0802 MOTOR 1 53 0116-0031 PRESSURE FILTER 2
45 0111-6301 MOTOR 1 54 0116-0033 SUCTION FILTER 1
PL -3-
L-4
55 0118-0284 SPOOL VALVE 1 64 0143-1502 COUPLING 1
56 0118-0285 SPOOL VALVE 1 65 0145-1601 TAPER LOCK 1
57 0119-0014 FLUID LEVEL GAUGE 1 66 0145-1602 TAPER LOCK 1
60 0141-8000 DRIVE BELT 8 69 0145-3003 TAPER LOCK 1
61 0143-0030 COUPLING 1 70 0149-0001 ROSTA TENSIONER 2
62 0143-1101 COUPLING 1 71 0150-0186 ROLLER 16
63 0143-1103 COUPLING ELEMENT 1 72 0152-0191 ROLLER 12
PL -4-
L-5
73 0152-1296 ROLLER 3 82 0190-0101 COMPRESSION SPRING 11
74 0152-2596 ROLLER 2 83 5120-0002 E-STOP SWITCH 4
75 0152-2841 ROLLER 8 84 5102-0003 MASTER SWITCH 2
BEARING HOUSING GA - OPEN &

76 0153-0846 ROLLER 6 85 1142-0001 1
FIXED
BEARING HOUSING GA - CLOSED &

77 0155-1850 ROLLER 6 86 1142-0006 1
FIXED

78 0159-0100 IMPACT BAR 7 87 1142-0011 2
FLOAT
79 0169-0101 APRON SEAL 2 88 5111-0009 FUSES 50A 2
80 0169-0102 SKIRT RUBBER 2 89 5111-0010 FUSES 80A 2
81 0166-0005 CONVEYOR BELT 1 90 5111-0021 CIRCUIT BREAKER 1A 1
PL -5-
L-6
91 5111-0022 CIRCUIT BREAKER 4A 1 100 1100-102 ADAPTOR SLEEVE 2
92 5111-0012 CIRCUIT BREAKER 10A 1 101 1100-103 SEAL 2
93 5111-0013 CIRCUIT BREAKER 16A 1 102 1100-109 SPACING 2
94 5120-0007 NO CONTACTS 6
95 5120-0009 NC CONTACTS 6
96 5120-0003 E-STOP CONTACTS 10
97 5120-0002 E-STOP COMPLETE 2
98 5120-0021 LANYARD SWITCH 2
99 1100-101 BEARING 2
PL -6-
L-7
1 0150-0291 ROLLER 12 10 0166-4011 CONVEYOR BELT 1
2 0152-0696 ROLLER 1 11 0111-4003 MOTOR 2
BEARING HOUSING GA - OPEN &

3 0142-0131 BEARING UNIT 6 12 1142-0001 1
FIXED

4 0111-4001 MOTOR 1 13 1142-0006 1
FIXED

5 0145-2501 TAPER LOCK 3 14 1142-0011 2
FLOAT
6 0145-2505 TAPER LOCK 1 15 0143-0030 COUPLING 1
7 0143-0025 COUPLING 2 16 0145-3001 TAPER LOCK 1
8 0142-0141 BEARING UNIT 2 17 0145-3003 TAPER LOCK 1
9 0166-0003 CONVEYOR BELT 1 18 0149-0001 ROSTA TENSIONER 2
PL -7-
L-8
19 0142-0018 BEARING 2
20 0143-1101 COUPLING 1
21 0145-1603 TAPER LOCK 1
22 0145-1602 TAPER LOCK 1
23 0111-0503 MOTOR 1
24 0118-0284 SPOOL VALVE 2
PL -8-
L-9
HQR1112
SECTION : Hydraulic Schematics
ISSUE: 01/2017

M-1
HQR1112
ISSUE: 01/2017

M-2
HQR1112
ISSUE: 01/2017

M-3
HQR1112
ISSUE: 01/2017

M-4
HQR1112
ISSUE: 01/2017

M-5
HQR1112
ISSUE: 01/2017

M-6
HQR1112
SECTION : Electrical Schematics
ISSUE: 01/2017

N-1
HQR1112
ISSUE: 01/2017

N-2
HQR1112
ISSUE: 01/2017

N-3
HQR1112
ISSUE: 01/2017

N-4
HQR1112
ISSUE: 01/2017

N-5
HQR1112
ISSUE: 01/2017

N-6
HQR1112
ISSUE: 01/2017

N-7
HQR1112
ISSUE: 01/2017

N-8
HQR1112
ISSUE: 01/2017

N-9
HQR1112
ISSUE: 01/2017

N-10
HQR1112
ISSUE: 01/2017

N-11
HQR1112
ISSUE: 01/2017

N-12
HQR1112
SECTION : Impactor Crusher
ISSUE: 01/2017

O-1
SCE 1112 HD
STRIKER - Operating Instructions
ISSUE: 01/2012
STRIKER 1112 HD IMPACTOR
OPERATION MANUAL


O-2
SCE 1112 HD
ISSUE: 01/2012
List of contents Page

Hazard warning O-4
The main components ( sketch ) O-5
The main components O-6
Initial start‐up of Impactor O-7
Adjustment of impact arms O-8
The rotor O-9
The rotor locking procedure prior to blow bar changing. O-10
Blow bar changing O-11
Blow bar – fitting O-12
Blow bar changing sequence – Lifting O-13
Blow bar changing sequence – Turning O-14
Blow bars – wearing O-15

Blow bars – specifications O-16

Rotor – Two active blows O-17

Fixings O-18
Bearings O-19

Anti‐friction bearings O-20

Lubrication points O-21

Wear plate arrangement
Spare parts sheet 1
Spare parts sheet 2
Bearing Arrangement
Arrangement
Base & inlet flanges


O-3
SCE 1112 HD
ISSUE: 01/2012
WARNING!

DANGER TO LIFE!

The initial start‐up of the machine must not be carried out until all protective devices(belt guards,
shaft guard, etc,) have been fitted.

Make sure that all erection and service flaps, inspection doors and hinged sections are closed and
locked.

Do not open any doors whilst the machine is running.

Do not thrust bars or similar tools into the machines.

Servicing and repair work is only to be carried out when the machine is at a standstill.

The same applies to and work on or in ancillary equipment.

Make sure that the main switch is locked.

Please observe the instructions contained in this Operating & Maintenance Manual.


O-4
SCE 1112 HD
STRIKE
ER - Opera
ating Instructions
ISSUE: 01/2012
0
The maiin componen
nts
3
5
6
7 4

5 1

10
13
1
14
11
1
12
15
5

8 9

Unlimitted Solutio
ons For Limited Res
sources
O-5
SCE 1112 HD
STRIKE
ER - Opera
ating Instructions
ISSUE: 01/2012
0
Access

Part No Desiggnation
1 Base
2 Housing upper reaar
3 Housing upper fro ont
4 Bearinng housings
5 Inspecction doors
6 Hydraaulic cylinderrs
7 Hinge
e pins
8 Rotorr
9 Blow bars
10 Top im
mpact arm
11 Centre impact arm m
12 Btm. iimpact arm
13 Hydraaulic cylinderr – Top impact
14 Hydraaulic cylinderr – Centre im
mpact

15 Hydraaulic cylinderr – Btm. impaact
Unlimitted Solutio
ons For Limited Res
sources
O-6
SCE 1112 HD
ISSUE: 01/2012
Initial start‐up of the STRIKER 1112‐HD Impactor:

1. On initial start‐up, or following longer periods of operation, check the gap between the
lower edge of the impact plate and the blow bars. Increasing or decreasing this gap will
affect the degree of reduction.

2. Start the motor and bring it up to full operating speed. Check that the rotor is turning in the
correct direction.

3. Let the impactor run for a short period and check for any untoward vibrations.

4. The rotor is carefully balanced at the works, so the cause of any vibrations will probably be
blow bars having varying weights. When changing blow bars, ensure they are of equal
weight.

5. Check that the drive runs smoothly.

6. Check the correct functioning of the auxiliary equipment (feed / discharge units, conveyors,
etc) under no‐load conditions.

7. Now commence feeding slowly and uniformly, gradually bringing the impactor up to full
load. It is essential that the feed material is distributed evenly across the full width of the
inlet opening; otherwise the result could be uneven blow bar wear and reduced capacity.

8. Check the bearing temperatures periodically. The maximum admissible temperature is 80
degrees C, and the normal operating temperature 50 to 70 C.

9. On shut‐down, stop the feed and empty the impactor before switching off the impactor
motor.
Important!
Wear plates, impact plates and blow bars must not worked on with welding or cutting
equipment, etc.

O-7
SCE 1112 HD
STRIKE
ER - Opera
ating Instructions
ISSUE: 01/2012
0

Adjustmment of imp pact arms:

Suggested gap for initiaal adjustmen
nt

A = 150 mm m
B = 75 mm m
C = 40 mm m

WARNING

Gap adjustment must be maade only wh hen the
rotor is at a standstill. Th
he gap has to be
adjusted accord ding to the required product
p
size, capacity and plant layyout. ( clo
osed or
openn circuit )
As thiss depends on
o the structture of the feed
f materiaal, the above mentioned
d gap dimen
nsion is
only a guide.

nal adjustmeent is determ
The fin mined during commissioning and during the initial trial run period.

Adjusttment of the spindle nutss by tightenin ng the spindle nut, dimen
ng/slackenin nsion
“A” ,”B” or “C” is aaltered.

Spindle thread M3 36 x 5mm

1 turn of the spind dle nut reducces/enlarges dimensions “A” ,”B” or ““C” by 5 mm m
djustment: anti‐clockwise = smaller ggap
Gap ad
C
Clockwise = llarger gap
Resstraining spanner
Lo
ocking nut
spiindle nut
Proceddure:
Raise tthe restrainin
ng spanner.
Raise tthe impact apron hydrau ulically until tthe spindle n
nut is relieved.
Releasse the protecctive cover/lo
ocking nut.
Tighten or slacken the spindle nut accordin ng to the reqquired gap seetting.
Lower the impact aapron hydraulically until the spindle nut is engagged.
Tighten the protecctive cover/loocking nut.
Lower the restraining spanner..

Unlimitted Solutio
ons For Limited Res
sources
O-8
SCE 1112 HD
STRIKE
ER - Opera
ating Instructions
ISSUE: 01/2012
0

The Ro otor

The rotor of the STTRIKER 1112 2 HD Impacto or is an openn disc style, comprising o
of four heavvy discs,
four blow bars, sup pport beamss and the spaacer tube.

All SCEE rotors aree stress relieeved and baalanced afte
er manufactu ure to ensure smooth reliable
operattion

The blo ow bars are fitted, remo oved or adjussted from the top and seecured by weedges againsst radial
movem ment. Lockingg plates prevvent axial mo ovement.

The weedges retaining bolts sho ould be replaaced every time they aree removed. TThey shouldN NOT be
over tightened. The correct pro ocedure is too snug tighteen then unsccrew the nutt half a turn. Nylock
lock nuuts must be u used.

Since tthe retainingg wedges are subject to w wear, they haave to be rep placed from ttime to time e.
This is best carried out togetheer with a blow w bar change e.

The rotor body is ssecured to th he rotor shaaft by a ring feeder. The ring feeder bolts are tigghtened
with a torque wren nch in our wo orks, and reqquire no furtther attention.

Duringg each blow b bar change the rotor sho ould be checkked for wearr.

RO
OTATION
N Whe en fitting neew blow baars, makesu ure the
same e weights arre fitted opp posite each o other. (
1 kg total variatioon )

Incorrect weightt distribution
n of the blo
ow bars
will cause vibraations, whicch could severely
damage the bearrings.

WAR RNING
The rotor mustt be secureed against rotating
r
when fitting or aadjusting thee blow bars.TThis can
be run as a high
h‐speed roto
or with two active
bars,, which enables the feedmaterial to
pene t crushing circle. This option
etrate into the
prodduces more ffines.
Unlimitted Solutio
ons For Limited Res
sources
O-9
SCE 1112 HD
ISSUE: 01/2012
The rotor locking procedure prior to blow bar changing.
1. Rotor locking rod.
2. Blow bar changing support frame.
3. Approved lifting device ( by others )

DANGER!
Before any blow bar changing is attempted, the rotor must be locked in position, in order
to prevent the rotor from moving unexpectedly when the blow bars are removed! Accident
risk!

To lock the rotor in position, a locking rod is inserted into the hole provided in the blow bar
support beam and then tightened to secure the rotor against turning. The blow bar changing
support frame is then positioned into the lifting holes provided. The top blow bar can now be
removed or adjusted as required with the aid of the blow bar lifting bracket and the use of a
approved lifting device ( by others ).

On completion of the replacement or adjustment of the top blow bar this procedure is to be
repeated on the other three blow bar.

DANGER!
While unlocking the rotor after the first adjustment be careful as the rotor may move
unexpectedly due to the blow bars being of unequal weight! Accident risk!

O-10
SCE 1112 HD
STRIKE
ER - Opera
ating Instructions
ISSUE: 01/2012
0
Blow baar changing.

Blow Bar
Wedge
Wedgee retaining bolts
Positio
on for locking rod
Position for
lifting framee

Crusheer stopped and rotor bro ought to a staandstill.

Togglee bolts betweeen the fixed d and hinged d casing releaased and insp
pection doorr checked that it is
closed.

Top reear casing opened up hyd draulically.

Motorr turned off aand tagged o out. ‐ DANGEER

Rotor tturned into p position andd locking rod inserted to p prevent the rotor from turning. ‐ DANGER

Clean out materiall build‐up beetween the w wedge and th he blow bar.

Fit lifting frame and with liftingg device takee the weight of the blow bar.

Removve wedge rettaining boltss and push w wedge down aand along sid deways untill free to remove.

Blow b bar can now be removed and replaceed, lifted or tturned as req quired.

Replacce wedges an nd retaining bolts. Snug ttighten then unscrew nut half a turn.. ‐ Importantt

Removve lifting fram me and locking rod and tturn the roto or by hand to
o ensure barss are correcttly
positio oned and theey do‐not claash with the internals of tthe crusher. ‐ Importantt

Check impact platees, wear plattes for wear or cracks and replace as required. – Important

Adjustt bottom imp pact arm to tthe required gap.

Clean mating surfaaces of material then un‐‐tag motor, tturn on and cclose casing ensuring all
person nal are clear of the machine. ‐ DANGER

Togglee bolts engagged and tighttened.

Open sside door and adjust top impact arm to the requiired gap.
Unlimitted Solutio
ons For Limited Res
sources
O-11
SCE 1112 HD
STRIKE
ER - Opera
ating Instructions
ISSUE: 01/2012
0
Blow baar – Fitting

Left handed
d caps Rigght handed ccaps
M16 N
Nyloc nut & w
washer

sn unscrew the nut half as tturn
nug tighten u

The gap between tthe locking caaps is 1 ‐ 2m
mm. This allow
ws the blow bars to throw
w out approx.
7mm ddue to centrifugal forces..

DANNGER

Shouuld the gap between the locking caaps and
the bblow bars vaary from tighht to loose thhe blow
bar ccould throw out on an an ngle. This will cause
severe vibrationns to the w
whole machin ne and
lead to bearing f ailure.

ATTENNTION

Lockingg caps should be ground
d back if too ttight or shim
mmed if toolo oose to prod duce a constaant gap
of betw
ween 1 – 2mmm.

ATTEENTION

The blow bar liftting frame is supplied to enable
the safe handlinng in either the fitting, lifting,
turning or removving of the blow bars.

Unlimitted Solutio
ons For Limited Res
sources
O-12
SCE 1112 HD
STRIKE
ER - Opera
ating Instructions
ISSUE: 01/2012
0
Blow baar changing ssequence – LLifting

RO
OTATION
N R
ROTATIO
ON
Installation ‐ New blo
ow bar 1st Stagee – Wearing LLimit Before

RO
OTATION
N R
ROTATIO
ON

nd
2 Staage – First Lift of Blow B Bar and weearing 3rd Stage – Seecond Lift o of Blow Baar Final
Limit Wearing Limits

Notee:

On thhe 2nd stagee if the blow w bar is worn n down to be etween 52 and 64 ( as sh hown ). This blow
bar could be turn ned instead o of lifting provviding a min.. support of 65 is maintained as showwn on
page 11.

On th b must‐nott be worn down too farr, otherwise the rear support
he 3rd stagee the blow bar
beamms will be exp posed to weaar.

The ddimension 30 0 will vary depending on n rotor speedd and wear p pattern overr the width o
of the
blow bars.

Unlimitted Solutio
ons For Limited Res
sources
O-13
SCE 1112 HD
STRIKE
ER - Opera
ating Instructions
ISSUE: 01/2012
0
Blow baar changing ssequence – TTurning

RO
OTATION
N R
ROTATIO
ON

Installation ‐ New blo
ow bar 1st Sttage – Weariing Limit

RO
OTATION
N R
ROTATIO
ON

2nd Stagee – Turning B
Blow Bar 3rd Sttage – Wearring Limit

Notee:

On thhe 1ststage the blow bar must not bee worn down n to far, otherwise after turning the blow
bars you will nott have the 65
6 min. supp
port require
ed. This dimeension depeends on the wear
patteern.

DANG GER OF BLOW W BARS BEING RELEASEED.

On th
he 3rd stagee the blow bar
b must‐nott be worn down too farr, otherwise the rear support
beamms will be exp posed to weaar.

The ddimension 30 0 will vary depending on n rotor speedd and wear p pattern overr the width o of the
blow bars.

Unlimitted Solutio
ons For Limited Res
sources
O-14
SCE 1112 HD
STRIKE
ER - Opera
ating Instructions
ISSUE: 01/2012
0
Blow baars – Wearin
ng

Guide O
Only – Variess with feed ssize and material

Rotor speed ‐ Slo ow
Wearring pattern indicates th he rotor is ruunning
to slow and thee feed material is penettrating
too far into the rootor.

ATTEENTION
Dangger of wearr to the rootor, wedge es and
wedgge retaining bolts.

ATTEENTION
You wwill not be abble to turn b
blow bars.
Rotor speed ‐ Fasst
Wearring pattern indicates th he rotor is ruunning
too fast
f and the feed matterial is failing to
peneetrate into th ow bar wearing flat
he rotor. Blo
acrosss the top.

ATTEENTION
Impaactors will have a reducced crushingg ratio
and reduced capacity.
c Th
his increasees the
operaating costs.
w bar – centraal wear
Blow
Impaactors should d be fed byy feeders orr from
ens to give an even feed of material across
scree
the full width of tthe blow barr.

Shouldd the blow bar be dished d out in the ccentre the in
nside of the feed chute sshould be ch hecked
for material build u up or other o obstructions..

ATTENNTION

This wiill restrict thee lifting of th
he blow bar aand reduce tthe full utilizaation of the blow bars.

ATTENNTION

Blow bbars should b be checked fo or damage and wear dailly.
Unlimitted Solutio
ons For Limited Res
sources
O-15
SCE 1112 HD
STRIKE
ER - Opera
ating Instructions
ISSUE: 01/2012
0
Blow baar specificatiions.

The blow bars supp
plied are maanufactured from 18% manganese,
m u
unless requeested otherw
wise. For
alternattive materials please contact SCE.

Sttd wedge Sp
pecial wedgee
These blow bars aree supplied 12 20mm thick.
Other siizes can be supplied by changing the wedges on rrequest to SC CE.

Care mu ust be taken in handling and metal p protection prrovided to thhe feed mateerial to guardd against
breakagge. These barrs cannot be welded.

To ensuure against breakage of
o blow bars the feed size of thee different m
materials sh
hould be
controlled.

ow is a guide
List belo e with average values on
nly.

Stone Density Abrasio on Index Work Indexx Max. Feed
(t/m3) Ai Wi Size ((mm)
Andesiite 2.9 0.25 17 35
50
Basalt 2.9 0.19 22 35
50
Bauxitee 3.0 0.08 16 60
00
Dolomite 2.7 0.04 11 60
00
Granitee 2.7 0.44 15 35
50
Greywacke 2.7 0.39 18 35
50
Rhyolitte 2.7 0.38 22 35
50
River G
Gravel 2.7 0.42 17 35
50
Sandsttone 2.5 0.31 12 60
00
Limestone 2.7 0.02 22 60
00

Contactt SCE for specific applicattions.
Unlimitted Solutio
ons For Limited Res
sources
O-16
SCE 1112 HD
STRIKE
ER - Opera
ating Instructions
ISSUE: 01/2012
0
Rotor – Two active blow bars

Neww blow bar o
or worn ATTENTION

b
bar lifted up Running your rotorr with two active
blow bars and two o dummy baars can
ow bar
Worn blo only be done when the feed siize and
type of material tto be crusshed is
left down suitable.

or speed is in
The roto ncreased to ensure
correct penetration of the feed
material into the roto or.

ADVANTTAGES
Higher iimpact forcees due to thee higher speeed gives largger reductio on ratios with h lower recirculating
loads.

Wear co osts reduced and increased efficiencyy reduces costs per tonne.

ATTENTTION
n circumstaances is the rotor to be run with‐ou
Under no ut blow barss or dummyy bars proteccting the
slots.

List belo
ow is a guide
e with average values on nly.

Stone Density Abrasio
on Index Work Indexx Max. Feed
(t/m3) Ai Wi Size ((mm)
Basalt 2.9 0.19 22 1550
Bauxitee 3.0 0.08 16 1550
Dolomite 2.7 0.04 11 2550
Sandsttone 2.5 0.31 12 2550
Limestone 2.7 0.02 11 2550

Contactt SCE for specific applicattions
Unlimitted Solutio
ons For Limited Res
sources
O-17
SCE 1112 HD
STRIKE ating Instructions
ER - Opera
ISSUE: 01/2012
0
Fixings

M 30 Nut
Caast Impact plate
c/ww M30 Stud
M 30 Half lockk nut

M 30 Springg washer Impact arm base plate

ATTEN NTION
Cast wwear plates to be checkeed for wear d daily and rep
placed when n worn. A large number of cast
impactt plates are
a identicaal so theyy can be interchangged to no on‐wearing areas.

WARN NING
All imp oose are in danger of falling into the rotor &
pact and weaar plates thatt are worn, ccracked or lo
doing mmajor damagge to the maachine.
Cast Wear Plate
M2
20 Nyloc nut & washer

ATTEENTION

If the
e end of feeed chute is w worn away m material
can fall
f down th he back withhout being crrushed.
This could also happen if tthe blow baars are
worn n down to far
f or beforee turning. Ch heck to
see if the recircculating load
d has increaased or
mate erial without being crushed is present in
the sstockpile.

Unlimitted Solutio
ons For Limited Res
sources
O-18
SCE 1112 HD
STRIKE
ER - Opera
ating Instructions
ISSUE: 01/2012
0
Bearingss
9
4
7
7 8
5
5 6
10
2
2
Fixed Beearing
F
Floating Beearing
3
3
1

Part Description
1 Bearing
2 Sleeve
3 Lip seal
4 Brg. Housingg
5 Outer labyriinth
6 Outer labyriinth
7 Inner labyrin
nth
8 Inner labyrin
nth
9 Locking ringg

10
0 Collar nut w
with locking p
plate
Unlimitted Solutio
ons For Limited Res
sources
O-19
SCE 1112 HD
STRIKE
ER - Opera
ating Instructions
ISSUE: 01/2012
0
Anti‐fricction bearinggs

The roto or is fitted w with self‐align ning bearingss. These are ssecured to th he rotor shafft by adaptor
sleeves. The operatiing temperatture of the b bearings shou
uld not exceeed 80°C. Usu
ually it is betw
ween 50
and 70°C. Use a greaase gun to reegress the beearings via th he nipples on
n the housing weekly and d
regresseed the labyrinths via the nipples dailyy.

The beaarings have a grease‐volu ume control, allowing surrplus and useed grease to be expelled from
the bearing housingg.

ATTEN NTION 5
5

Shift outer labyrintth out by up p to 5mm if
bearingg is runningg hot or greease is not
purging.
Outer Labyrinth
Grub Screw
ws

Lubrican nts
Use onlyy unadulteraated mineral lubricants. O On no account should the lubricant ccontain un‐co ombined
mineral acids, free‐aalkaline or mmetal‐corroding additives.

Use Calttex EP greasee C 2 or similar approved d.

Bearingg play

Bearing Tyype : 23140 K / H 3140
Maker SKF M
Maker FAG
C3 – p
play
Bearinng as supplied 0
0.200 – 0.26 0 0.2200 – 0.260
Play to
o be taken up 0
0.090 – 0.13 0 0.0090 – 0.130
Remaining play 0.100 min. 0..100 min.

The playy must alwayys be measurred across bo oth rollers!

Warniing!

When carrying outt welding on the impacto or, always en nsure that th
he welding cu
urrent does nnot
pass through the b bearings. If this happens the rollers mmay become cold‐welded d to the race
es,
ruiningg the bearinggs
Unlimitted Solutio
ons For Limited Res
sources
O-20
SCE 1112 HD
STRIKE
ER - Opera
ating Instructions
ISSUE: 01/2012
0
Lubricattion points

4
4
1,2,3
5
4

Part Description
n Freq
quency
1 Beearing housin
ng d
daily
2 Outer labyrintth d
daily
3 Inner labyrinth
h d
daily
4 Cyylinder hinge
e weeekly
5 Hiinge weeekly

Use Caltex EP grrease C 2 or ssimilar appro
oved
Unlimitted Solutio
ons For Limited Res
sources
O-21
HQR1112
SECTION : Engine
ISSUE: 01/2017

P-1
HQR1112
SECTION : Engine
ISSUE: 01/2017
Table of Contents

16.1.1 Presentation slides on Cold Weather Operation
16.2.1 Cold Weather Recommendations for All Caterpillar Machines
16.3.1 Engine Pre‐Start‐Up Inspection and Operating Requirement
16.4.1 Refer to Engine Manual

P-2
Solutions & Systems Integration
Cold Weather Operation
Michael Barrett
Agenda
• Literature
• Fluids
– Oil
– Coolant
– Fuel
• Starters/ Batteries/Chargers
• Room/Enclosure Design
• Intake Air
• Gas Engine Issues
EP Project Solutions & Systems Integration – Malaga March 26- 28, 2007
Cold Weather Reference Materials
• Service Media:
– “Cold Weather Recommendations for All Caterpillar Machines” -
SEBU5898
– “Caterpillar Commercial Diesel Engine Fluids
Recommendations” - SEBU6251
– “Cold Weather Recommendations for On-Highway Diesel Truck
Engines” – SEBU6740
• Application and Installation Manuals (A&I)

– “Engine Room Ventilation” - LEBW4971
– “Fuel System” - LEBW4976
– “Cooling System” - LEBW4978
What is Cold Weather?
Caterpillar
– Temperatures above 0C (32F) are considered normal operation
Cold Weather Considerations
• Proper Engine fluids – CRITICAL:
– Engine Oil :
• Viscosity
› Use the highest viscosity that meets the minimum ambient
temp
› Special Artic Recommendations:
» For starts below-20°C (-4°F) use base oils that can
flow in low temperatures. These oils have lubricant
viscosity grade of SAE 0W or of SAE 5W
» For starts below -30°C (-22°F), use a synthetic base
stock multigrade oil. The oil should have a lubricant
viscosity grade of SAE 0W or SAE 5W.
• Change oil and filter prior to colder weather
• Do not diluted with kerosene
› Kerosene will evaporate in the engine
Engine Oil (cont.)
• Use supplemental heat for starts below oil ambient temp

rating
› Lube oil heaters
» Units with thermostats
» Circulating pumps
» Unitized Oil/Water pump
» Immersion-type oil heaters are not recommended
› Oil Coolers
» Consider Thermostatic Control
Proper Engine fluids (cont):
• Coolant
–Use a coolant rated for minimum ambient temp
• 60% Ethylene Glycol rate to -520 C (-620 F)
•Propylene Glycol provide less protection
• Coolant (Cont.)
–Jacket water heaters (JWH)
• Recommend for all cold weather operation < 00 C (320 F)
• Improves startability
• Maintains operating temperature in lightly loaded conditions
• Circulating pumps preferred to siphon pump
• Diesel fuel fired JWH
• Grease
– Artic Platinum = -600 to 180 C (-760 to 650 F)
• Fuel:
– Pour Point
• Should be at least 6°C (10°F) below the lowest ambient
temperature :
› Modifying with additives
› Mix the diesel fuel with a different fuel that has a lower pour
point( No. 1 diesel fuel or kerosene)
› Use fuel tank heaters
– Cloud Point
• Must be low than ambient temp to prevent wax from blocking the
filter
› Use fuel heaters
» Typically use coolant or exhaust heat
› Change in the location of fuel filters and/or supply lines and
the addition of insulation.
› Use de-icers or cold flow improvers
Fuel (cont).
• Diesel No 1 vs No 2
– Lower Cloud Point
– Lower Pour Point
– Lower Energy Rating
Charts are for reference only: Please consult your fuel supplier for correct properties and blends
Fuel (cont).
• Lubricity
– Lighter fuels such as are Jet A-1, JP-8, JP-5, and kerosene frequently are used
in arctic conditions
(1) Lubricity is not a requirement
•
.
Contact the Fuel Supplier for the recommended additives in order to maintain the
proper fuel lubricity.
• Fuel cooling may be required in order to maintain the minimum viscosity of 1.4 cSt at
the fuel pump and injectors .
Charts are for reference only: Please consult your fuel supplier for correct properties and blends
Fuel (cont).
• Cetane Number
– Measure of the ignition quality of a diesel fuel
– Affects the engine’s ability to start
– A cetane number above 40 will permit acceptable engine starts in
normal conditions
– A higher cetane value may be required for operation in cold weather
operation
• Starting temperature can be improved approximately 7 to 8°C (12 to
15°F) for every increase of ten in the cetane number.
– Improve the Cetane Number
• Mix fuels
• Cetane additives
• Ether Starting Aids
› Not recommended by factory
• Starters/ Batteries/Chargers:
– Starter Select
• Select Heavy-duty and/or oversized starters (if available)
› High lubricant viscosity increase torque required to turn over
engines
• Dual motors will slightly decrease the starting time
• Starter Cranking Current requirements by Model, oil viscosity and
ambient temp are available in TMI
• A standard crank cycle is a 30-second crank followed by a two-
minute cooling period.
» 5 Max cycles will prevent starting motor overheating
• Batteries
– Size batteries for starter requirements at lowest ambient
temperature
• CCA - the amperes a battery, at –17.8 deg. C (0 deg. F) can
deliver for 30 seconds and maintain a terminal voltage of 7.2
volts or higher.
• Arctic Batteries have higher specific gravity acid to lower freeze
point to -45 degrees
• Battery Heater
– Improves battery cranking power
• Battery Voltage drops with Temperature
– Maintain specific gravity
• Ref Chart (SEBU5898): Correct Specific Gravity of Batteries at
Specified Temperatures
• Charger
– Use Temp Compensated Charger
• Charging voltage increases at lower temps
› 2.74 volts per cell (16.4 volts) at –40 °C to2.3 volts per cell
(13.8 volts) at 50 °
• Cables
• Size properly to minimize voltage drop
• Room/Enclosure:
– Keep the room warm:
• Airtight
• Space heaters
• Exhaust piping arrangement
• Eliminate air flow across the engine
› Remote Radiators
» Two-speed or variable speed radiator fans
» Radiator shutters should be considered (Sensor Control)
• Duct combustion air from outside
• Valve component damaged by carbon buildup may occur if
frequently started and stopped in very cold temperatures
Extreme Cold - Louver Control
• Below -25° C / -13° F
– Impacts Engine Performance

• Increased Cylinder
Pressure
• Rough Combustion
@ Light Loads
• Control Intake Temperature

– Louvers
• Air Intake (Combustion)

– May need to preheat inlet air
• Suggested minimum Inlet Manifold Temperature (IMAT) of +10°C
(50°F) for good starting
• Prevent icing
› Air source valve operation for low idle
› Engine room air can be ducted to the intake during icing
conditions
› Heavy duty air cleaners reduce icing
– Turbine Precleaner
Controlling Air Intake Temperature
• Regulate Duct Air Temperature

– Thermostatic Control
– Fin Type Heat Exchanger
– Adds System Restriction
• Does not work well under

light loads
Extreme Cold Weather Considerations
•Warm Inlet Air to prevent icing of the air cleaners
• Cooling System Design

–Provide thermostatic controlled bypass of charge air cooler for ATAAC
–Use remote fan
–Thermostatic control
›Inlet control preferred
›Provides constant temperature to jacket water pump inlet
›Minimizes thermal shock
›Outlet control
»Replace bleed orifice housing or block with manually operated
vent line
»Example:
3.78 lpm (1 gpm) flow though the radiator
at –50C (-60F) ambient returns coolant at 132 C
(240 F) colder than target 82C (180F).
= Approximately 30kW of cooling
Extreme Cold Weather Considerations
•The radiator should be in a separate room from the engine.

• In warm temperatures, the weather enclosure can be opened.
• Radiator cooling air is drawn in through a roof or side door.
Gas Engine Considerations
• Air Temperature Effects

– Emissions
– Detonation Margin
• Low Pressure Gas Engines

– Controlling Air Intake Temperature
– Air to Gas Heat Exchanger
Gas Engine Considerations
• Must Control Temperature Variation Difference Between Gas

and Inlet Air
– 3500A and 3500B
• Fuel System Controls Volume of Gas to Volume of Air
• Add Heat Exchanger

– Flow Losses
• Gas Train System
• Air Intake System
Conclusions:
• Literature
• Fluids
– Oil Prepare for Cold
– Coolant Weather Operation:
– Fuel
A Bit of Preparation
• Starters/ Batteries/Chargers
will prevent a lot of
• Room/Enclosure Design
• Intake Air
problems!
• Gas Engines Issues
Conclusions:
Questions?
SEBU5898
01/02/2009
Cold Weather Recommendations for All

Caterpillar Machines
Table of Contents
Foreword ………………………………………………………………………... 2
Information Section …………………………………………………………… 5
Cold Weather Information ……………………………………………… 5
Operation Section ……………………………………………………………... 8
Parking Recommendations ……………………………………………. 8
Starting Recommendations ……………………………………………. 9
Before Starting Engine …………………………………………. 9

Engine and Machine Warm-Up ……………………………….. 10
Engine Starting Information ……………………………………. 12
Engine Starting With Auxiliary Start Receptacle ……………. 16
Engine Starting With Jump Start Cables ……………………... 18
Engine Starting With Starting Aid ……………………………... 21
Maintenance Section …………………………………………………………. 29
Battery Recommendation ……………………………………………… 29

Fluid Recommendations ……………………………………………….. 31
Tire Inflation Recommendation ………………………………………... 41
Reference Information Section ……………………………………………... 44
1
Operation and Maintenance Manual
Cold Weather Recommendations for All Caterpillar Machines
Media Number – SEBU5898-12 Publication Date – 01/02/2009 Date updated – 02/03/2009
Foreword
SMCS – 1000; 7000
Literature Information
This manual should be stored in the operator's compartment in the literature holder or
seat back literature storage area.
The information contained in this document is the most current information available for
coolant, fuels, and lubricants. Special lubricants are required for some machine
compartments. Refer to the Operation and Maintenance Manual for your machine for
any special lubrication requirements.
Whenever a question arises regarding the machine, this publication, or the Operation
and Maintenance Manual, please consult any Caterpillar dealer for the latest available
information.
Safety
Refer to the Operation and Maintenance Manual for your machine for all safety
information. Read and understand the basic safety precautions listed in the Safety
Section. In addition to safety precautions, this section identifies the text and locations of
warning signs used on the machine.
Read and understand the basic precautions listed in the Safety Section before operating
or performing lubrication, maintenance and repair on the machine.
Maintenance
Refer to the Operation and Maintenance Manual for your machine to determine all
maintenance requirements.
Maintenance Interval Schedule
Use the Maintenance Interval Schedule in the Operation and Maintenance Manual for
your machine to determine servicing intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour meter intervals if they provide more
convenient servicing schedules and approximate the indicated service hour meter
reading. Recommended service should always be performed at the interval that occurs
first.
2
Under extremely severe, dusty or wet operating conditions, more frequent lubrication
than is specified in the Maintenance Interval Schedule might be necessary.
Extended Engine Oil Drains and Warranty
Failures that result from extended oil drain periods are not Caterpillar factory defects
and therefore are not covered by Caterpillar's warranty. In addition, failures that result
from not using the recommended oil type are not Caterpillar factory defects and
therefore are not covered by Caterpillar's warranty.
Refer to the applicable Operation and Maintenance Manual for standard oil drain
periods and to the Maintenance Section, "Lubricant Specifications" of this publication for
engine oil type and viscosity grade recommendations.
To reduce the potential risk of failures associated with extended oil drain periods; it is
recommended that oil drain intervals only be extended based on oil analysis, and
subsequent engine inspections. Oil analysis alone does not provide an indication of the
rate of formation of lacquer, varnish and/or carbon on pistons and other engine
surfaces. The only accurate way to evaluate specific oil performance in a specific
engine and application that utilizes extended oil drain periods is to observe the effects
on the engine components. This involves tear-down inspections of engines that have
run to their normal overhaul period with extended oil drain intervals. Following this
recommendation will help ensure that excessive component wear does not take place in
a given application.
---------------------------------------------------------------------------------------------------------------------
NOTICE
Light loads, low hour accumulation, and excessive idling time can contribute to
excessive water in the crankcase oil. Corrosive damage, piston deposits and
increased oil consumption can also result. If oil analysis is not done or the
results are ignored, the potential for corrosive damage and piston deposits
increases. Refer to the appropriate Operation and Maintenance Manual for
guidance.
---------------------------------------------------------------------------------------------------------------------
Note: Failures that result from extended oil drain periods are not warrantable failures,
regardless of
use of this recommended procedure. Failures that result from extended engine oil drain
periods are
considered improper use under the warranty.
3
Aftermarket Products and Warranty
---------------------------------------------------------------------------------------------------------------------
NOTICE
When auxiliary devices, accessories or consumables (filters, oil, additives,

catalysts, fuel, etc.) made by other manufacturers are used on Caterpillar
products, the Caterpillar warranty is not affected simply because of such use.
Failures that result from the installation or usage of other manufacturers auxiliary
devices, accessories or consumables, however, are not Caterpillar factory
defects and therefore are NOT covered by Caterpillar's warranty. Caterpillar is not
in a position to evaluate the many auxiliary devices, accessories or consumables
promoted by other manufacturers and their effect on Caterpillar products.
Installation or use of such items is at the discretion of the customer who
assumes ALL risks for the effects that result from this usage. Furthermore,
Caterpillar does not authorize the use of its trade name, trademark, or logo in a
manner which implies our endorsement of these aftermarket products.
---------------------------------------------------------------------------------------------------------------------
4
Cold Weather Information
SMCS - 1000; 7000
The information that is contained in this document is an aid to the operation and
maintenance of your Caterpillar machine in cold weather. This information will cover
operating your machine in temperatures from 9 °C (48 °F) to -40 °C (-40 °F). When you
operate the machine in temperatures above 9 °C (48 °F), refer to the Operation and
Maintenance Manual for your machine. It is difficult to outline the operation and
maintenance of a machine that is used in freezing temperatures for a general
publication. The difficulty in outlining the requirements is caused by the following
conditions: the unlimited differences in weather conditions, applications and the supplies
that are available in your area. In order to provide the best possible guidelines, use the
information in this document and the following criteria: varying factors,
recommendations from your Caterpillar dealer and past proven practices.
Hints for Cold Weather
Make sure that you read the information for selecting the lubricants to use in cold
weather. Refer to Special Publication, SEBU6250, "Lubricant Viscosities" for more
information. Prepare the machine for the weather conditions. Use the following options
to keep the machine warm: heaters, enclosures for compartments and storage facilities.
 To assist in warm-up, block the radiator. Blocking the radiator will restrict air from
the fan.
 Before the beginning of cold weather, install the correct lubricant in each
compartment.
 Keep all starting fluid at room temperature. Inject starting fluid only while the
engine is cranking.
 Provide cooling system protection for the lowest expected outside temperature.
Premix the antifreeze solution for the cooling system. At the minimum, the freeze
protection that is provided by the solution should be equal to the system protection
requirements.
 Check all rubber parts weekly: hoses, tires and fan drive belts.
 Check all electrical wiring and connections for any fraying or for damaged
insulation.
 Keep all batteries fully charged and warm.
 Fill the fuel tank at the end of each shift.
 Check the air cleaners and the air intake daily. If snow is present, check the air
intake more frequently.
5
Steering response on equipment with hydraulic steering may become very slow at very
low temperatures. This can happen even if the correct oils are used.
If the engine is started, run the engine until the engine reaches operating temperature.
Achieving operating temperature will help prevent the intake valves and exhaust valves
from sticking.
-------------------------------------------------------------------------------------------------------------------------------
NOTICE
Alcohol should never be injected or pured into the air brake system. The use of
alcohol in the air brake system can cause components to wear prematurely. The
use of alcohol in the air brake system will void the warranty of the system
components.
Do not store starting fluid or store alcohol in the operator's compartment.
Do not inject alcohol or pour alcohol into the air brake system. The use of alcohol in the
air brake system can cause components to wear prematurely. The use of alcohol in the
air brake system will void the warranty of the system components. Alcohol may be
injected in certain air compressors in order to prevent moisture from freezing. Consult
your Caterpillar dealer for further information.
The cooling system and the lubrication system for the engine do not lose heat
immediately upon shutdown. The transmission and the hydraulic system lose heat more
rapidly because of more exposed areas. Gear cases cool rapidly, since the gear cases
do not operate as warm as other compartments.
This means that an engine can maintain the ability to start readily after being shut down
for a few hours. The other systems will lose heat more rapidly. The equipment will
require exercising upon starting. If the engine is shut down for at least sixteen hours, the
engine will cool down to the outside temperature.
Running the engine at idle will keep the engine compartment warm. The compartment
for the transmission will also be kept warm. However, running the engine will not keep
hydraulic systems warm.
6
The outer wrapper on hydraulic hoses can crack when flexing occurs in cold
temperatures. This does not mean that the hoses have failed. The hoses will still carry
oil under pressure.
Condition the hydraulic hoses on the equipment before the temperatures decrease
below -40°C (-40°F).
Perform the following steps in order to condition the hoses with the hoses on the
machine: Operate at 66°C (150°F) hydraulic oil temperature for at least one hour. Use
an oil that has a pour point of -54°C (-65°F).
Normal machine operation will condition the hoses if arctic fluids have been put into the
system.
However, the arctic fluid must be put into the system before cold weather begins.
Condition the hoses before installation if the ambient temperature is lower than -40°C (-
40°F).
Perform the following steps in order to condition a hose before installation:

 Fill the hose assembly with kerosene or with a winter blend of diesel fuel. Leave
the couplings attached.
 Keep the hoses filled for a minimum of eight hours at a temperature of 22°C
(72°F).
 Hose assemblies should be installed within thirty days of conditioning.
Check the machine in order to be sure that the voltage of the electric heaters matches
the power source.
Correct track tension is especially important during cold weather operation in snow. For
adjustment procedures, refer to the Operation and Maintenance Manual for the
machine.
7
Parking
SMCS – 7000
Always park the machine in the proper area. Park the machine on wooden planks. The
planks will keep the machine from freezing to the ground.
Before parking a track-type machine, operate the machine in forward and in reverse, on
hard, dry material. Travel in second speed and in third speed. Move the machine 15 to
20 meters (40 to 60 feet) in each direction. This procedure ensures that the track parts
are free.
Clean all debris from the roller frames and from the track. Support the attachments on
wood blocks. The wood blocks will keep the attachments from freezing to the ground.
Follow the recommendations for stopping and for parking that are in the Operation and
Maintenance Manual for your machine.
8
Before Starting Engine

SMCS - 1000; 7000
---------------------------------------------------------------------------------------------------------------------
NOTICE
Do not remove the air cleaner element when snow packing occurs. This could
cause severe engine damage. Instead, rework the air intake so air is taken in
under the hood. Do not use a torch to heat a compartment. This causes fires,
burns wiring, gaskets and seals, or melts the battery case. When using canvas
covers, do not install them near exhaust systems. This helps to prevent fires.
---------------------------------------------------------------------------------------------------------------------
Check the air cleaner daily before starting the machine. If you operate the machine in
heavy snow, attach a burlap sack loosely to the precleaner. By moving freely, the sack
will prevent the snow from accumulating around the precleaner. Keep the burlap sack
away from heated parts. The hot exhaust piping may ignite the burlap sack. Also, make
sure that the burlap sack does not touch any moving parts.
In order to assist in warm-up, block the radiator. Blocking the radiator will restrict air
from the fan. Additional items may be needed to assist in warm-up. The use of the
following items may be required: coolant heaters, block heaters, tents and additional
batteries.
Before entering the operator's station, inspect the condition of the following parts:
hydraulic hoses, tires and fan drive belts. Carefully inspect these components for any of
these conditions: cuts, cracks and worn spots. Check all electrical wiring and check
electrical connections for any fraying or for damaged insulation.
If the machine is equipped with a gasoline starting engine, check the gasoline tank and
check the sediment bowl. At every fifty service hours, check for moisture and check for
dirt.
9
Engine and Machine Warm-Up

SMCS - 1000; 7000
Whenever a machine has been parked for a long period of time, some of the systems
will cool to below normal operating temperatures. Always warm the machine systems
before operating the machine at full operation.
Damage to engine valve control components can result from engine operation for short
intervals during operation in very cold weather conditions. If the engine is not allowed to
warm completely, the engine can be damaged by repeated starting and stopping.
During engine operation below normal operating temperature, fuel and oil are not
completely burned in the combustion chambers. This fuel and oil causes soft carbon
deposits on the valve stems. Generally, these deposits do not cause problems because
these deposits are burned off during operation at normal engine temperatures.
Carbon deposits will interfere with valve operation. When the engine is started and
stopped at short intervals, carbon deposits will form. The short operating times do not
allow the engine to reach normal operating temperature. The carbon deposits will
continue to build up. Valve operation is affected by carbon deposits. Carbon deposits
can cause the following problems: burned valves, bent pushrods and other damage to
valve mechanism components.
To avoid valve damage, always run the engine until the coolant temperature is at least
82°C (180°F). This will keep carbon deposits on the valve stems at a minimum.
Thoroughly warming the engine will keep the other engine parts in better condition. This
could also extend the service life of the engine. With less acid and less sludge in the oil,
lubrication will be improved. This will give longer service life for engine bearings, piston
rings, and other parts.
White smoke is generated when you start the engine in cold weather. In order to
minimize white smoke, owners of 3208 Diesel Engines can install a 9N-3771 Cetane
Injection Group. See your Caterpillar dealer for more information.
After the engine is warm, warm up the other systems. Start with the hydraulics. Run the
engine at less than one-third throttle, and slowly move the control lever in order to lift
the attachment. Initially, lift the control lever for a few centimeters (inches). Lower the
attachment slowly. Continue the sequence: raising, lowering, extending and retracting.
Extend the travel during each cycle. Perform this operation for all hydraulic circuits.
Alternate between all of the attachments. Exercise the transmission and the power train.
If you cannot move the control for the transmission, perform the following steps:
10
 Engage the parking brake or apply the brake pedal.
 Run the engine slightly above LOW IDLE.
 Shift the transmission several times from FIRST GEAR FORWARD to FIRST
REVERSE.
Release the brake. Move the equipment forward and backward for several meters
(feet). Exercise the machine for several minutes.
In order to reduce the total warm up time, start exercising the entire machine before you
complete the hydraulic warm up time.
Operate under light load until the systems reach normal operating temperatures. If the
engine temperature is not high enough, enclose the engine and block the radiator. A
thermostat that opens at a higher temperature will not increase the engine temperature
if the engine is not under load.
In order to prevent seal damage and gasket damage, keep the engine crankcase
breather pipe clear of blockage.
In extreme conditions, use a canvas over the engine compartment. Heat the engine
area with a space heater. This will aid in starting the engine. Extending the canvas over
the hydraulic components will provide initial warming of the components.
Multigrade lubricants (10W30) may be used successfully at ambient temperatures

below the pour point of the oil. However, in order to use this oil, you must leave the
engine running at low idle. This helps keep lubricants and compartments warm for the
engine and for the transmission. Running the engine at low idle will not keep the
hydraulic systems warm.
Cold weather operations require more time for completion than other operations. The
extra time that is spent in properly caring for the equipment can prolong the life of the
equipment. Longer equipment life will decrease overall cost. This is especially true in
extreme conditions.
11
Engine Starting Information

SMCS - 1000; 7000
Categories
Table 1
Categories of Cold Weather
Category Temperature Range
Category 1 9 to -9.5 °C (48 to 15 °F)
Category 2 -9.5 to -18 °C (15 to 0 °F)
Category 3 -18 to -30 °C (0 to -22 °F)
Category 4 -30 to -40 °C (-22 to -40 °F)
The fluids in all compartments must have a pour point below the outside starting
temperature.
Category 1
9 to -9.5 °C (48 to 15 °F)
At operating altitudes of 460 m (1500 ft) or less, a Caterpillar diesel engine will not
normally require any starting aids for temperatures in "Category 1".
At operating altitudes of 460 m (1500 ft) or higher, a Caterpillar diesel engine may
require a starting aid. The use of starting aids depends on the engine model and the
altitude.
12
Table 2
Category 1 Starting Aids
Altitude Engine Model Recommended Optional
0 to 460 m (0 to 1500 ft) All Models None None
above 3126B, C-9, C7, C9 Continuous Flow Ether None
460 m (1500 ft)

All Other Models None
Note: Continuous flow ether is controlled by the engine ECM. Manual operation during
starting is not required.
Use only Caterpillar SAE 15W-40, 10W-30 oils or any commercial SAE multigrade oil
that meets the ECF-1 requirements. Refer to the machine Operation and Maintenance
Manual and Special Publication, SEBU6251 for more information.
Category 2
-9.5 to -18 °C (15 to 0 °F)
Table 3
All Altitudes All Models Continuous Flow Ether Coolant Heater
Heavy Duty Battery and

Starter Package (1)
(1) Contact your Caterpillar dealer for availability for your machine model.
13
Use only Caterpillar 10W-30 oil, or a lower viscosity multigrade oil, that meets ECF-1
requirements. Do not use SAE 15W multigrade oil in category 2 temperatures. Refer to
the machine Operation and Maintenance Manual and Special Publication, SEBU6251
for more information.
Category 3
-18 to -30 °C (0 to -22 °F)
Table 4
All Altitudes All Models Continuous Flow Ether Oil Heater
Coolant Heater Fuel Heater
Heavy Duty Battery and Starter (1) Battery Warmer
Only use SAE 5W-40 or a lower viscosity multigrade oil. Do not use any SAE 15W or
10W multigrade oils in category 3 temperatures. Refer to the machine Operation and
Maintenance Manual and Special Publication, SEBU6251 for more information.
14
Category 4
-30 to -40 °C (-22 to -40 °F)
Table 5
All Altitudes All Models Continuous Flow Ether Oil Heater
Coolant Heater Fuel Heater
Heavy Duty Battery and Starter (1) Battery Warmer
Use only SAE 0W-40 or a lower viscosity multigrade oil. Do not use any SAE 15W, SAE
10W or 5W multigrade oils in category 3 temperatures. Refer to the machine Operation
and Maintenance Manual and Special Publication, SEBU6251 for more information.
15
Engine Starting with Auxiliary Start Receptacle
SMCS - 1000; 7000
Some Caterpillar products may be equipped with auxiliary starting receptacles as

standard equipment. All other machines can be equipped with a receptacle from parts
service. The installation of an auxiliary starting receptacle will provide a permanent
receptacle for jump starting.
Two cable assemblies are also available in order to jump start the stalled machine from
another machine that is also equipped with this receptacle or with an auxiliary power
pack. Your Caterpillar dealer can provide the correct cables for your application.
1. Make the initial determination of the machine's failure to crank. Refer to Special
Instruction, SEHS7768, "Use of 6V-2150 Starting Charging Analyzer Group". The
procedure is applicable, even if the machine does not have a diagnostic
connector.
2. Move the transmission control of the stalled machine into the NEUTRAL position.
Engage the parking brake. Lower the attachment to the ground. Move all controls
to the HOLD position.
3. Turn the engine start switch of the stalled machine to the OFF position. Turn off
all accessories.
4. Turn the battery disconnect switch of the stalled machine to the ON position.
5. Move the machine that is being used as a power source so that the jump start
cables can reach the stalled machine. Do not allow the machines to contact
each other.
6. Stop the engine on the machine that is being used as a power source. If you are
using an auxiliary power source, turn off the charging system.
7. On the stalled machine, connect the appropriate jump start cable to the auxiliary
starting receptacle.
8. Connect the other end of the jump start cable to the auxiliary starting receptacle
that is on the power source.
16
9. Start the engine on the machine that is being used as a power source. If you are
using an auxiliary power source, energize the charging system on the auxiliary
power source.
10. Wait for a minimum of two minutes while the batteries in the stalled machine
partially charge.
11. Attempt to start the stalled engine. Refer to Operation and Maintenance Manual,
"Starting Above 0°C".
12. Immediately after you start the stalled engine, disconnect the jump start cable
from the machine that is being used as a power source.
13. Disconnect the other end of the jump start cable from the stalled machine.
14. When the engine is running and the charging system is in operation, conclude
the failure analysis on the starting charging system of the stalled machine, as
required.
17
Engine Starting with Jump Start Cables

SMCS - 1000; 7000
Batteries give off flammable fumes that can explode resulting in personal
injury.
Prevent sparks near the batteries. They could cause vapors to explode.
Do not allow the jump start cable ends to contact each other or the machine.
Do not smoke when checking battery electrolyte levels.
Electrolyte is an acid and can cause personal injury if it contacts skin or eyes.
Always wear eye protection when starting a machine with jump start cables.
Improper jump start procedures can cause an explosion resulting in personal

injury.
Always connect the battery positive (+) to battery positive (+) and the battery
negative (−) to battery negative (−).
Jump start only with an energy source with the same voltage as the stalled
machine.
Turn off all lights and accessories on the stalled machine. Otherwise, they will
operate when the energy source is connected.
--------------------------------------------------------------------------------------------------------
NOTICE
When starting from another machine, make sure that the machines do not touch.
This could prevent damage to engine bearings and electrical circuits.
Turn on (close) the battery disconnect switch prior to the boost connection to
prevent damage to electrical components on the stalled machine.
Severely discharged maintenance free batteries do not fully recharge from the
alternator after jump starting. The batteries must be charged to proper voltage
18
with a battery charger. Many batteries thought to be unusable are still
rechargeable.
Use only equal voltage for starting. Check the battery and starter voltage rating of
your machine. Use only the same voltage for jump starting. Use of a welder or
higher voltage damages the electrical system.
Refer to Special Instruction, Battery Test Procedure, SEHS7633, available from

your Caterpillar dealer, for complete testing and charging information.
--------------------------------------------------------------------------------------------------------
Severely discharged maintenance free batteries will not fully recharge from the
alternator alone after you jump start the machine. The batteries must be charged to the
proper voltage with a battery charger. Many batteries that are considered to be
unusable can still be recharged by this method.
Refer to Special Instruction, SEHS7633, "Battery Test Procedure" for complete

information about testing and about charging. This document is available from your
Caterpillar dealer.
When auxiliary starting receptacles are not available, use the following procedure.
1. Determine the reason that the engine will not crank. See Special Instruction,
SEHS7768 for instructions about the use of a 6V-2150 Starting/Charging
Analyzer. This is still a valid procedure if the machine does not have a diagnostic
connector.
2. Engage the parking brake on the stalled machine. Place the transmission into
neutral. Lower the equipment to the ground. Move all controls to the HOLD
position.
3. Turn the start switch on the stalled machine to the OFF position. Turn off all
accessories.
4. Turn the battery disconnect switch on the stalled machine to the ON position.
5. Move the machine that is being used as an electrical source near the stalled
machine so that the jump start cables reach the stalled machine. Do not allow
the machines to contact each other.
6. Stop the engine of the machine that is being used as an electrical source. If you
are using an auxiliary power source, turn off the charging system.
7. Ensure that battery caps on both machines are tight and correctly placed. Ensure
that batteries in the stalled machine are not frozen. Make sure that the batteries
have enough electrolytes.
19
8. The positive ends of the jump start cable are red. Connect one positive end of
the jump start cable to the positive cable terminal of the discharged battery.
Some machines have battery sets.
Note: Batteries that are in series may be in separate compartments. Use the terminal
that is connected to the starter solenoid. This battery or battery set is normally on the
same side of the machine as the starter. The positive ends of the jump start cable are
red. Connect one positive end of the jump start cable to the positive cable terminal of
the discharged battery. Do not allow the positive cable clamps to contact any metal
except for the battery terminals.
9. Connect the other positive end of the jump start cable to the positive cable
terminal of the electrical source.
10. Connect one negative end of the jump start cable to the negative cable terminal
of the electrical source.
Note: In 24 volt battery systems, the negative cable terminal of the electrical
source is connected to the battery disconnect switch in the same battery set that
is used in Step 9.
11. Finally, connect the other negative end of the jump start cable to the frame of the
stalled machine. Do not connect the jump start cable to the battery post. Do not
allow the jump start cables to contact the battery cables, the fuel lines, the
hydraulic lines, or any moving parts.
12. Start the engine of the machine that is being used as an electrical source or
energize the charging system on the auxiliary power source.
13. Wait at least two minutes before you attempt to start the stalled machine. This
will allow the batteries in the stalled machine to partially charge.
14. Attempt to start the stalled engine. See your machine's Operation and
Maintenance Manual, "Starting Above 0°C (+32°F)" for the correct starting
procedure.
15. Immediately after you start the stalled engine, disconnect the jump start cables in
reverse order.
16. Conclude the failure analysis on the starting system of the stalled machine and/or
on the charging system of the stalled machine.
20
Engine Starting with Starting Aid
SMCS - 1000; 1090; 1456; 7000
Diesel Engines That Are Equipped With Gasoline Starting Engines
1. Place the lever that is used to release compression into the START position.
2. Move the engine governor control to the SHUTOFF position.
3. Shift the transmission for the gasoline starting engine into the LOW speed
position. Start cranking the diesel engine with the gasoline starting engine.
4. After the diesel engine cranks freely, disengage the clutch for the gasoline
starting engine. Shift the transmission for the gasoline starting engine to HIGH
speed. Engage the clutch for the gasoline starting engine. Crank the diesel
engine for several minutes in order to warm the engine. As a result of cranking
the diesel engine, the oil pressure should attain the NORMAL range on the
gauge. Also, the pressure of the diesel fuel should register NORMAL.
5. Place the lever that is used to release compression into the RUN position. Move
the diesel engine's governor control lever to the HIGH IDLE position.
______________________________________________________
NOTICE
Start the diesel engine with the starting engine transmission in

High only.
______________________________________________________
6. After the diesel engine starts, reduce the rpm of the diesel engine. Disengage the
clutch for the gasoline starting engine. Turn off the fuel to the gasoline starting
engine. Continue to run the gasoline starting engine until the gasoline starting
engine's carburetor bowl is dry.
21
Diesel Engines That Are Equipped With Gasoline Starting Engines and Glow
Plugs
1. Place the lever that is used to release compression into the START position.
2. Move the governor control lever to the SHUTOFF position.
3. Start cranking the diesel engine with the gasoline starting engine's transmission
in LOW speed.
4. After the diesel engine cranks freely, disengage the clutch for the gasoline
starting engine. Shift the transmission for the gasoline starting engine to HIGH
speed. Engage the clutch for the gasoline starting engine. Crank the diesel
engine for several minutes in order to warm the engine. Cranking the diesel
engine will also bring the oil pressure to the NORMAL range on the gauges. Also,
the pressure for the diesel fuel should register NORMAL.
5. Disengage the clutch for the gasoline starting engine, but allow the gasoline
starting engine to run.
6. Turn the heat switch for the glow plug to the HEAT position. Allow the glow plug
to operate for two to five minutes. Do not crank the diesel engine.
7. After warming the engine with the glow plug, move the lever that is used to
release compression into the RUN position. Engage the clutch in order to crank
the diesel engine.
8. With the heat switch in the ON position, allow the gasoline starting engine to
crank the diesel engine. Continue cranking the diesel engine until normal
cranking rpm is achieved.
______________________________________________________
NOTICE
Start the diesel engine with the starting engine transmission in

High only.
______________________________________________________
9. While you crank the engine with the heat switch in the ON position, move the
governor control lever to the HIGH IDLE position.
10. Keep the heat switch in the ON position until the engine starts and the engine
runs smoothly. After the engine starts, reduce the rpm of the engine.
22
______________________________________________________
NOTICE
Do not turn the heat switch to the Heat position if the engine is
warm and running. Engine damage could result.
______________________________________________________
11. Disengage the clutch for the gasoline starting engine. Turn off the fuel for the
gasoline starting engine. Continue to run the gasoline starting engine until the
engine's carburetor bowl is dry.
23
Diesel Engines That Are Equipped With Ether Starting Aid
Manual Metered Ether Injection System
Ether is poisonous and flammable.
Breathing ether vapors or repeated contact of ether with skin can cause
personal injury.
Use ether only in well ventilated areas.
Do not smoke while changing ether cylinders.
Use ether with care to avoid fires.
Do not store replacement ether cylinders in living areas or in the operator's

compartment.
Do not store ether cylinders in direct sunlight or at temperatures above

49 °C (120 °F).
Discard cylinders in a safe place. Do not puncture or burn cylinders.
Keep ether cylinders out of the reach of unauthorized personnel.
To avoid possible injury, be sure the brakes are applied and all controls are in
Hold or Neutral when starting the engine.
At temperatures above 0°C (32°F), the use of ether is not normally necessary. At
temperatures between 0°C (32°F) and −18°C (0°F), one to six injections of ether may
be required. The amount of ether that is required will depend on the type of engine and
the cranking rpm.
When you start the engine below −18°C (0°F), use a new container of ether to make
sure that there is adequate delivery pressure.
24
______________________________________________________
NOTICE
Inject starting aid (ether), only while cranking the engine.
______________________________________________________
At temperatures below −18°C (0°F), three to six injections of ether will be required to
start the engine. After the engine starts, and cranking is stopped, continue to inject ether
until the engine runs smoothly and/or the white smoke stops. This may require as many
as ten to twelve injections of ether.
Continuous Flow Ether System
The continuous flow ether system that is used as a starting aid in cold weather is
controlled by the engine ECM and engine software. The continuous flow ether system is
dependent on coolant temperature and altitude. The starting procedure is not affected
during ether injection.
Note: On machine engines that are equipped with an air inlet heater and continuous
flow ether, the heater indicator light may not illuminate under certain conditions. The
ECM and engine software insure that ether injection will not occur when the air inlet
heater is in use.
Note: Check the ether bottle to insure that the bottle contains an adequate supply of
ether in order to aid engine starting. This can be done by removing the bottle and
shaking the bottle. Replace with a new bottle if the bottle is empty.
Note: Insure the continuous flow ether is turned on using electronic technician (ET).
Consult your Caterpillar dealer for more information.
Automatic Metered Ether Injection System
Start the engine with the ether starting aid in the AUTOMATIC position.
After the engine starts, move the ether starting aid switch to the MANUAL position. Hold
the switch in the MANUAL position until the engine runs smoothly and/or the white
exhaust smoke stops.
Note: Regardless of the switch position, if the jacket water coolant temperature is at
least 13°C (55°F), ether will not be injected.
Allow the engine to warm up at low idle for a minimum of five minutes before operating
the machine.
25
Diesel Engines That Are Equipped With Glow Plugs
1. Move the engine governor control to the FULL THROTTLE position.
2. Turn the heat-start switch to the HEAT position. Maintain heat to the engine for
the time that is indicated in table 1.
Table 1
Times For Glow Plug Starting Aid
Starting Temperature Glow Plug Heating Time
Above 16°C (60°F) Zero minutes
16 to 0°C (60 to 32°F) One minute
0 to −18°C (32 to 0°F) Two minutes
Lower Than −18°C (0°F) Three minutes
3. Turn the heat-start switch to the START position. Spray ether starting fluid into
the air intake while you crank the engine.
Note: Ether starting fluid may not be required in all instances.
26
______________________________________________________
NOTICE
Never operate the starter for more than twenty seconds at a time
without allowing two minutes for the engine to cool before
attempting to start again.
Do not turn the heat start switch to the Heat position or the Start
position with the engine warm or running. Engine damage could
result.
Use ether sparingly. Spray ether into the air intake for
approximately one second. Wait approximately two seconds
before spraying again. Spray ether only while cranking the
engine. Follow instructions on the container.
______________________________________________________
4. When the engine starts, return the engine governor control to the LOW IDLE
position. Run the engine at the rpm that allows the engine to run smoothly. If
necessary, return the heat-start switch to the HEAT position until the engine runs
smoothly.
5. When the engine is stopped, turn the disconnect switch to the OFF position in
order to prevent battery discharge.
If your engine is equipped with an air inlet heater (AIH) for cold weather
starting, only use an approved continuous flow ether system that is installed
by Caterpillar or by a Caterpillar dealer. The engine software must be activated
in order to insure that ether injection and AIH operation will not occure at the
same time. Use of any other manually or automatically operated ether started
aid system could cause an explosion resulting in injury or death.
27
Explosion hazard! This machine is equipped with an air inlet heater. Do not
spray aerosol starting aids such as ether manually into the intake. The use of
ether without an ether attachment could result in an explosion or fires that
could cause personal injury or death.
1. Engage the parking brake.
2. Unlock the steering column and the steering wheel. Adjust the steering column
and the steering wheel to the desired position. Lock the steering column and the
steering wheel.
3. Move the control levers to the HOLD position.
4. Push in the starting aid switch for the air inlet heater and release the starting aid
switch.
5. The indicator light for the air inlet heater may come on during engine start-up.
When the indicator light goes off, turn the engine start switch to the START
position.
6. Depress the throttle pedal by 1/3 of the full pedal travel during engine cranking.
7. When the engine starts, release the engine start switch key and the throttle
pedal. The throttle pedal will return to the low idle position.
After engine start-up, the air inlet heater can be activated for an extended postheat
cycle. The air inlet heater will operate for an additional 30 seconds in order to smooth a
rough running engine.
When you are starting the engine at temperatures below −9.5 °C (15 °F) or below 9 °C
(48 °F) when above 460 m (1500 ft), the use of additional cold weather starting aids is
recommended. A coolant heater, a fuel heater, an oil heater, or extra battery capacity
may be required.
28
Battery Information
SMCS – 1401
Personal injury can result from battery fumes or explosion. Batteries give off
flammable fumes that can explode. Electrolyte is an acid and can cause
personal injury if it contacts the skin or eyes. Prevent sparks near the
batteries. Sparks could cause vapors to explode. Do not allow jumper cable
ends to contact each other or the engine. Improper jumper cable
connections can cause an explosion. Always wear protective glasses when
working with batteries.
The 1U-7297 Coolant/Battery Tester (Fahrenheit) or the 1U-7298 Coolant/Battery

Tester (Celsius) are available for testing the condition of the battery fluid and for
checking the freezing point of the coolant. These testers are optical refractometers. The
optical refractometer will automatically compensate for temperature. The readings are
correct without adjustment for temperature.
The temperature of the battery affects the battery's cranking power. When the battery is
too cold, the battery will not crank the engine, even though the engine is warm. Keeping
the battery warm will maintain at least 70 percent of the battery's cranking power. When
possible, keep the batteries warm. Batteries may be stored in a warm environment or
the battery compartment can be heated.
Whenever the engine operates below the normal rpm, the batteries may not be
recharged. Whenever an engine is not being operated in cold weather, use a battery
charger to keep the battery charged. A full charge prevents the battery from freezing.
All batteries should be kept charged to a corrected specific gravity of 1.250 or above.
If a hydrometer is used in place of the recommended refractometer, use the following
table or follow the procedure to correct the reading.
In order to achieve the corrected reading, use the following procedure.
At the temperature of 27°C (81°F), the specific gravity should be 1.220. Subtract .004
from the reading for each increment of 6°C (10°F) below 27°C (81°F). The result should
be 1.220.
29
Table 1
Corrected Specific Gravity for the Battery at the Specified Temperatures
Temperature Actual Readings of the Hydrometer That Were Taken at

Specific Temperatures (1)
27°C (80°F) 1.300 1.280 1.250 1.220 1.190 1.160
−18°C (0°F) 1.332 1.312 1.282 1.252 1.222 1.192
−23°C (−10°F) 1.336 1.316 1.286 1.256 1.226 1.196
−29°C (−20°F) 1.340 1.320 1.290 1.260 1.230 1.200
−34°C (−30°F) 1.344 1.324 1.294 1.264 1.234 1.204
−43°C (−45°F) 1.350 1.330 1.300 1.270 1.240 1.210
−54°C (−65°F) 1.358 1.338 1.308 1.278 1.248 1.218
Approximate State
of Charge Shown 100 90 75 50 25 0
as a percent of
Full charge
(1) Scales of the hydrometer do not usually show decimal readings. A reading of 1280 is equivalent
to a specific gravity of 1.280.
30
Fluid Recommendations
SMCS - 1000; 1250; 1280; 1350; 1395; 7000; 7581
Reference: Refer to Special Publication, SEBU6250, and “Caterpillar Machine Fluids

Recommendations" for more information on fluids in your machine.
Antifreeze
_____________________________________________________
NOTICE
Adding coolant to an overheated engine could result in
damage to the engine. Allow the engine to cool before
adding coolant.
If the machine is to be stored in, or shipped to, an area with

freezing temperatures, the cooling system must be
protected to the lowest outside (ambient) temperature.
The engine cooling system is normally protected to a

minimum of−29°C (−20°F) with Caterpillar Antifreeze, when
shipped from the factory unless special requirements are
defined.
___________________________________________________________
Frequently check the specific gravity of the antifreeze in order to ensure proper
protection.
Glycol in the antifreeze provides freeze protection. Glycol in the antifreeze prevents
water pump cavitation. Glycol in the antifreeze also reduces cylinder liner pitting. For
optimum performance, Caterpillar recommends a solution that contains a 50/50 mixture
of water and of glycol.
31
_____________________________________________________
NOTICE
All Caterpillar diesel engines equipped with air-to-air
aftercooling (ATAAC) require a minimum of 30 percent
glycol to prevent water pump cavitation.
___________________________________________________________
Most heavy-duty antifreezes use ethylene glycol. Propylene glycol may also be used. In
a mixture that is 50 percent water, ethylene glycol and propylene glycol have similar
properties that are relative to the following elements: freeze protection, control of
corrosion and compatibility with the seal. Check the glycol level of the antifreeze with
the 1U-7298 Coolant/Battery Tester (Degrees Celsius) or with the 1U-7297
Coolant/Battery Tester (Degrees Fahrenheit). Tables 1 and 2 define the freeze
protection for ethylene glycol and for propylene glycol.
Table 1
Ethylene Glycol
Concentration Freeze Protection
50 Percent −37°C (−34°F)
60 Percent −51°C (−60°F)
Table 2
Propylene Glycol
Concentration Freeze Protection
50 Percent −29°C (−20°F)
32
_____________________________________________________
NOTICE
Do not use propylene glycol in concentrations that exceed
50 percent glycol because of propylene glycol's reduced
heat transfer capability. Use ethylene glycol in conditions
that require additional freeze or antiboil protection.
___________________________________________________________
Note: Propylene glycol antifreeze that is used in Caterpillar Diesel Engine cooling
systems must meet "ASTM D6211-98 "Fully-Formulated Propylene Glycol-Based
Engine Coolant for Heavy- Duty Engines". When Propylene glycol antifreeze is used in
heavy-duty diesel engines, regular treatments of Supplemental Coolant Additive (SCA)
is required for protection of the liner. Consult your Caterpillar dealer for more
information.
Fuel Recommendations
 Purchase fuel from a reputable supplier.
 Use fuel that at least meets the specifications for distillate fuel. These fuels have
a minimum lubricity level of 3100 g. This result is obtained by conducting the
Scuffing Load Wear Test (SBOCLE). If a High Frequency Reciprocating Rig
(HFRR) is used for testing, you may expect a wear scar of .45 mm (0.018 inch)
maximum at 60°C (140°F) or a wear scar of .38 mm (0.015 inch) at 25°C (77°F).
 Keep the fuel storage tank clean of water, debris and sediment.
 Drain water and sediment from the fuel storage tank weekly. Drain water and
sediment before the tank is refilled.
 Keep the area around the fuel tank filler neck clean of debris in order to prevent
contamination of the fuel tank.
 As required, clean the inside of the vehicle's fuel tank.
 Drain water and sediment from the vehicle's fuel tank daily. Drain the tank at the
start of a shift. After the fuel tank has been filled, allow the fuel to settle for ten
minutes. This will allow the water and sediment to separate from the fuel. Then,
drain the water and sediment from the tank.
 Install water separators.
 Drain the water from the water separator daily.
33
 For some applications, Caterpillar high efficiency fuel filters are required in order
to provide maximum life to the fuel system.
 Change fuel filters at the scheduled interval. Never fill the new fuel filter with fuel
before installation. Use the fuel priming pump to remove air from the system.
 Install breather filters on the fuel tanks.
Fuel Information for Gasoline Engines
Use a regular grade of fuel or use an unleaded grade of fuel. These fuels must have a
minimum octane rating of 87.
Fuel Information for Engines That Use LP Gas
Use grade HD5 LPB. LP Gas is a highly volatile fuel. LP Gas has an octane rating of
100 to 140. Follow local ordinances regarding the storage of tanks of LP Gas. Follow
local ordinances regarding the filling of tanks for LP Gas.
Fuel Information for Diesel Engines Only
When diesel fuel is stored outdoors, the water will freeze after the water separates from
the diesel fuel. Any effect that is caused by storing the fuel outdoors should immediately
appear in the fuel. Fuel that is stored in underground tanks or fuel that is stored in a
heated area will be easier to pump. However, moisture in the fuel will not freeze until the
fuel is in the machine. Any effect that is caused by cold weather will not appear until the
fuel has cooled to the outside temperature. It is preferable to determine any detrimental
effects of temperature before the fuel is in the machine.
The two basic types of diesel fuel are No. 2 diesel fuel and No. 1 diesel fuel. No. 2
diesel fuel is a heavier diesel fuel than No. 1 diesel fuel. Heavier fuels can cause
problems with fuel filters, fuel lines, fuel tanks, and fuel storage in cold weather. Heavier
diesel fuels such as No. 2 diesel fuel can be used in diesel engines that operate in cold
temperatures with a minimum amount of pour point depressant additive. For more
information on fuels which include blends of No. 1 and No. 2 diesel fuel, consult your
fuel supplier.
When you use No. 2 diesel fuel or other heavier fuels, some of the fuel's qualities may
interfere with successful cold weather operation.
Reference: Refer to Special Publication, SEBU6250, "Caterpillar Machine Fluids

Recommendations", "Characteristics of Diesel Fuel and Modification to Characteristics
of Diesel Fuel" for more information.
34
There are several possible methods that can be used to compensate for the fuel
qualities that may interfere with cold weather operation. These methods include the use
of starting aids, engine coolant heaters, fuel heaters, and de-icers.
Starting Aids
The use of a starting aid is a conventional method of assistance for cold starts in low
temperature conditions. A variety of starting aids are available for Caterpillar engines.
Follow the recommendations that are provided by the manufacturer of the starting aid.
Information about the use of starting aids is included in the Operation and Maintenance
Manual for your machine.
Engine Coolant Heaters
These heaters heat the engine coolant. The heated coolant flows through the cylinder
block. The flow of heated coolant keeps the engine warm. A warm engine is easier to
start in cold weather. Most coolant heaters use electrical power. A source of electricity is
necessary for this type of heater. Other heaters that burn fuel are available as a source
of heat. These heaters may be used in place of the electrical heaters.
With either type of heater, starting aids and/or fuels with higher cetane numbers are less
important because the engine is warm. Problems with fuel cloud point can cause the
plugging of fuel filters. Problems with fuel cloud point cannot be corrected by engine
coolant heaters. This is especially true for machines that allow the fuel filter to be cooled
by air flow during operation.
Fuel Heaters
The fuel cloud point is related to problems with fuel filters. The heater heats the fuel
above the cloud point before the fuel enters the fuel filter. This prevents wax from
blocking the filter. Fuel can flow through pumps and lines at temperatures below the
cloud point. The cloud point is often above the pour point of a fuel. While the fuel can
flow through these lines, the wax in the fuel can still plug the fuel filter.
In some engine installations, small modifications can prevent problems that are caused
by the cloud point. One of the following changes can prevent problems in many
conditions: a change in the location of fuel filters and/or supply lines and the addition of
insulation. In extreme temperatures, heating of the fuel may be required to prevent the
filters from plugging. There are several types of fuel heaters that are available. The
heaters use either engine coolant or exhaust gas as a heat source. Most of these
systems will prevent problems with the filters without the use of de-icers. These systems
may be ineffective when the fuel contains a large amount of dirt or of water. Use of a
fuel heater can help eliminate some cold weather problems. A fuel heater should be
installed so that the fuel is heated before flowing into the fuel filter.
Note: Only use fuel heaters that are controlled by thermostats or use fuel heaters that
are selfregulated. Do not use fuel heaters in warm temperatures.
35
Select a fuel heater that is mechanically simple, yet adequate for the application. The
fuel heater should also prevent overheating of the fuel. Disconnect the fuel heater or
deactivate the fuel heater in warm weather. An unacceptable loss of fuel viscosity and
engine power will occur if the fuel supply temperature is allowed to become too hot.
For additional information on fuel heaters, see your Caterpillar dealer.
De-Icers
De-icers lower the freezing point of the moisture in the fuel. De-icers are not generally
needed when fuel heaters are used. If you experience trouble, consult your fuel supplier
for recommendations of a compatible commercial de-icer.
Lubricants for Cold Weather
Before attempting to start the engine, make sure that the oil in the engine, the oil in the
transmission, and the oil in the hydraulic system are fluid enough to flow. Check the oil
by removing the dipsticks. If the oil will drip from the dipstick, then the oil is fluid enough
to start the engine. Do not use oil that has been diluted with kerosene. Kerosene will
evaporate in the engine. This will cause the oil to thicken. Kerosene will cause swelling
and softening of the silicone seals. If your machine is equipped with a gasoline starting
engine (earlier machine), make sure that the oil is fluid enough to flow.
If the viscosity of the oil is changed for colder weather, also change the filter element. If
the filter is not changed, the filter element and the filter housing can become a solid
mass. Drain all hydraulic cylinders and lines. After you change the oil, operate the
equipment in order to circulate the thinner oil.
When you start an engine or when you operate an engine in ambient temperatures that
are below−20°C (−4°F) use base oils that can flow in low temperatures. These oils have
lubricant viscosity grade of SAE 0W or of SAE 5W.
When you start a machine or when you operate a machine in ambient temperatures that
are below −30°C (−22°F), use synthetic base stock multigrade oil. The oil should have a
lubricant viscosity grade of SAE 0W or SAE 5W. Use an oil with a pour point that is
lower than −50°C (−58°F).
Because the number of acceptable lubricants is limited in arctic conditions, Caterpillar

has special recommendations for arctic conditions. Refer to Special Publication,
SEBU6250, "Caterpillar Machine Fluids Recomendations", "Lubricant Viscosities" for
more information.
36
 Engine Oils
_____________________________________________________
NOTICE
Using oils that are not recommended as first choice oils
could result in shortened life of the engine.
___________________________________________________________
First Choice - use a Cat DEO multigrade or a commercial diesel engine oil that meets
the Cat ECF-1 specification with one of the following lubricant viscosity grades: SAE
0W-20, SAE 0W-30, SAE 0W-40, SAE 5W-30 and SAE 5W-40.
Second Choice - use a commercial oil that is API CI-4 (API CI-4 PLUS), API CH-4, or
API CG-4 licensed. The oil must have one of the following lubricant viscosity grades:
SAE 0W-20, SAE 0W- 30, SAE 0W-40, SAE 5W-30 and SAE 5W-40.
Note: Do not use API CF-4 oils in Caterpillar machine diesel engines.
 Transmission/Drive Train Oils
_____________________________________________________
NOTICE
Use of oils that are not recommended as first choice oils
could result in reduced performance and shortened life to
the transmission, differential, and final drive.
___________________________________________________________
First Choice - use Cat Arctic TDTO or commercial oil that meets the following
requirements: formulated from a full synthetic base stock without the viscosity index
improvers, meets the performance requirements of the TO-4 specification and
requirements for the SAE 30 lubricant viscosity grade. Typical lubricant viscosity grades
are listed below: SAE 0W-30, SAE 5W-30 and SAE 0W-20.
Second Choice - use a commercial oil with a TO-4 type additive package and use one
of the following lubricant viscosity grades: SAE 0W-30, SAE 5W-30 and SAE 0W-20.
These oils have not been tested against the TO-4 specifications.
Note: For maximum service life, use an oil with the highest lubricant viscosity grade that
is allowed for the ambient temperature. Refer to the "Lubricant Viscosities for
Ambient Temperatures" tables and the associated footnotes in order to determine
the recommended oil viscosity.
37
 Hydraulic Oils
Any of the oils that have a minimum zinc additive of 0.09 percent (900 ppm) are
acceptable. These oils are listed under the heading of "Engine Oils" or
"Transmission/Drive Train Oils".
 Final Drive and Axle Oil
First Choice - Cat FDAO (Final Drive and Axle Oil) of the recommended viscosity
grade.
Second Choice - commercial oil of the recommended viscosity grade that meets the
Caterpillar FD-1 specification.
_____________________________________________________
NOTICE
Cat FDAO or commercial oil meeting the Caterpillar FD-1
specification should not be used in compartments that
contain friction material unless otherwise specified,
because they do not develop sufficient friction coefficient to
satisfy the requirements of most clutches and brakes.
___________________________________________________________
 Multipurpose Tractor Oil (MTO)
Cat MTO (Multipurpose Tractor Oil) is available for use in the following systems for the
Caterpillar Challenger tractor: implement steering, hydraulic systems and steering
control mechanisms. Cat MTO is also recommended for use in the rear drive axles of
the Caterpillar Backhoe Loader and certain 500 Series Vibratory Soil Compactors. This
oil has an ambient temperature range of −25°C (−13°F ) to 40°C (104°F) for these
applications.
Note: For recommendations that are specific to your machine, refer to the Operation
and Maintenance Manual for your machine.
_____________________________________________________
NOTICE
Cat MTO is not the same as Cat TDTO, and does not meet
the Caterpillar TO-4 or TO-4M transmission/drive train oil
specification. Cat MTO should not be used in compartments
that specify TO-4 or TO-4M oil.
___________________________________________________________
38
_____________________________________________________
NOTICE
Cat MTO is not the same as Cat FDAO, and does not meet
the Caterpillar FD-1 final drive and axle oil specification. Cat
MTO should not be used in compartments that specify FD-1
oil.
___________________________________________________________
Warm-Up Procedures for Machines that are used in Cold Weather (Generic)
Note: For recommendations that are specific to your machine, refer to the Operation
and Maintenance Manual for your machine. After the engine is warm, warm up the other
systems. Start with the hydraulic system. Run the engine at less than one-third throttle
and slowly move the control lever in order to lift the attachment. Initially, lift the control
lever for a few centimeters (inches). Lower the attachment slowly. Continue the
following sequence: raising, lowering, extending and retracting. Extend the travel during
each cycle. Perform this operation for all hydraulic circuits. Alternate between all of the
attachments.
Exercise the transmission and the power train. If you cannot move the control for the
transmission, perform the following steps:
 Engage the parking brake or apply the parking brake.
 Run the engine slightly above LOW IDLE.
 Shift the transmission several times from FIRST GEAR FORWARD to FIRST
REVERSE
Release the brake. Move the equipment forward and backward for several meters
(yards). Exercise the machine for several minutes.
In order to reduce the total warm up time, start exercising the entire machine before you
complete the hydraulic warm up time.
Operate under a light load until the systems reach normal operating temperatures.
If the engine temperature is not high enough, enclose the engine and block the radiator.
A thermostat that opens at a higher temperature will not increase the engine
temperature if the engine is not under load.
In order to prevent seal damage and gasket damage, keep the pipe for the engine
crankcase breather clear of blockage.
39
In extreme conditions, use a canvas over the engine compartment. Heat the engine
area with a space heater. This will aid in starting the engine. Extending the canvas over
the hydraulic components will provide initial warming of the components. Follow all
applicable safety guidelines.
Running the engine at low idle will not keep the hydraulic systems warm.
Cold weather operations require more time for completion than other operations. The
extra time that is spent in properly caring for the equipment can prolong the life of the
equipment. This is especially true in extreme conditions. Longer equipment life will
decrease overall cost.
40
Tire Inflation Information
SMCS – 4203
Tires that are inflated below the recommended pressure will have shortened life. A tire
that is inflated to the correct pressure in a 18 to 21°C (64 to 70°F) warm shop area will
have an incorrect tire pressure in freezing temperatures.
Use dry nitrogen gas to inflate the tires. Nitrogen gas is N 2. Dry nitrogen is
recommended in order to eliminate ice crystals. Ice crystals could hold the valve stem
open in the tire.
The table shows the correct pressures for tires that are inflated in an area with a
temperature of 18 to 21°C (64 to 70°F). These pressures are adjusted for the
environmental working temperature of the machine.
Tire inflation should be done in a heated area. The tire bead will seat better when the
tire bead is warm. The initial tire pressure should be fifteen to twenty percent higher
than the operating pressure in order to seat the tire bead against the rim. Deflate the
tires to operating pressure before operating the machine. The contact surface of tires
will become flat in cold weather when a machine is parked. To return the tire to a normal
shape, move the machine gradually.
Some tractors and some wheel tractor-scrapers are equipped with wheel coolant in
order to prevent overheating of the rims and overheating of the tires during the braking
operation. This coolant consists of a mixture of twenty percent ethylene glycol and
eighty percent water. Even though freezing may begin at −12°C (10°F), these coolant
solutions can be used in temperatures of approximately −51°C (−60°F).
41
Table 1
Recommended Recommended Inflation Pressure that is Adjusted for a Specific
Inflation Ambient Temperature

Pressure
−1°C (30°F) −18°C (0°F) −29°C (−20°F) −40°C (−40°F)
205 kPa (30 230 kPa 250 kPa 270 kPa 285 kPa (41
psi) psi)
(33 psi) (36 psi) (39 psi)
psi) psi)
(38 psi) (42 psi) (45 psi)
psi) psi)
(44 psi) (48 psi) (51 psi)
psi) psi)
(49 psi) (53 psi) (57 psi)
psi) psi)
(55 psi) (59 psi) (62 psi)
psi) psi)
(60 psi) (65 psi) (68 psi)
psi) psi)
(65 psi) (71 psi) (74 psi)
psi) psi)
(71 psi) (75 psi) (80 psi)
psi) psi)
(75 psi) (83 psi) (86 psi)
42
psi) psi)
(81 psi) (88 psi) (91 psi)
psi) psi)
(87 psi) (93 psi) (99 psi)
psi) psi)
(91 psi) (99 psi) (104 psi)
psi) psi)
(97 psi) (105 psi) (110 psi)
psi) psi)
(103 psi) (110 psi) (116 psi)
psi) psi)
(108 psi) (116 psi) (122 psi)
psi) psi)
(113 psi) (122 psi) (128 psi)
760 kPa ( 110 820 kPa 885 kPa 925 kPa 980 kPa (142
psi) psi)
(119 psi) (128 psi) (134 psi)
psi) psi)
(124 psi) (134 psi) (140 psi)
psi) psi)
(129 psi) (140 psi) (146 psi)
43
Reference Material
SMCS - 1000; 7000
Special Publication, PEHP9536, "Product Data Sheet for Caterpillar Diesel Engine Oils
(DEO)" CH- 4 diesel engine oils (International markets)
Special Publication, PEHP7062, "Product Data Sheet for Caterpillar Full Synthetic
Diesel Engine Oil (DEO)" CH-4 diesel engine oils (North American Markets)
Special Publication, PEHP6047, "Product Data Sheet for Caterpillar Biodegradable

Hydraulic Oil (HEES)" (not available in all markets)
Special Publication, PEHP7508, "Product Data Sheet for Caterpillar Gear Oil (GO)"
Special Publication, PEHP3050, "Product Data Sheet for Caterpillar Multipurpose

Tractor Oil (MTO)"
Special Publication, PEHP7506, "Product Data Sheet for Caterpillar Transmission /

Drive Train Oil (TDTO)" Exceeds the Caterpillar TO-4 specification requirements.
Special Publication, PEHP8035, "Product Data Sheet for TDTO Transmission Multi-
Season (TMS)" Exceeds the Caterpillar TO-4/TO-4M specification requirements.
Special Publication, PEHP9530, "Product Data Sheet for Caterpillar Final Drive and
Axle Oil (FDAO)" Exceeds the Caterpillar FD-1 specification requirements.
Special Publication, PEHP9570, "Product Data Sheet for Caterpillar Final Drive and
Axle Oil Synthetic (FDAO Syn)" Exceeds the Caterpillar FD-1 specification
requirements.
Special Publication, NEHP5621, "How To Select The Right Grease For Any Job". This
publication lists the typical characteristics for eleven of Caterpillar's greases.
Special Publication, NEDG6022, "Product Data Sheet for Multipurpose Lithium Complex
Grease with Molybdenum (MPGM)"
Special Publication, NEHP6015, "Product Data Sheet for Special Purpose Grease
(SPG) Bearing Lubricant"
Special Publication, NEHP6011, "Product Data Sheet for Arctic Platinum (AP) Grease"
Special Publication, NEHP6012, "Product Data Sheet for Desert Gold (DG) Grease"
44
Special Publication, PECP9061, "One Safe Source" (English language for use in
NACD)
Special Publication, PECP9068, "One Safe Source" (English language for use in
EAME)
Special Publication, PECP9067, "One Safe Source"(World English language for use in
non NACD and non EAME)
Special Publication, SEBD0640, "Oil and Your Engine"
Special Publication, SEBU6250, "Caterpillar Machine Fluids Recomendations"
Special Publication, PEHP7076, "Understanding the S-O-S Oil Analysis Tests"
Special Publication, PEHP6001, "How to Take a Good Oil Sample"
Special Publication, NEHP6013, "S-O-S Fluid Analysis Products"
Special Publication, PEDP7035, "Optimizing Oil Change Intervals" (diesel engines)
Special Publication, PEDP7036, "S-O-S Services"
Special Publication, PEDP7052, "Making the Most of Your S-O-S Program"
Special Publication, PEHP7057, "S·O·S Coolant Analysis"
Special Publication, PEHP4036, "Product Data Sheet for Caterpillar ELC" (For North
and South America)
Special Publication, PEHP9557, "Product Data Sheet for Caterpillar ELC" (For Europe,
Africa, and Middle Eastern Countries)
Special Publication, REHS1063, "Special Instruction - Know Your Track-Type Tractor

Cooling System"
Special Publication, PEEP5027, "Label - ELC Radiator Label"
Special Publication, PELE0761, "Hydraulic Fluid Recommendations" (service fill)
Special Publication, AECQ1042, "Caterpillar Product Line Brochure"
45
HQR1112
SECTION : Engine
ISSUE: 01/2017



HQR1112
SECTION : Engine
ISSUE: 01/2017
Lube Oil:

regularly.
Exhaust System:

Cooling System:

Air Inlet System:


Battery:
engine starting.

NOTE:


HQR1112
SECTION : Tracks
ISSUE: 01/2017

Q-1
INSTALLATION, OPERATION AND
MAINTENANCE MANUAL
WARNING
Do not attempt to operate these track systems
unless you have read and understood
these instructions.
copyright Strickland Tracks Ltd Nov-2004, The Heath Works, Cropthorne, Pershore, Worcs. WR10 3NE. Tel +44 (0)1386 862800 Fax: +44 (0)1386 862801
E-mail: tracksystems@stricklanduk.com Web: www.stricklandtracks.com
CONTENTS
SECTION 1: GENERAL INFORMATION
1.1 MANUFACTURER’S STATEMENT -1-
1.2 INTRODUCTION -2-
1.3 UNDERCARRIAGE IDENTIFICATION -3-
1.4 GENERAL SAFETY AND ACCIDENT PREVENTION -4-
1.4.1 Protective Equipment
1.4.2 Unauthorised Modifications
1.4.3 Pressurised Items
1.4.4 Lifting
1.5 SAFE LIFTING AND HANDLING OF TRACK SYSTEM -5–
1.5.1 Using Overhead Crane
1.5.2 Using Forklift Truck -7-
1.6 OPERATING PRECAUTIONS -8-
1.7 WORKING CONDITIONS -9-
SECTION 2: TRACK SYSTEM INSTALLATION

2.1 INSTALLATION OF TRACK SYSTEMS - 10 -
2.1.1 Installation of Weld-on Track System
2.1.2 Installation of Bolt-on Track System - 11 -
2.2 HYDRAULIC INSTALLATION - 12 -
2.2.1 Hydraulic Track Drives
2.2.2 Track Drive Ports and Port Functions -13 -
2.2.3 Motion Control / Brake Release Valves -14 -
SECTION 3: BASIC MAINTENANCE

3.1 CORRECT MAINTENANCE PROCEDURE - 15 -
3.2 MAINTENANCE CHECKS - 16 -
3.3 CHECKING TRACK TENSION - 17 -
3.4 ADJUSTMENT OF TRACK TENSION - 18 -
3.4.1 Tightening the Track - 19 -
3.4.2 Slackening the Track
3.5 MASTER PINS - 20 -
3.5.1 Press Type Master Pin
3.5.2 Dowel Type Master Pin
3.6 REMOVING THE TRACK - 21 -
3.7 REJOINING THE TRACK - 22 –
3.7.1 Rejoining Track Using Press Type Master Pin
3.7.2 Rejoining Track Using Dowel Type Master Pin
3.8 TRACK REPAIR LINK KIT - 23 -
3.9 TRACK DRIVE UNITS - 24 -
3.9.1 Oil Filling
3.9.2 Oil Draining
3.10 LEAKS AND SEIZURES - 25 –
3.10.1 General Components
3.10.2 Track Chains
SECTION 4: WEAR LIMITS

4.1 WEAR LIMITS - 26 -
4.2 TRACK SHOE WEAR - 27 -
4.3 TRACK LINK WEAR - 28 -
4.4 INTERNAL PIN AND BUSH WEAR - 29 -
4.5 EXTERNAL PIN AND BUSH WEAR - 30 -
4.6 LOWER ROLLER WEAR - 31 -
4.7 CARRIER ROLLER WEAR - 32 -
4.8 FRONT IDLER WEAR - 33 -
4.9 SPROCKET WEAR - 34 -
SECTION 5: TROUBLESHOOTING
5.1 TRACK TENSION - 35 -
5.2 LOSS OF DRIVE - 36 -
5.3 LOSS OF PARALLEL DRIVE - 37 -
SECTION 6: APPENDIX
6.1 BOLT TORQUE TABLE - 38 -
SECTION : 1
GENERAL INFORMATION
1.1 MANUFACTURER’S STATEMENT
Relevant to the incorporation of track systems into host machines.
The tracked undercarriage system is designed as a modular unit for integration to a host machine. It is
not intended to be cycled, driven or operated in the free standing condition.
Strickland Tracks Ltd will not be held responsible for the attachment method to the host machine
and/or any failures of the crawler track system relating to these procedures unless approved in writing
by Strickland Tracks Ltd.
Modification or abuse of the original design may negate manufacturer’s warranty or guarantee which
could conflict with health and safety standards and should not be undertaken without prior consultation
with the manufacturer. For full warranty cover, any modification or attachment must be approved in
writing by Strickland Tracks Ltd.
This installation, operation and maintenance manual must be issued to the machine user, Strickland
Tracks Ltd will not be held responsible for any misuse or failure due to lack of maintenance of the track
system in accordance with instructions in this manual. Failure to issue this manual to the machine user
will invalidate the track systems warranty.
For further details, please refer to section 18 under Terms and Conditions of Sales agreement. No
claims of whatever nature for work carried out to a Strickland crawler undercarriage in the warranty
period will be entertained unless we have given our prior authorisation in writing for work or
replacements to be fitted.
Help line is available Monday to Friday, 9am to 5pm, for procedures relating to; attachment, safety,
operating or maintenance.
E-mail: tracksystems@stricklanduk.com Web: www.stricklandtracks.com -Page 1-
Rev. 280211
1.2 INTRODUCTION
The purpose of this manual is to allow customers to correctly install, operate and maintain the crawler
track system undercarriage on the appropriate machine.
Read this manual with care before conducting any maintenance work on undercarriage
supplied by Strickland Tracks Ltd.
Continuous improvements to undercarriages produced by Strickland Tracks Ltd, may result
in some of the illustrations in this manual being slightly different from the actual parts used.
It is necessary when requesting any spare parts, that all serial numbers relating to the
undercarriage are quoted.
For full technical support contact our Head Office at:
Strickland Tracks Limited

Heath Park
Main Road
Cropthorne, Pershore
Worcestershire
WR10 3NE
ENGLAND
Tel No: +44 (0)1386 862800

Fax No: +44 (0)1386 862801
E-mail: tracksystems@stricklanduk.com
Website: www.stricklandtracks.com
Note: For a comprehensive parts list breakdown/hydraulic installation/technical information for your
relevant track system, please refer to the separate Parts List and Hydraulic Specifications
document.
Electronic versions are available at www.stricklandtracks.com by entering your password,
which can be obtained by directly contacting us.
Below are typical screenshots for Parts List and Hydraulic Specification documents.
Parts Breakdown
Parts list Hydraulic parts list and Track drive ports,

hydraulic installation operating Pressure and
information flow information
Rev. 280211
1.3 UNDERCARRIAGE IDENTIFICATION
All track systems manufactured by Strickland Tracks Ltd can be identified through a 6 digit serial
number. This serial number is recorded along with other information on the Identification Plate. Below is
a typical image of an identification plate.
This identification plate is located on the outside face of each left and right hand track frame
fabrications, forward from the drive end of the tracks. The serial number is also stamped into the skid
plate of each track frame in case the identification plate is lost or damaged.
Serial number stamped here
Identification Plate fitted here
Rev. 280211
1.4 GENERAL SAFETY AND ACCIDENT PREVENTION
Please ensure all safety precautions and instructions are adhered to when installing, operating
and/or performing maintenance on the track systems.
1.4.1 Protective Equipment
Always wear protective clothing and footwear as required by job

conditions when working around this product. Wear protective glasses
when in risk of splintering debris. Use welders’ gloves, facial/eye
protection and other protective clothing appropriate to welding job being
performed. Avoid loose clothing.
1.4.2 Unauthorised Modifications
It is important not to carry out modifications to the track system which

could compromise proper operation and safety. Strickland Tracks Ltd
is not responsible for any injury or damage caused by unauthorised
modifications.
1.4.3 Pressurised Items
Avoid welding near pressurised hydraulic pipelines, track tensioner,

track recoils or other flammable materials. Excessive heating near to
pressurised hydraulic pipelines can cause failure, generating a
flammable spray with the possibility of severe injuries to nearby
persons.
1.4.4 Lifting
Use a hoist when lifting components weighing more than 23 Kg (50lbs).

Ensure all hooks, chains, slings etc., are in good condition and tested
to an adequate safe working load, and be sure hooks or slings are
positioned correctly.
Rev. 280211
1.5 SAFE LIFTING AND HANDLING OF TRACK SYSTEM
Always check the weight stamped on the identification plate before lifting or
moving the track system.
1.5.1 Using Overhead Crane
When using overhead cranes to lift or move a track system, choker chains must be used. Wrap the
choker chains around the top of track groups by inserting one lifting eye of the chain through the
opposing eye, as illustrated in picture below.
For safety reasons, always use two choker chains in the positions shown below, for even weight
distribution of the track system.
Ensure the adjoining sling which connects the choker chains to the crane hoist has an adequate load
rating.
Rev. 280211
The following pictures demonstrate a track system being safely lifted in the air using an overhead crane
with choker chains.
PRECAUTIONS
Chains, sling and hoists are identified by their safe-load lifting capacities.
Do not lift loads exceeding the rated capacity of chains, sling or hoists.
Raise and lower track systems slowly and avoid quick starts or stops.
When moving the raised track system, always keep it as close to the floor
as possible. If the load starts swinging, quickly stop the crane to avoid any
accidental damage to the track system or injuries to any persons working
nearby.
Rev. 280211
1.5.2 Using Forklift Truck
When using a forklift truck to lift the track system, always position the forks under the roller mounting
plates. Ensure that the forks are evenly positioned between the lower rollers to balance the track
system properly as shown below.
Ensure the forks reach through the track system to the other side of the roller mounting plates,
supporting the track system fully as demonstrated below.
The picture shown below illustrates a track system lifted safely and correctly using fork lift truck.
PRECAUTIONS
Ensure the total weight of the track system does not exceed the safe load
capacity of the forklift truck.
Ensure each track system is lifted as a single unit not in pairs.
Rev. 280211
1.6 OPERATING PRECAUTIONS
When travelling up a gradient, the tracks should be driven forward (i.e. idlers first, drive sprocket to the
rear). When travelling down a gradient, tracks should be driven sprocket first.
ALWAYS:-
Park the machine on flat, level ground. If it is necessary to park the machine on a gradient,
the tracks should be solidly blocked.
Ensure the terrain the machine is working on is firm enough to adequately support the
machine.
Make certain the machine is tracked at least 10m in either direction on a daily basis, to
minimise risk of track chain seizure.
Ensure the track systems are free from debris before moving the machine.
Make certain the tracks are not frozen to the ground before moving the machine.
Ensure no leakage of oil from gearbox, roller and idler before and during tracking.
Stop the machine for 30 minutes after tracking it continuously for 30 minutes, to allow the
components to cool down.
NEVER:-
Attempt to track the machine if there is any build up of material around the tracks and drive
sprockets.
Attempt to track the machine if the tracks are frozen to the ground.
Push or tow the machine when it is unable to free itself.
Track the machine constantly more than 30 minutes without providing adequate rest.
IF IN DOUBT, PLEASE CONTACT HELPLINE +44 (0)1386 862800.
WARNING
Failure to observe the above precautions could result in danger
to persons and damage to the track systems and may also
invalidate the warranty.
Rev. 280211
1.7 WORKING CONDITIONS
1.7.1 Working Material
If your machine will be working in materials which can cause corrosion to carbon steel, you must replace
the standard track chains with lubricated chains to avoid seizure of the track joints. Lubricated track
chains are available as an optional extra from new or as a retrofit for customers entering adverse
working conditions.
1.7.2 Operating Temperature
The operating temperature range for track systems is -10°C to +40°C. Always consult Strickland
Tracks Ltd when temperatures fall outside this working range, as alternate component specifications
will be required.
Rev. 280211
SECTION : 2
TRACK SYSTEM INSTALLATION
2.1 INSTALLATION OF TRACK SYSTEMS
2.1.1 Installation of Weld-on Track System
Weld-on track systems are installed onto machines by welding the track fabrication to structural
members of chassis. When welding the track system to machine chassis, the following points must be
considered:
Track system should be welded onto chassis within the preferred welding area. Highlighted in
red are the recommended welding positions.
It is highly recommended to weld structural members of the chassis back to the division plate of
frame. The division plate divides the drive housing from the main body of the frame.
Recommended welding positions are shown below in red.
Ensure the structural members of the chassis are welded onto the track system in line with
internal stiffener plates to evenly distribute machine load.
For proper load distribution, we highly recommend welding connections across the top of the U-
pressing and the lower roller mounting plates as shown below.
Chassis welded across the top of U-

pressing
Internal Stiffener plate
Chassis welded across the lower roller

mounting plates
Rev. 280211
2.1.2 Installation of Bolt-on Track System
Strickland Tracks Ltd offer a wide range of bolt on track systems which assemble on to the machine
via bolt on mounting plates, mating to opposing plates on the host chassis. The image below shows a
typical bolt on track system with mounting plates.
No slots in this position
In most cases where mounting plates are adopted, there is need to reduce the drive housing section.
Due to the reduction of strength this causes, the drive housing must be connected to the chassis using
a substantial bracket, typically shown in the above image.
When considering the design of bracket, always ensure slots are not used in the horizontal plane, this
will ensure drive housing is braced correctly, and guarantee drive rigidity.
PRECAUTIONS
Prior to assembling track systems, remove any grease or rust left on
the machine face of brackets for secure assembly.
Chassis mounting plates must have flatness within the size tolerance
±1mm on machining face to match with the flatness tolerance of
mounting plate on the track system. Failure to maintain this tolerance
could result in misalignment of the track system installation.
Rev. 280211
2.2 HYDRAULICS INSTALLATION
Hydraulic installation of each individual track system is fully explained in Parts List and Hydraulic
Specification document. This document also includes following information:
Hydraulic hose and fitting kit
Track drive ports identification and sizes
Required hydraulic connections
Hydraulic schematic
Direction of rotation of track drive
Operating pressures and flows
Gearbox oil type, quantity and operating temperature, and
Hydraulic filtration and cleanliness.
Electronic versions are available at www.stricklandtracks.com by entering your password, which can be
obtained by directly contacting us
2.2.1 Hydraulic Track Drives
Primarily, Strickland track systems are installed with track drive gearboxes with two types of hydraulic
motors.
Dual displacement (2-speed)
Fixed displacement (single speed)
2.2.1.1 Track Drives Fitted with Dual Displacement Motor
These dual displacement track drives are fitted with hydraulically controlled 2-speed motors, switchable
between displacements by applying a separate pressure to the displacement change port.
They can be run as 2-speed motors or single speed, depending upon the connections made as shown
below.
A. Dual speed motor connections B. Single speed drive connections
Note: Drain line connected to port T, must be installed in such a manner that the motor
housing cannot empty when standing still, i.e. drain line at highest possible point.
Rev. 280211
2.2.1.2 Track Drives Fitted with Fixed Displacement Motor
2.2.2 Track Drive Ports and Port Functions
2.2.2.1 Main Flow Ports, A & B or V1 & V2
Flow and pressure of hydraulic oil is applied to these ports, main drive is achieved. Torque
and speed output is dependent on the pressure and flow applied.
2.2.2.2 Case Drain Port, T
Case drain port allows any excess hydraulic oil to return to tank.
2.2.2.3 Brake Release Port, F
With a pressure applied to this port, multi disc parking brake is released, allowing rotation
of the track drive. When no pressure is applied, the parking brake is locked on.
2.2.2.4 Displacement Change Port, X
Pilot pressure port for controlling the displacement change of the motor between maximum
and minimum, with a relative affect on the output speed of the final drive.
2.2.2.5 Measuring Ports, MA & MB
Measuring ports are used to measure running pressures for testing purposes if required.
Ports are blanked off during normal operation.
Rev. 280211
2.2.3 Motion Control / Brake Release Valves
Motion control / brake release valves are designed for use on open loop hydraulic circuits only. These
valves are generally supplied fitted and hosed to the hydraulic motor flange as shown in above image,
section 2.2.1.2.
The valve has two main functions:
To take a feed from the main pressure line to pressurise the brake release port of the gearbox
with a controlled pressure, releasing the multi disc parking brake whenever any flow/pressure is
applied to the hydraulic motors, prior to driving the gearbox.
To prevent overrun of the motor as the machine descends any gradient, avoiding over-speeding
and therefore a run-away condition. This motion control function operates in both directions of
rotation.
PRECAUTIONS
Before connecting track drives to any hydraulic circuit, ensure all
pipes are removed and flushed through with the hydraulic system
prior to connection.
To ensure proper function of the hydraulic motor, the filtration of
the pressure fluid must provide a cleanliness level of at least:
20/18/15 according to ISO 4406
Rev. 280211
SECTION : 3
BASIC MAINTENANCE
3.1 CORRECT MAINTENANCE PROCEDURE
In order to maintain the reliability of the track systems, regular maintenance is essential. It is imperative
that the tracks are maintained as outlined within this maintenance section.
ALWAYS:-
Perform maintenance on a level and solid surface.
Ensure the track system is solidly supported if work is necessary under the track systems.
Remove any build-up of grease, oil or debris.
Repair all damage and replace worn or broken parts immediately.
Check for oil leaks and damaged hydraulic hoses.
Use only specified lubricants. Do not mix different brands or types.
Use great care when maintaining the hydraulic system since oil may be very hot when the
machine has just been working.
Use only Strickland Tracks Ltd supplied / approved replacement parts. Use of unapproved
parts will invalidate the warranty.
Dispose of lubricants in the proper manner.
Rev. 280211
3.2 MAINTENANCE CHECKS
Please note the maintenance intervals specified below are for track systems working under normal
conditions. If the track system is used in severe working conditions, the maintenance and safety checks
must be performed more frequently.
Monthly
Components Checklist Daily Checks Weekly Checks
Checks
Oil Leakage 
Idler
Wear Limits  
Loose nuts and bolts 

Lower Roller Oil Leakage 
Wear Limits  

Sprockets
Wear Limits  

Track Drive Oil Quantity 
Oil Leakage 
Any damage to track links,


pins and track shoes
Tight or Seized track joints 
Track Group
Track tension 
Wear Limits on track links  
Wear Limits on track
 
shoes
Track System Structural damage or


Fabrication failure
After identifying any problems, take corrective action immediately; tighten bolts and nuts to correct
torque, replace damaged or worn components, and refill oil up to recommended levels.
WARNING
DO NOT operate the tracks with damaged or defective
components. Any persistent problem should be
reported to the machine manufacturer.
Rev. 280211
3.3 CHECKING TRACK TENSION
Stop your machine on solid and level ground and drive 2 metres (minimum) in a forward direction.
Measure the sag on the top part of the track on the longest section of unsupported track as shown
below.
(Carrier roller or skid plate

Sag of Track
whichever is fitted)
The sag of the track must be between 5mm and 15mm.
The above conditions must be fulfilled on a new track system. This must also be regularly checked and
corrected if necessary, by adding grease to the grease tensioner, as described in Section 3.4.
Rev. 280211
3.4 ADJUSTMENT OF TRACK TENSION
Track systems use a grease cylinder to keep each track chain in tension. Screwed into the end of the
grease cylinder is a grease fitting, enabling grease to be pumped into the grease chamber and released
from it, tightening and slackening the track.
Tensioner Seals
Straight Edge
Grease Fitting
The grease inside the track tensioner (Lithium EP2) is pressurised so care must be taken when
loosening the grease fitting.
If the tracks repeatedly become slack, carry out the below mentioned checks:
1. Check for any leakage on the outer face of grease fitting, if so replace grease fitting.
2. Check if there is any grease leakage at contact surface between the grease tensioner
and grease fitting, if so replace bonded seal.
3. Make sure the tensioner seals are not damaged. To replace tensioner seals, simply
unscrew grease fitting, push or pull out inner cylinder to expose lip seal and inner seal.
Replacement seals should be ordered from the machine manufacturer, if required. Prior to
replacing tensioner seals, place a straight edge along the cylinder barrel as shown above to
ensure outer sleeve has not swollen due to overloading. If tensioner is damaged, the complete
tensioner unit need to be replaced.
If there is a risk of over tensioning or over loading of the grease tensioner, a safety valve can be used.
To order safety valves, please contact Strickland Tracks Ltd quoting the serial no. of your track
system.
Safety Valve for Tensioner
Rev. 280211
3.4.1 Tightening the Track
1. Loosen the three screws and swing access cover away from access aperture on the side of
the track frame.
2. Ensure the grease fitting and grease gun adaptor is clean; ingress of dirt into the grease fitting
can result in failure. Connect a grease gun to the grease fitting and add grease until the track
tension is within the specified values given in Section 3.3.
3. Drive 50 metres forwards and 50 metres backwards and repeat the above procedure if the
track slackens.
3.4.2 Slackening the Track
1. Loosen the three screws and swing access cover away from access aperture on the side of
the track frame.
2. Loosen the grease fitting, by turning in an anti-clockwise direction, using gradual increments
until the grease begins to be expelled. Care must be taken not to loosen the grease fitting too
quickly.
3. When the correct track tension has been obtained, tighten the grease fitting by turning in a
clockwise direction and clean away all trace of extruded grease. Be sure not to over tighten
the grease fitting.
If the track fails to slacken after grease fitting has been loosened; DO NOT attempt to remove the tracks
or disassemble the track tensioner, and DO NOT remove the grease fitting from the tensioner. It is
possible that running the tracks a short distance in both directions with the grease fitting loosened may
help to expel the grease.
WARNING
The above procedure involves working with grease contained at
high pressure and must only be carried out by qualified fitters.
Rev. 280211
3.5 MASTER PINS
There are two main types of master pins used on Strickland tracks as explained below:
3.5.1 Press Type Master Pin
Press type master pins are identified either by an X-mark or a centre drill mark on the end faces. To
remove or install press type master pins a hydraulic press must be used (shown in section 3.7.1).
Pictorial views of press type master pin including spacers are shown below.
3.5.2 Dowel Type Master Pin
Dowel type master pins are more common and can be identified by the location type head. Dowel type
master pins can easily be installed using a copper hammer due to the clearance fit. Pictorial view of a
dowel type master pin including spacers is shown below.
Note: For further information regarding master pin installed on your track system, please
refer to Parts List and Hydraulic Specifications document provided with your track
system.
Rev. 280211
3.6 REMOVING THE TRACK
To uncouple the track group the following procedure must be followed:
1. Jack up the machine and block safely on firm, level ground.
2. Locate the master pin.
a. If tracks are installed with Press type master pin. This can be identified by small circular
indentations, or by an X marked on each of the end faces.
b. If tracks are assembled using Dowel type master pin. The flat head of master pin or
slotted face of links should be used for identification.
OR
3. Rotate the track until the pin is in approximate position (as shown above) and place a block
under the front of track. This prevents the chain from dropping once the master pin has been
removed.
4. Release the tension on the tracks as described in Section 3.4; this should only be carried out by
a qualified fitter.
5. Removing master pin.
a. In case of Press type master pin, the pin can be pressed out from the chain, separating
the track.
b. To remove Dowel type master pin, unsecure the dowel first and use copper hammer to
strike the master pin out.
6. The track can now be pulled from under the machine.
WARNING
When removing the press type master pin, do not use
a sledge hammer. This may cause splintering of the
metal with the possibility of personal injury.
Rev. 280211
3.7 REJOINING THE TRACK
To rejoin the track group, the following procedure must be followed, but should only be carried out by
qualified fitters:
3.7.1 Rejoining Track Using Press Type Master Pin
1. Position the pin collars into the counter bore of the mating links.
2. Ensure the pin holes and the bushings are aligned and insert a dummy pin.
3. With the master pin in position, set up the track press.
4. Using track press, push the master pin fully into the chain links, pushing the dummy pin
through the link. Picture below shows a typical example of C-press.
3.7.2 Rejoining Track Using Dowel Type Master Pin
1. Position the pin collars into the counter bore of the mating links.
2. Ensure the pin holes and the bushings are aligned.
3. Use the copper hammer to strike the flat head of master pin to tap it into the chain links.
4. With the master pin inserted fully into the chain links, it must be secured in position using a
dowel (locking pin). Following picture demonstrates the use of copper hammer to tap in the
hammer type master pin.
Incorrect dowel position Correct dowel position
WARNING
When rejoining tracks using press type master pin, do not use
a sledge hammer. This may cause splintering of the
metal with the possibility of personal injury.
Rev. 280211
3.8 TRACK REPAIR LINK KIT
A typical image of track repair link kit is shown below followed by list of components and their quantities
included in kit.
Index Component Description Quantity

1 Left hand master link 1
2 Right hand master link 1
3 Master bushing 1
4 Master pin with collars (Press type) 1
5 Master pin with collars (Dowel type) 1
6 Track shoe bolt 4
7 Track shoe nut 4
Note: The kit is supplied with the master bushing pressed into the left and right hand links.
To order a new track repair link kit, Please contact Strickland Tracks Ltd. quoting your track serial
number or track part number or track repair link kit part number. Please refer to Parts List and Hydraulic
Specification document to identify track repair link kit part number.
Rev. 280211
3.9 TRACK DRIVE UNITS
3.9.1 Oil Filling
To fill, track the machine until the gearbox casing is level with a plug positioned at 12 o’clock as shown
below. Unscrew the two plugs and fill from the upper hole until oil reaches the level of the lower hole.
Oil Fill
Maximum Level
3.9.2 Oil Draining
To drain, track the machine until a plug is at 6 o’clock position as shown below. Unscrew both plugs and
allow all oil to discharge into a suitable container. Dispose of waste oil in a safe and approved way .
Venting
Drain Port
NOTE: Please refer to Parts List and Hydraulic specifications document for accurate oil
quantities and type.
WARNING
Do not fill oil in the track drive without checking oil level inside it.
All track systems are supplied by Strickland Tracks Ltd. with
a measured quantity of oil in track drive.
Rev. 280211
3.10 LEAKS AND SEIZURES
3.10.1 General Components
Many components fitted to crawler track systems such as rollers and idlers are lubricated with oil.
Regular checks should be made to ensure these components are not leaking and rotate freely when the
tracks are driven. Any items such as rollers which show signs of leaking, or fail to rotate when the
tracks are driven should be replaced immediately.
3.10.2 Track Chains
It is important to be aware of the type of conditions in which the tracks are working. If the tracks are
working in materials which cause corrosion to carbon steel, you must replace standard tracks with
lubricated tracks to avoid seizure of the track joints. Lubricated tracks are available as an optional extra
from new or as a retrofit for customers entering adverse working conditions.
Track chains can also seize in particular conditions if they remain stationary for more than a few days,
causing kinks in the chain. This can be prevented by tracking the machine 50 meters forward and 50
meters backwards on a daily basis. However, should this problem occur, it may be possible to remedy
by applying penetrating fluid to the seized pin, leaving for several hours, then tracking the machine
several meters forward and back.
If lubricating the pin is unsuccessful, the problem can be resolved by cutting out the seized link including
the pin and bush, replacing it with a complete repair link.
If there are several links seized on a single track chain, it may be necessary to remove the track from
the machine and have it repaired at a specialized track repair shop, or to replace the complete track
chain.
Rev. 280211
SECTION : 4
WEAR LIMITS
4.1 WEAR LIMITS
To ensure the most economical use of the track systems, it is important to determine the appropriate
time to replace each of the worn parts.
The following section will describe the most accurate methods of measuring the wear of the various
track system components. If the wear of these components is monitored and the replacements made,
you should ensure the proper functioning of the track system and avoid unnecessary damage and costly
renewal expenses.
Exact wear limits are dependent on the specific parts fitted to the track system supplied. Please refer to
the Parts Supplement relative to the specification of track system supplied to find the required
component part numbers.
WARNING
Under no circumstances should the machine be operated if the
wear of any component is in excess of 100%.
Rev. 280211
4.2 TRACK SHOE WEAR
The most important wear of a track shoe is the relative height of the grouser to the top of the shoe plate.
A depth gauge should be used to measure this, as shown in the diagram below:-
Grouser Height
Wear Percentage
New Shoe
Shoe Part No. 25% 50% 75% 100%
mm
mm
TBG 505X00-12-X 42.5 41.5 40.5 39.5 38.5
TBG 510X00916-X 22.0 21.2 20.4 19.6 18.8
TBG 014X00-58-X 25 24.2 23.4 22.6 21.8
TBG 020X00-18-X 25.3 25 24.7 24.4 24.1
TBG 026X00-34-X 26.5 25.9 25.3 24.7 24.1
TBG 532X00-20-X 28 27.3 26.6 25.9 25.2
TBG 027X00-34-X 26.5 25.9 25.3 24.7 24.1
Rev. 280211
4.3 TRACK LINK WEAR
To measure the wear use a depth gauge and measure the depth from the bottom of the grouser shoe to
the running surface of the track link.
Link Height
Wear Percentage
New Link
Link Part No. 25% 50% 75% 100%
mm
mm
TLS 040LH/RH-5 70 69.75 69.5 69.25 69
TLS 045LH/RH-5
83 82.8 82.6 82.4 82.2
TLS 045LH/RH-XHD
TLS 007LH/RH-58-1
96 95.6 95.2 94.8 94.4
TLS 007LH/RH-58-XHD
TLS 210LH/RH-8 103.2 103 102.8 102.6 102.4
TLS 013LH/RH-8 121.5 121.1 120.7 120.3 119.9
TLS 660LH/RH-0 116 115.6 115.2 114.8 114.4
Rev. 280211
4.4 INTERNAL PIN AND BUSH WEAR
To determine the average internal pin and bushing wear measure across 4 sections of track chain
comprising of 4 links (5 pins). This track section must not include the master pin, and should be on
the upper side of the track. Block the track using a 40mm diameter steel bar in the sprocket, being
careful not to foul the track frame or chassis of the machine. Reverse the machine until the track is
taut across the top of the track system (maximum 1/8 turn of sprocket).
Measurement is made of the elongation of the chain pitch. A standard steel tape can be used.
Measure as shown below:
4 Sections of the Link Assembly
Wear Percentage
New Chain
Chain Part No. 25% 50% 75% 100%
mm
Mm
TCA 040XX-X 560.0 560.5 561.0 561.5 562.0
TCA 045XX-X 640.0 640.5 641.0 641.5 642.0
TCA 811XX-X 685.8 686.2 686.6 687.0 687.4
TCA 640XX-X 702.0 702.6 703.2 703.8 704.4
TCA 071XX-X 811.6 812.4 813.2 814.0 814.8
TCA 660XX-X 760.0 761.0 762.0 763.0 764.0
TCA 077XX-X 811.6 812.4 813.2 814.0 814.8
Rev. 280211
4.5 EXTERNAL PIN AND BUSH WEAR
Wear of the bushes is caused at the point of contact between the bushing and the sprocket tooth. To
measure this wear use a small outside calliper.
Forward Drive
forward driveSide Wear
side wear
Radial Wear
Reverse Drive
Side Wear
Outer Diameter
Outside wear of the bushings can be of any of the 3 types shown above. Measurements should be
taken in each position and the area where wear is maximum should be considered.
Wear Percentage
New Chain
Chain Part No. 25% 50% 75% 100%
mm
Mm
TCA 040XX-X 37.0 36.9 36.8 36.7 36.6
TCA 045XX-X 45 44.9 44.8 44.7 44.6
TCA 072XX-X 50.8 50.6 50.4 50.2 50.0
TCA 811XX-X 53.8 53.6 53.4 53.2 53.0
TCA 640XX-X 58.738 58.6 58.5 58.4 58.3
TCA 071XX-X 66.675 66.6 66.5 66.4 66.3
TCA 660XX-X 60.0 59.9 59.8 59.7 59.6
TCA 077XX-X 66.7 66.6 66.5 66.4 66.3
Rev. 280211
4.6 LOWER ROLLER WEAR
The tread wear of the roller is the most important wear area and is measured on the roller diameter.
The most suitable tool is a large outside caliper.
Rail Diameter
The correct measurement is to measure the diameter of both tread surfaces of the roller. Consider the
tread with the smallest diameter.
Wear Percentage
New Roller
Roller Part No. 25% 50% 75% 100%
mm
Mm
LRG 000SC003-X 135.0 134.5 134.0 133.5 133.0
LRG 000SF60B-X 160.0 159.5 159.0 158.5 158.0
LRG 000SC40A-X 155.0 154.5 154.0 153.5 153.0
LRG 000SC60A-X 154.0 153.5 153.0 152.5 152.0
LRG 000VA774-0 172.0 171.5 171.0 170.5 170.0
LRG 000SC70A-X 180 179.5 179 178.5 178
Rev. 280211
4.7 CARRIER ROLLER WEAR
The tread wear of the roller is the most important wear area and is measured on the roller diameter. The
most suitable tool is a large outside calliper.
Rail Diameter
The correct measurement is to measure the diameter of both tread surfaces of the roller. Consider the
tread with the smallest diameter.
Wear Percentage
New Roller
Roller Part No. 25% 50% 75% 100%
mm
Mm
CRG 130-A 140.0 139.5 139.0 138.5 138.0
LRG SF60B-SD 135 134.5 134 133.5 133
Rev. 280211
4.8 FRONT IDLER WEAR
Radial tread wear is the most important factor. The simplest method of measuring tread wear is to
measure the depth of tread from the centre of the idler.
Rail Height
Wear Percentage
New Idler
Idler Part No. mm 25% 50% 75% 100%
Mm
IRT 140-2761-02 16.0 16.2 16.4 16.6 16.8
IDG 5061-5
17.0 17.2 17.4 17.6 17.8
IDG 5061-XHD
IDG 600-A 17.0 17.25 17.5 17.75 18.0
IDG 502-A
26.0 26.25 26.5 26.75 27.0
IDG 502-XHD
IDG 660550-7
20.0 20.25 20.5 20.75 21.0
IDG 660550-A
IDG 610-0 20.0 20.25 20.5 20.75 21.0
IDG 0770-0 22.5 22.75 23 23.25 23.5
Rev. 280211
4.9 SPROCKET WEAR
Sprocket wear is very difficult to assess accurately. In fact, under normal working conditions, the wear
occurs in such a way that no trace of the original toothing remains as a valid reference for measuring
the wear. It is therefore impossible to provide 100% accurate data for wear measurement.
Tooth Depth
As an approximate rule, the sprocket should be replaced when wear has reached the limits shown in the
above illustration.
As the wear is never uniform, it is necessary to consider the point at which the wear is at a maximum.
New Wear Percentage

Sprocket Part No. Teeth 25% 50% 75% 100%
mm Mm
SPA 100-DTXXXX 26.0 26.2 26.4 26.6 26.8
SPA 200-DKXXXX 33.2 33.4 33.6 33.8 34.0
SPA 300-DLXXXX 34.1 34.4 34.7 35.0 35.3
SPA 400-NSXXXX 34.8 34.1 34.4 34.7 35.0
SPA 190-XXXXXX 42.0 42.2 42.4 42.6 42.8
SPA 500-DNXXXX 41.5 41.7 41.9 42.1 42.3
Rev. 280211
SECTION : 5
TROUBLESHOOTING
5.1 TRACK TENSION
Track systems use a grease cylinder to keep the track chains in tension. Loss of tension in the tracks
can result in the sprocket jumping in the track chain, and also allowing the track chain to run off the
idler/sprocket. This can hinder the tracking ability of the machine and damage many of the components
of the track systems if not resolved quickly.
The tension of the tracks should be checked on a regular basis according to the parameters set out in
Section 3.3 of this manual; General Maintenance. If the tension of the track is outside these parameters,
and the adjustment method given in paragraph 3.4 has no effect, please read below checks that can be
made and possible causes:
___________________________________________________________________
Check 1: - With the greaser access plate removed (see Section 3.4), make a
visual inspection of the greaser, looking for any signs of leaking grease.
Possible Cause: - If grease is leaking from the base of the greaser, where it screws into
the end of the tensioner, either the gasket has failed and needs
replacing, or the greaser is not screwed in properly and needs
tightening.
If grease is leaking from the end of the greaser where the grease gun
connects to it, the greaser valve has failed and should be replaced.
___________________________________________________________________
Check 2: - When the machine is stationary and blocked, make a visual inspection
of the track below the adjusting end of the tensioner, looking for any
signs of leaking grease.
Also, reach under the frame, feeling the adjusting end of the tensioner
for any grease.
Possible Cause: - If grease is leaking from the adjusting end of the cylinder, the seals
may have failed. This requires the tensioner to be removed from the
tracks frame, to be either fitted with new seals, or replaced with a
complete new grease tensioner.
___________________________________________________________________
If the above checks have been carried out with no signs of any faults, please contact the helpline for
further assistance.
Rev. 280211
5.2 LOSS OF DRIVE
Crawler track systems are driven using hydraulic motors connected to planetary drive gearboxes. The
hydraulic motors are driven using the hydraulics fitted to the machine.
Begin by making a visual inspection of the tracks, particularly around the sprocket, idler and bottom
rollers where material / objects can sometimes lodge. Follow this by inspecting all hoses and
connections, ensuring there are no leaks or blocks. If there are no physical impedances in the tracks
and no faults are found with hoses and connectors, please read below checks that can be made and
possible causes:
___________________________________________________________________
Check 1: - Using pressure / flow testing equipment, measure the values of the
flow and pressure being applied to the hydraulic motors.
Possible Cause: - If the values of the flow and pressure passing to the hydraulic motors
is less than that required to drive the tracks (see machine
manufacturer’s separate publication), there may be a fault in the
machines hydraulic system.
___________________________________________________________________
Check 2: - Test the pressure being applied to the brake release port on the
gearbox. In order to release the brake, this should be fed with a
pressure of between 12 and 50 bar.
Possible Cause: - If the pressure is below 12 bar, do not attempt to drive the tracks. With
a pressure below 12 bar, the brake will not release when driving the
tracks is attempted. This can cause the brakes to seize requiring a
replacement unit to be fitted.
___________________________________________________________________
Check 3: - If a valve is fitted to the hydraulic motor flange, ensure there are no
visible faults with the valve, and none of the connections are damaged /
leaking.
Possible Cause: - If there are no visual faults with the valve, and all other checks identify
any faults, the valve block may need replacing.
___________________________________________________________________
further assistance.
Rev. 280211
5.3 Loss of Parallel Drive
Crawler track systems are driven by hydraulic track drive units. Drives consist of a hydraulic motor
connected to planetary drive gearbox.
Power is relative to the hydraulic pressure and speed is relative to the hydraulic flow from the machines
hydraulic circuit. Please refer to the Parts List and Hydraulic Specifications document for maximum
pressure and flow settings for each individual track system. Under recommended pressure and flow
conditions, if tracked undercarriage shows loss of parallel drive and machine starts slewing, please read
below checks that can be made and possible causes:
___________________________________________________________________
Check 1: - Using pressure and flow testing equipment check the values of the
flow and pressure being applied at the hydraulic motors.
Possible Cause: - If hydraulic pressure and flow being supplied to the motors is different
from one another, the machine hydraulic pressure and flow settings
may need to be adjusted.
___________________________________________________________________
Check 2: - Test to ensure a pressure is being applied to the brake release

function on the gearbox. To release the brakes, generally pressure
ranges between 12 and 50 bar.
Possible Cause: - If the pressure being applied at brake release port is below required
pressure, do not attempt to drive the track system. Trying to drive the
tracks without releasing the brakes could result in gearbox failure and
void the warranty.
___________________________________________________________________
Check 3: - Using pressure testing equipment, test pressure on return drain line
from motor to ensure back pressure does not exceed 2 bar. Excessive
back pressure in the drain can cause automated switching of motor
displacement on integrated motors.
Possible Cause: - Drain Blockage in hydraulic circuit between motor and hydraulic tank.
___________________________________________________________________
further assistance.
Rev. 280211
SECTION : 6
APPENDIX
6.1 Bolt Torque Table
If not otherwise specified, use the following torque settings. Suggested torque for normal applications
(10%), using bolts/nuts without lubricant. Bolts and nuts with lubricant reduce mean torque by 15%,
depending on lubrication used.
Standard Metric Coarse and Fine Thread Bolts and Nuts

Thread Coarse I.S.O. Grade 10.9 Fine I.S.O. Grade 12.9
(Exceeds S.A.E.
Diameter Thread (Approx. Equivalent S.A.E. Grade 8) Thread
Grade 8)
Pitch Coarse Fine Pitch Fine
mm mm Ibs/ft Nm Ibs/ft Nm mm Ibs/ft Nm
M8 1.25 27 37 29 40 1.00 35 47
M10 1.50 54 73 57 78 1.25 67 91
M12 1.75 95 129 100 135 1.25 110 150
M14 2.00 150 203 165 223 1.50 190 258
M16 2.00 230 312 250 339 1.50 290 393
M18 2.50 320 434 365 495 1.50 425 576
M20 2.50 450 610 510 691 1.50 600 813
M22 2.50 620 841 690 935 1.50 805 1091
M24 3.00 785 1064 860 1166 2.00 1005 1362
M27 3.00 1158 1570 1254 1700 2.00 1468 1990
Standard UNC and UNF Bolts and Nuts

Thread I.S.O. Grade 10.9 I.S.O. Grade 12.9
(Exceeds S.A.E.
Diameter (Approx. Equivalent S.A.E. Grade 8)
Grade 8)
UNC UNF UNF
Inches Ibs/ft Nm Ibs/ft Nm Ibs/ft Nm
5/16" 21 28 23 31 - -
3/8" 36 49 41 56 - -
7/16" 58 79 64 87 70 95
1/2" 88 119 99 134 132 179
9/16" 127 172 141 191 186 252
5/8" 175 237 195 264 264 358
3/4" 311 422 345 468 457 620
7/8" 500 678 550 746 736 998
1" 750 1017 820 1112 1118 1516
Rev. 280211

Parts List and Hydraulic Specifications

Please note this exploded view is for representation
Parts Breakdown purposes only. This may slightly differ from your actual
track system. If in doubt, please contact Strickland
010 040 050 100 090 080 Tracks Ltd.
Exploded View: 005
070
020
060 220 230 235

030
200 180

210
160

190
170

186 150

185 140
110

120

130

280

250
240 ‐ Track Group
260

270
300 – Master Pin and Collars
290 ‐ Track Repair Link Kit

DL384L-JC225JASDT10
1. Parts List for Track System
Qty per Qty per

Item No. Strickland Part No. Description
Track Pair
010 FDM784-JC225NM Track Drive Gearbox w/o Hydraulic Motor 1 2
Socket Head Capscrew (Gearbox to Track
BHM 520250065-1 13 26
Frame)-Torque to 615 Nm (454 Ibs/ft)
020
Socket Head Capscrew (Gearbox to Track
BHM 520250040-0 3 6
Frame)-Torque to 615 Nm (454 Ibs/ft)
030 MOT0JA-FDMOTOR Fixed Displacement Motor 1 2
040 FDG RRTD-DRNPLG Oil Fill/Drain Plug 2 4
050 POL 00280W/90-0 Gear oil SAE 80W/90 3.0L 6.0L
060 N/A Brake Release Stand-off Pipe N/A N/A
070 FMVA04-A04MM Brake Release Adaptor 1 2
080 FMVA14-DBS04 Brake Release Seal 1 2
090 SPA 300-DLHB21-3 Drive Sprocket 1 2
Socket Head Capscrew (Sprocket to
100 BHM 516150055-0 20 40
Gearbox) – Torque to 336 Nm (248 Ibs/ft)
110 LRG 000SC40A-A Single Flanged Lower Roller 8 16
Hex Head Bolt (Roller to Track Frame)
120 BHM 016200085-8 32 64
-Torque to 314 Nm (232 Ibs/ft)
130 WFH 019-2 Hardened Washer 32 64
140 IDG 502-XHD Front Idler Group 1 2
150 IDY 171-502-XHD Idler Yoke 1 2
Hex Head Bolt (Yoke to Idler) –Torque to
160 BHM 012175050-7 4 8
127 Nm (93 Ibs/ft)
170 WSH 023-HD-3 Spring Washer 4 8
180 RSA 171-502-XHD Spring Recoil 1 2
Hex Head Bolt (Recoil to Yoke) –Torque to
185 BHM 016200060-7 4 8
314 Nm (232 Ibs/ft)
186 WSH 015-2 Spring Washer 4 8
190 TTA 171-175-XHD Grease Tensioner 1 2
Hex Head Bolt (Tensioner to Track Frame)
200 BHM 016200065-0 4 8
- Torque to 314 Nm (232 Ibs/ft)
210 WSH015-2 Spring Washer 4 8
220 IDM 889-2 Tensioner Grease Fitting 1 2
230 IDM 888-6 Gasket for Grease Fitting 1 2
235 TLG 080-9 Grease Gun Adaptor N/A N/A
240 TG-0738-D4D-56L-400 Track Group 1 2
250 TCA 81156-XHD Track Link Assembly 1 2
260 TBG 014400-58-0 Track Shoe (400mm Wide Triple Grouser) 56 112
Track Shoe Bolt -Torque to 358 Nm (264
270 TSB 02250-3 224 448
Ibs/ft)
280 TSN 014-1 Track Shoe Nut 224 448
290 TRL 099-3-XHD Track Repair Link Kit N/A N/A
300 MPG 0044-XHD Master Pin and Collars 1 2
Note: For more details on Parts Breakdown Please refer to EXPLODED VIEW: 005
Rev. 091027
DL384L-JC225JASDT10
2. Hydraulic Hose and Fitting Kit
Qty per Qty per
Item No. Strickland Part No. Description
Track Pair
Motion Control / Brake Release Valve
510 FMV000-06008057-2 1 2
Block
520 FMV063-8F5267-SPACE A2FE63 Valve Transfer Plate 1 2
Socket Head Capscrew
530 BHM000-510150120-0 (Valve block/Transfer Plate to Motor 8 16
Flange)
Hose And Fitting Kit (Includes all hoses
540 FMV090-06008057-HOS 1 2
and fittings shown below)
3. Required Connections
Highlighted below are main connections required to operate the track drive.
T, Drain Port
Connection,
1/2” BSPP
V1 & V2, Main Flow

Ports Connections,
3/4” BSPP
4. Hydraulic Schematic 5. Direction of Rotation

Below is the general hydraulic circuit diagram for the When connecting to the track drives, it is
track drive gearbox and fixed displacement motor important to check that the direction of rotation
combination with a motion control and brake release corresponds to forwards movement of the
valve fitted. machine, when the drives are positioned at the
rear of the machine.
The diagram above shows the direction of

rotation of the track drive in relation to the input
flow to motor.
Rev. 091027
DL384L-JC225JASDT10
6. Hydraulic Port Description and Sizes
A & B, Main Flow Ports
T, Motor Case
Drain Port
F, Gearbox Brake
Release Port
Ports Size on Gearbox and Motor

A & B, Motor Main Flow Ports 3/4” SAE
T, Motor Case Drain Port M18 x 1.5
F, Gearbox Brake Release Port 1/4" BSPP
7. Hydraulic Specifications
Operating Pressures / Flows
Maximum Continuous Pressure 330 bar
Maximum Permissible Case Drain Pressure at Port T 2 bar
(Min) 24 bar
Brake Release Pressure
(Max) 50 bar
(Min) N/A
Variable Speed Control Pressure at Port X
(Max) N/A
Maximum Oil Inlet Flow through Ports A & B 120 l/min
Gearbox Oil Type, Volume and Operating Temperature
Oil Type SAE80W/90
Oil Volume 3.0L per Gearbox
Minimum Operating temperature of Oil -25°c
Maximum Operating temperature of Oil 90°c
8. Hydraulic Filtration and Cleanliness

Before connecting track drives to hydraulic circuit, ensure all pipes are removed and flushed through with the
hydraulic system prior to connection.
To ensure proper function of hydraulic motor, the filtration of pressure fluid must provide a cleanliness level
of at least: 20/18/18 according to ISO 4406.
Rev. 091027
HQR1112
SECTION : Clutch
ISSUE: 01/2017

R-1
NORME D’INSTALLAZIONE E MANUTENZIONE
PRIMA DI MONTARE E METTERE IN FUNZIONE IL PRODOTTO, LEGGERE
ATTENTAMENTE TUTTE LE ISTRUZIONI SULLA SICUREZZA ED IL
FUNZIONAMENTO RIPORTATE NEL PRESENTE MANUALE.
SEGUIRE SEMPRE TUTTE LE AVVERTENZE ED ASSICURARSI CHE G L I
O P E R ATO R I P R E S E N T I I N P RO S S I M I TA ’ DELL’APPARECCHIATURA
INDOSSINO TUTTI I DISPOSITIVI DI PROTEZIONE RICHIESTI PER LA
SICUREZZA NELL’ AMBIENTE DI LAVORO.
NON UTILIZZARE L’APPARECCHIATURA SE LE PRESENTI ISTRUZIONI NON
DOVESSERO RISULTARE CHIARE, E CONTATTARE IMMEDIATAMENTE IL
COSTRUTTORE O IL DISTRIBUTORE PER L’ASSISTENZA NECESSARIA.
IL PRODOTTO DEVE ESSERE PROTETTO DA UNA COPERTURA ADEGUATA
PER EVITARE DANNI ALLE PERSONE.
LO SCHERMO DEVE SEMPRE PREVEDERE APERTURE ASSIALI E RADIALI
PER LA VENTILAZIONE DEL GIUNTO.
SE FOSSE MONTATO IL TAPPO FUSIBILE, LE SUDDETTE APERTURE NON
DEVONO ESSERE ORIENTATE VERSO GLI OPERATORI, PARTI CALDE O
COLLEGAMENTI ELETTRICI.
INSTALLATION AND MAINTENANCE

BEFORE ASSEMBLING AND OPERATING THE PRODUCT, CAREFULLY READ
ALL THE SAFETY AND OPERATING INSTRUCTIONS REPORTED IN THIS
MANUAL.
ALWAYS FOLLOW ALL THE INSTRUCTIONS AND ASSURE THAT ALL THE
OPERATORS STANDING BY THE MACHINERY ARE WEARING ALL THE
PROTECTIVE EQUIPMENT NECESSARY FOR THE JOB TYPE AND
APPLICATION BEING PERFORMED.
DO NOT USE THE MACHINERY IF YOU DO NOT UNDERSTAND THESE
INSTRUCTIONS, AND IMMEDIATELY REFER TO THE MANUFACTURER OR
THE CUSTOMER SERVICE DESK FOR ASSISTANCE.
THE PRODUCT MUST BE PROTECTED BY A CONVENIENT COVER GUARD
TO AVOID PERSONAL INJURY TO PEOPLE.
AXIAL AND RADIAL VENTILATION OPENINGS SHOULD BE INCORPORATED
IN THE GUARD FOR HEAT EXCHANGE.
IF THE PRODUCT IS FITTED WITH FUSIBLE PLUGS, THE SAID OPENINGS
SHOULD NOT BE DIRECTED TOWARDS OPERATORS OR ANY HOT OR
ELECTRICAL INSTALLATION.
FLUID COUPLINGS
19 KPTO
SPEC. NR. 2518-D
SERIAL NR. KP -
19 K P T O
trasmissioni industriali SPEC. 2518-D
SERIAL NR. KP .....……..
DOCUMENT REV DESCRIPTION

TF 6113 7 features-use and maintenance
TF 6231 1 Procedures for conservation
TF 6093-A 2 radial load
TF 6042 4 torsional vibration calculation data
TF 6114 1 Arcusaflex technical data
TF 6115 1 recommended oil
TF 6014 2 hydraulic scheme
TF 6007-Q 1 electric connection
TF 5938-E 3 filter spares
TF 6051 2 solenoid valve spares
TB 1066-C 3 KPT spares
TB 1070-B 8 KPT spares
TB 1071-A 6 KPT spares
TB 1072-B 14 KPT spares description
TF 6119/1 4 trouble shooting
A6563 3 KPT installation drawing
index 19k-gb-.doc 02/02/01

WORKING AND MAINTENANCE TF 6113
INSTRUCTIONS FOR Rev. 7
trasmissioni industriali KPTO/KPTU FLUID COUPLING SERIES Sheet 1/3
FEATURES
1 - KPT for internal combustion engine (named KPTO or KPTU depending on radial output or
in line output) is a drain type fluid coupling. If drained out it works as a disconnected
clutch.; if progressively filled up it works as a soft starter.
2 - KPT can be flanged to any internal combustion engine having a SAE housing and
flywheel.
3 - KPT has a incorporated feed oil pump. This oil flow is used to fill up the fluid coupling,
to dissipate the heat generated during start up and steady running, to lubricate
bearings.
4 - KPT has some orifices, fitted on peripheral part, which continuously drain the oil
supplied by feed oil pump. Orifices have calculated diameter depending on
application. Because orifices are made in threaded plugs, they can be replaced to
optimise performances. Quick release valves, supplied as optional, drain oil in few
seconds.
5 - Through an electric valve (24V d.c. [standard] or: 12V d.c.; 110V a.c.; 220V a.c.) the
pump oil flow can be diverted to the oil tank. In such a way the fluid coupling is
drained out (time required depends by orifices diameter and input speed) while oil flow
continues to assure the tank cooling and bearings lubrication.
6 - Oil is cleaned through a 25 micron filter with replaceable paper cartridge. Filter
clogging is indicated on pressure switchgauge dial (see TF6007-…) when is 1.7 bar over
the rated pressure (rated pressure is established during first start up as soon as oil
temperature has reached the working value). Pressure switch, already set during
workshop test (becarefull to check if setting was correct according to actual working
condition like pipes length and oil temperature) must be used as alarm signal for filter
clogging.
7 - Temperature switch (see TF6007-…), already set (see the test certificate), must be used
as alarm signal therefore should be connected to any device in respect of safety rules.
Just as suggestion, it could switch off electric valve or shut down the engine. When KPT
is cooled by engine jacket water, temperature switch setting could be max 95°C.
8 - Cooler, either oil/water (see TF5999...) or oil/air (see relevant dwg.), is supplied
according to required working specifications and must be fitted in line between pump and
filter (see TF6014...; see relevant dwg.).
9 - Overload and speed controller is a reading device of KPT output speed and also an
alarm device in case of unwished decreasing of speed (high slip). Connection of
alarm switch has the same target of temperature switch (see TF 5800-…).
TF6113 rev.7 GB.doc

INSTALLATION
- Check that flywheel be within SAE tolerances (see FIG.1 and also SAE J1033 rules).
- Mount elastic coupling driving ring on to the flywheel. Then mount KPT on to the flywheel
housing.
- First tight screws on flywheel housing then tight screws on support side flanges (both side
flanges must be fitted).
- Check (KPTO) that belts tension is within permissible value (see radial load table in this
manual).
- Connect oil and water pipes (if any) in respect of pump pressure side diameter (suction and
pressure side diameters in case of separate pump).
- Supply correct water flow to the cooler (see final Transfluid technical quotation)
- Supply correct Voltage to electric motors, if any (check electric connections), electric valve
and devices (see test certificate).
START UP
IMPORTANT
- Check rotation direction of the pump. Once the pump is running, if no pressure is read
on filter pressure gauge, check again rotation (electric motor connections), pipes
connection and oil level (see maintenance for correct level).
- Check pressure be within correct value at steady running temperature (see test certificate).
a - Switch OFF electric valve.
b - Switch on the pump (whether electric motor pump is installed) and start engine.
c - Switch ON electric valve.
DISENGAGEMENT (STOP)
Switch OFF electric valve.
WITH INTEGRAL FEED PUMP

WHILE MAIN ENGINE IS RUNNING SWITCH OFF SOLENOID VALVE TO DISENGAGE (LOAD STOP)
FLUID COUPLING.
BEARINGS LUBRICATION, IS ASSURED BY FEED PUMP THAT IS MECHANICALLY DRIVEN BY THE
ENGINE.
WITH FEED ELECTRIC PUMP

WHILE MAIN ENGINE IS RUNNING SWITCH OFF SOLENOID VALVE TO DISENGAGE (LOAD STOP)
FLUID COUPLING.
FEED ELECTRIC PUMP MUST BE RUN TO ASSURE BEARINGS LUBRICATION.
TF6113 rev.7 GB.doc

MAINTENANCE & CHECKS
1 - Change oil after first 100 working hours.Change oil every 4000 working hours unless
evident oil colour change. Correct oil level is the blue line on oil level indicators (first fill
KPT, then run the pump, electric valve OFF, to full fill heat exchanger, hence check
level again, while engine is stopped).
2 - Change oil filter cartridge (25 micron) when pressure is 1.7 bar over rated value and/or
pressure switch is ON.
3 - Change rotating seals (items 46 and 58 in TB1070-…) in case of considerable oil leakage.
Recommended spare parts are supplied from Transfluid or local Distributor (see Sales
Network on back page of KPT catalogue).
4 - Keep the cooler clean.Whether was a water cooler, see dedicated instruction pages in this
manual (TF6094). Whether was an air cooler, clean the radiator pack with air pressure or
wash carefully by hand. Do not use water pressure, it can damage the Aluminum pack.
5 - Check periodically, possibly every 1000 hours, that pump chain be of correct length (hang
20 kg weight to stretch chain):
15 KPT Max length = 1265 mm

17-19 KPT Max length = 1362 mm
21-24 KPT Max lenght = 1556 mm
27 KPT Max length = 1914 mm
6- Check, periodically, elastic coupling condition.
7- Procedure in case of replacement of following parts (TB1070-… and TB1066-…):

elastic coupling hub (64) or input shaft (4) or washer (23).
It is necessary to shim the gap between washer and input shaft ; the gap must be within
0.05 mm and 0.15 mm. Be sure to seat hub tightly against bearing before measuring the
shim gap between the end of the input shaft and retainer washer clamping surface in the
hub. Use shims provided by Transfluid or equivalent (ask for table N2912).
Screws (24) must be refitted with Loctite and tightened at 50 Nm.
Fig.1
IMPORTANT
Any modification of orifices diameter must be approved by Transfluid not to penalize
warranty validity.
TF6113 rev.7 GB.doc

PROCEDURES FOR CONSERVATION
OF VARIABLE FILL FLUID COUPLING TF 6231
Rev. 1
trasmissioni industriali KPT - KSL
Following procedures are valid for unit in its original packaging, stored in dry, clean, dust
free indoor ambient.
CHECK CONTROL
1 - INTERNAL PARTS
1.1 - Spray inside housing 0,25 l of oil TECTYL 930 SAE 30.
1.2 - Put inside housing suitable amount of dryer packs (g/m3 according to packs
instructions). attach, externally, a warning signal like “REMOVE BEFORE
OPERATION”.
1.3 - Seal all openings and passes between housing and ambient (i.e. breather,
input/output for cooler).
2 - EXTERNAL PARTS
2.1 - Wet with protective fluid CRC 3.36 (or equivalent) all steel parts not already
painted or phosphated.
In case of marine enviroment, use protective fluid CRC 6.66 MARINE (or
equivalent) for 3 months protection, or CRC PROTECTIVE MARINE for 6
months protection.
After the 3 or the 6 months period, operation must be repeated first cleaning
CRC.
CRC is cleanable by means of CRC MARIN ELMEC CLEAN diluent.
2.2 - Rotating seals or labyrinths must be protected with grease AGIP 33 FD or

SHELL ALVANIA R3 or equivalent.
2.3 - Check that connection wiring box be well sealed.
2.4 - For motors, pumps, instruments, preserve the original packaging, if any.
TF6231-GB-REV.1
KPTO & KPTE TF 6093-A
PERMISSIBLE SIDE LOAD (N) Rev. 2
trasmissioni industriali AND SUGGESTED PULLEY TRANSMISSION
- Calculated bearings life over 10.000 hours.

- Engine speed over the max listed below, needs approval by Transfluid.
- Pulley diameter is the minimum permissible. (Over 35 m/s, dynamic balancing is recommended).
- Belts nr. is maximum permissible.
- Timing belts must be approved by Transfluid.
- “X” distance is according to belts type & number.
- Side load includes 2.5 belt tensioning factor.
15
Up to Max “X” (mm) Max belts nr
kW/rpm Max load (N) Type - Min pulley ∅
200 / 2600 91 / 17.000 10 x 5V - 220 mm
17 - 19
95 / 20.000 10 x 5V - 335 mm
250 / 1800 91 / 20.000 6 x 8V - 335 mm
95 / 20.000 7 x SPC - 335 mm
102 / 18.000 11 x 5V - 355 mm
300 / 2200 105 / 18.000 7 x 8V - 355 mm
107 / 18.000 8 x SPC - 355 mm
21
150 / 31.000 10 x 8 V - 335 mm
400 / 1800
160 / 31.000 12 x SPC - 335 mm
165 / 29.000 11 x 8 V - 355 mm
470 / 2200
170 / 29.000 13 x SPC - 355 mm
24
Overlap Overlap
Up to
Max “X” (mm) Max belts nr
kW/rpm
Max load (N) Type - Min pulley ∅
88 / 40.000 12 x 8 V - 355 mm
545 / 1800
95 / 40.000 14 x SPC - 355 mm
117 / 35.000 14 x 8 V - 380 mm
620 / 2200
120 / 35.000 16 x SPC - 380 mm
Pulley must be installed overlapping bearing carrier by 89 mm.
27
Overlap Overlap
Up to
Max “X” (mm) Max belts nr
kW/rpm
Max load (N) Type - Min pulley ∅
800 / 1800 133 / 55.000 17 x 8V - 380 mm
Pulley must be installed overlapping bearing carrier by 115 mm.
ASK TRANSFLUID FOR ANY APPLICATION DIFFERENT THAN ABOVE.
tf6093-a 02-00
KPT - TORSIONAL VIBRATIONS ANALYSIS DATA
TF 6042
KPT – DATI PER ANALISI VIBRAZIONI TORSIONALI Rev. 4
trasmissioni industriali
Dim.
TKN TKmax T
± KW
CT CTdyn ψ VR J1 JL
rpm T (°C)
Size (10Hz) max max
15/11S 860 2150 430 93 100 0.726 8.65 0.035 0.736 2600 120
15/11D 2060 6530 1030 461 691 0.726 8.65 0.082 0.782 2600 120
15/14S 1690 4220 845 206 309 0.726 8.65 0.180 0.836 2600 120
17/11D 2060 6530 1030 461 691 0.726 8.65 0.082 1.215 2600 120
17/14S 1690 4220 845 206 309 0.726 8.65 0.180 1.276 2600 120
19/11D 2060 6530 1030 461 691 0.726 8.65 0.082 1.773 2600 120
19/14S 1690 4220 845 206 309 0.726 8.65 0.180 1.833 2600 120
19/AC5-11 2500 7500 1250 13 1.25 5.03 0.065 1.832 2600 80
19/AC5-14 2500 7500 1250 13 1.25 5.03 0.179 1.830 2600 80
21/14D 3490 11040 1745 1010 1515 0.726 8.65 0.187 2.869 2200 120
21/AC6-14 4200 12600 2100 45 1.25 5.03 0.220 2.999 2600 80
24/14D 3490 11040 1745 1010 1515 0.726 8.65 0.187 5.332 2200 120
24/14D18 3490 11040 1745 1010 1515 0.726 8.65 0.870 5.332 2200 120
24/AC7-14 6300 18900 3100 100 1.25 5.03 0.312 5.742 2600 80
24/AC7-18 6300 18900 3100 100 1.25 5.03 0.519 5.742 2300 80
27/18D 5300 16720 2650 1885 2827 0.726 8.65 0.652 8.805 1800 120
27/AC8-18 7800 23400 3900 110 1.25 5.03 0.478 9.105 2300 80
TKN Coppia nominale - Nominal torque (Nm)

TKmax Coppia massima - Max torque (Nm)
Coppia continua vibratoria a 10 Hz (Nm) - Continuous vibratory torque at 10 Hz
TKW (10Hz) Per frequenze fx differenti vale la TKW √(10/fx) - For different fx frequencies TKW √(10/fx) is valid
CT Fattore statico di rigidità - Static stifness factor (Nm/rad)10³
CTdyn Fattore dinamico di rigidità - Dynamic stifness factor (Nm/rad)10³
ψ Smorzamento relativo - Relative damping
VR Fattore di risonanza - Resonance factor
J1 Inerzia parte motrice del giunto elastico - Elastic coupling driving part inertia (kgm2)
Inerzia parte condotta del giunto elastico + lato entrata del KPT
JL Elastic coupling driven part inertia + KPT input side
(kgm2)
PD2 = 4J
PDM_TF6042_GB+IT.doc
ARCUSAFLEX TF 6114
DATI TECNICI / TECHNICAL DATA Rev. 1
Coppia continua Velocità
Durezza Coppia Nominale Coppia max di vibrazione Elasticità dinamica Flangia tipo
ARCUSAFLEX max
Shore Nominal Torque Max Torque Continuous Dynamic Stiffness Flange Size
Tipo / Size Max Speed
hardness TkN (Nm) Tk max (Nm) Vibration Torque CTdyn. (Nm/rad) SAE J 620
* TkW (10 Hz) (Nm) (rpm)
WN 200 500 100 1100
NN 250 750 125 1700 6.5
AC 2 8
4200
SN 330 1000 165 3300
WN 330 750 165 1100
6.5
AC 2,3 NN 360 900 180 1700
8
4200
SN 400 1000 200 2500
WN 500 1250 250 2100 8 4200
AC 2,6 NN 600 1800 300 3100 10 3600
SN 700 2100 350 4500 11.5 3500
WN 800 2000 400 3600
10 3600
AC 3 NN 900 2700 450 5000
11.5 3500
SN 1000 3000 500 7500
WN 1200 3000 600 8000
11.5 3500
AC 4 NN 1350 3600 650 10000
14 3000
SN 1550 4200 750 13500
WN 1800 4500 900 8500
AC 5 NN 2000 5400 1000 13000 14 3000
SN 2500 7500 1250 22000
WN 3100 7700 1500 16000
14 3000
AC 6 NN 3450 10000 1700 30000
18 2300
SN 4200 12600 2100 45000
WN 4600 10000 2300 35000
14 2600
AC 7 NN 5200 15600 2600 56000
18 2300
SN 6300 18900 3100 100000
WN 6200 14000 3100 38000
18 2300
AC 8 NN 7000 21000 3500 75000
21 2000
SN 7800 23400 3900 110000
WN 12400 28000 6200 76000
18 2300
AC 8 D NN 14000 42000 7000 150000
21 2000
SN 15600 46800 7800 220000
WN 8000 18000 4200 55000
18 2300
AC 9 NN 9000 27000 4800 100000
21 2000
SN 10000 30000 5500 190000
WN 16000 36000 8400 110000
AC 9 D NN 18000 54000 9600 200000 21 2000
SN 20000 60000 11000 380000
Durezza / Shore hardness: WN = 50-55° Shore A

NN = 60-65° Shore A
SN = 70-75° Shore A
10
*= Coppia continua di vibrazione ± TkW: a ƒ = 10 Hz , per altre frequenze ƒx è valida TkW fx
10
Continuous Vibration Torque ± TkW: at ƒ = 10 Hz, for other frequency ƒx is valid TkW fx
Fattore di risonanza VR e relativo Damping Ψ

Resonance factor VR and relative Damping Ψ
Durezza
VR Ψ
Shore hardness
WN 7.85 0.8
NN 5.46 1.15
SN 5.0 1.25
tf6114-rev.1 02/2002
OLIO CONSIGLIATO TF 6115
RECOMMENDED OIL
trasmissioni industriali (ISO HM 32) Rev. 1
AGIP OSO 32
ARAL VITAM GF 32
BP ENERGOL HLP 32
CASTROL HYSPIN AWS 32
CHEVRON RYKON OILS AW - 32
ESSO NUTO H 32
MOBIL DTE 24
SHELL TELLUS 32
TEXACO RANDO HD 32
TOTAL AZOLLA ZS 32
TF6115 rev.1 IT-GB.doc

TF 5938...
FILTRO / FILTER REV. 3
RIFERIM. / REF. DIMENS. CARTUCCIA / CARTRIDGE
TF 5938-O 1” ¼ 25 µm
X TF 5938-E ¾” 25 µm
TF 5938-G ¾” 25 µm
TF 5938-K ¾” 10 µm
1
TESTATA
FILTER HEAD
2
BY-PASS
3
TENUTA VITON
VITON SEAL
4
CARTUCCIA
CARTRIDGE
TF5938-EK rev.3.doc / 09/06/04

ELETTROVALVOLA / ELECTRIC VALVE TF 6051
DFE 20 / 3A - 18ES - W201 - 24 Vdc - BSP
REV. 2
(REF. TF5937-E)
1
5
4
7
8
9
2
POS. CODICE - CODE Q. DESCRIZIONE - DESCRIPTION

1 3CO2261320 1 Corpo Housing DFE/20/3-BSP
2 4SPI512040 3 Spina Pin UNI6874 12x40
3 3CAS120341 1 Cassetto Spool DFE20/3A
4 4GUA123526 2 Gommino O Ring 23.47x2.62
5 3MOL117310 1 Molla Spring DF20 V.18ES
6 3TAP332200 1 Tappo Plug DFE20
7 4GUA130018 1 Gommino O Ring 29.87x1.78
8 4SOL519024 1 Bobina Solenoid 24VDC D19-46.79
9 4SOL519000 1 Cannotto Pusher D19x4O
tf6051 rev.2/07/05/02
KPTO-KPTU TB 1072-B
parts list
trasmissioni industriali (TB1066-C & TB1070-B & TB1071-A) Rev. 14
1 inner impeller 61 lock washer 122 lock washer

2 outer impeller 62 screw 123 chain drive
3 cover 63 lock washer 124 cover
4 outer impeller shaft 64 splined hub 125 screw
5 roll bearing 65 flange (RBD) 126 lock washer
6 snap ring 66 rubber block (RBD) 127 shim(s)
7 screw 67 driving ring (RBD) 128 O-ring
8 lock washer 68 screw (RBD) 129 tab washer
9 ring 69 nut (RBD) 130 tab washer
10 orifice plug 70 lock washer (RBD) 131 seal
11 splined hub 71 key 132 flange
12 snap ring 72 feed pump 133 screw
13 coupling bearing carrier 73 screw 134 lock washer
14 ball bearing 74 lock washer 135 screw
15 snap ring 75 hub 136 gasket
16 snap ring 76 key 137 gasket
17 screw 77 lock washer 138 elastic coupling (AC)
18 ring 78 screw 139 driving ring (AC)
19 short end stud / screw (for 27kpto) 79 gear 140 screw (AC)
20 nut 80 screw 142 lock washer (AC)
21 lock washer 85 straight end fitting 143 washer
22 O-ring 86 breather 148 reducing fitting
23 lock washer 87 solenoid valve 149 adapter
24 screw 88 nut 151 snap ring
31 housing 89 lock washer 152 nut (AC)
32 baffle 90 adapter 153 snap ring
33 screw 92 reducing fitting 154 QD-bushing
34 lock washer 93 copper packing 155 hub for QD-bushing
35 screw 94 “T” adapter 156 screw
36 lock washer 95 lubrication pipe 157 key
37 oil level indicator 96 straight end fitting 232 reducing fitting (only for 21÷29KPT)
40 magnetic plug 97 oil filter 263 shim(s)
41 O-ring 98 adapter 265 lock washer
42 cover 99 copper packing 266 lock washer
43 screw 100 adapter 379 plug
44 lock washer 101 copper packing 389 set screw
45 bearing carrier 102 feed tube
46 seal 103 adapter
47 double roll bearing (KPTO) 104 copper packing
47a ball bearing (KPTU) 105 drain tube
48 snap ring 106 plug
49 inner impeller shaft 107 copper packing
50 shim 108 panel
51 snap ring 109 pressure switch gauge
52 O-ring 110 temperature switch gauge
53 screw 111 pressure gauge pipe
54 lock washer 114 lubrication pipe
55 SAE flange 115 spacer
56 roll bearing 116 short end studs
57 bearing carrier 118 suction flange
58 seal 119 straight union fitting
59 O-ring 120 suction pipe
60 screw 121 straight end fitting
TB1072-B rev.14 GB.doc

KPTO (U) TF 6119/1
TROUBLE SHOOTING REV. 4
UNIT FAILS TO OPERATE
1 - Check KPT output shaft turns freely with engine shutdown.
2 - Check solenoid valve (item 87 - TB1071-…) is operating.
3 - Check oil level. It must be at blue line on level indicator (item 37 - TB1070-…).
4 - Check oil pressure (item 109 - TB1071-…) (see test certificate).
5 - Remove cover plate (item 42 - TB1070-…) and check:

a) four orifice plugs (item 10 - TB1066-…) be tight
b) nuts (item 20 - TB1066-…) be tight.
6 - Check oil flow by inserting flow meter in feed line from pump to KPTO.
7 - Check (on KPTO with integral pump) condition of pump driving chain.
8 - Check temperature alarm switch (item 110 - TB1071-…) is set at correct level (see test
certificate).
UNIT OPERATES AT REDUCED OUTPUT SPEED
1 - Carry out checks from 1) to 7) as above.
2 - Check engine high idle speed with KPTO dis-engaged.
3 - Check driven machine condition.
OIL LOSS
1 - Check all pipe connections.
3 - Check seals (item 46 and 58 - TB1070-…).
3 - Check engine flywheel housing.
4 - Check engine coolant is not contaminated.
If vapor comes out from the breather, wait until oil temperature reaches more than 55-
60° C. If oil comes out from the breather, check orientation of oil keeper under cover
(item 42 - TB1070-B).
TOO MUCH OIL PRESSURE
1 - Check filter cartridge and replace if necessary (item 97 - TB1071-…).
2 - Check pressure gauge (item 109 - TB1071-…) be not defective.
3 - Check not obstruction inside oil tubes.
tf6119-1-gb/4 05/03/01
GARANZIA BASE, TERMINI E CONDIZIONI BASIC GUARANTEE, TERMS AND CONDITIONS
TF 6401-I - rev. 0 TF 6401-GB - rev. 0
1) Premessa 1) Preamble
TRANSFLUID garantisce che i propri prodotti, al momento della TRANSFLUID guarantees that at the time of dispatch, its
spedizione, sono conformi alle specifiche pubblicate nei propri products comply with the specifications published in its
cataloghi o documenti tecnici validi al momento della spedizione catalogues or technical documents, which were valid at the time
stessa e che sono esenti da difetti nei materiali e nella of dispatch, and that the products are free from defects in
fabbricazione. Questi termini di garanzia sostituiscono tutte le material and workmanship. These terms of guarantee substitute
altre garanzie, anche legali, espresse o implicite, comprese, a all other guarantees, including legal, expressed or implicit
titolo esemplificativo e non esaustivo, le garanzie di guarantees, including but not limited to, guarantees of saleability
commerciabilità e di idoneità ad un uso particolare (e qualsiasi and suitability for a particular use (and any other implicit
garanzia implicita che sorga nel corso delle prestazioni, nel guarantee arising during the course of the services, negotiations
corso delle trattative o dell’uso commerciale). Fatti salvi i casi di or commercial use). Except in the event of serious negligence
dolo e colpa grave, in nessun caso TRANSFLUID sarà and fraud, under no circumstances will TRANSFLUID be held
responsabile per danni diretti, indiretti, consequenziali, fortuiti od liable for direct, indirect, consequential, fortuitous or extra
extracontrattuali basati su una richiesta d’indennizzo da parte contractual damage based upon claims for compensation by the
del Compratore per violazione di garanzia, violazione di Buyer for violation of the guarantee, contract or objective
contratto, responsabilità oggettiva. In nessun caso il risarcimento responsibility. Under no circumstances can the compensation by
da parte di TRANSFLUID potrà superare l’importo che il TRANSFLUID exceed the amount paid by the Buyer for the
Compratore ha pagato per il prodotto fornito da TRANSFLUID. product supplied by TRANSFLUID.
2) Durata e limiti della garanzia 2) Duration and limits of the guarantee

a) La durata della garanzia è pari a diciotto (18) mesi dalla a) The duration of the guarantee is equal to eighteen (18)
messa in servizio del prodotto fornito da TRANSFLUID e months from the time the product supplied by TRANSFLUID
comunque non oltre ventiquattro (24) mesi dalla data di is commissioned, and nonetheless, no more than twenty-four
spedizione del prodotto originale dallo stabilimento (24) months from the date of dispatch of the original product
TRANSFLUID. from TRANSFLUID’s plant.
b) I prodotti, se inutilizzati e stoccati a lungo termine, devono b) Product that are not used and stored for a long period must
essere immagazzinati e trattati in accordo alle linee guida be kept and handled in keeping with the guidelines, which are
redatte da TRANSFLUID per tipologia di prodotto che sono available upon request, drawn up by TRANSFLUID according
rese disponibili su richiesta. to product type.
c) La garanzia per le parti la cui usura o deterioramento è c) The wear or tear of parts, which is particularly due to
fortemente legata alle condizioni di impiego (tensionamento conditions of use (tension of the belts, environmental
delle cinghie, condizioni ambientali, urti e sovraccarichi non conditions, unforeseen knocks and overloading), or to the
previsti), alla sensibilità dell’operatore (utilizzo entro i limiti sensitivity of the operator (use within the approved limits) or to
approvati), ad eventi esterni (inceppamenti della macchina external circumstances (jamming of the machine), is not
condotta), non opera se tali parti sono state utilizzate (non covered by the guarantee if these parts have been used (are
sono nuove), o se non viene chiaramente dimostrato dal not new), unless the Buyer can clearly prove the
Compratore un eventuale difetto di fabbricazione riconducibile manufacturing defect, which is ascribable to TRANSFLUID.
a TRANSFLUID. Typical parts subject to wear or tear include:
Tipiche parti soggette ad usura o deteriorabili sono: - filters, seals and gaskets
- filtri, tenute e guarnizioni - springs, screws, plugs
- molle, viti, tappi - switches and fuses
- interruttori e fusibili - material and friction surfaces
- materiali e superfici di attrito - belts and chains
- cinghie e catene - lubricants in general
- lubrificanti in genere d) Installation and maintenance of TRANSFLUID products must
d) L’installazione e la manutenzione dei prodotti TRANSFLUID be carried out following the installation, use and maintenance
deve essere eseguita in conformità a quanto indicato nel manual, which is always supplied with each product.
manuale di installazione, uso e manutenzione che viene
sempre fornito a corredo di ogni prodotto. e) With regard to the supply of loose/disassembled parts, the
guarantee solely and exclusively covers faults of the
e) In caso di fornitura di componenti sfusi/disassemblati, la components themselves, related to the material or
garanzia copre solo ed esclusivamente eventuali difetti dei mechanical workmanship carried out by TRANSFLUID.
componenti stessi, relativamente al materiale o alle
lavorazioni meccaniche effettuate da TRANSFLUID. f) The guarantee is no longer valid when:
- the product is used exceeding the limits stated in the
f) La garanzia decade nei casi in cui: catalogues or installation manuals, or in applications that are
- il prodotto venga utilizzato oltre i limiti indicati nei cataloghi not approved by TRANSFLUID;
o manuali di installazione o in applicazioni non approvate da - breakage results from abuse, negligence, omission or
TRANSFLUID; inadequate maintenance, failed connection or control of the
- la rottura derivi da abuso, negligenza, omessa o inadeguata protection devices or as a result of accidents;
manutenzione, mancato collegamento o controllo dei - the product is modified or disassembled without
dispositivi di protezione o a seguito di incidenti; TRANSFLUID’S written approval.
- il prodotto venga modificato o disassemblato senza
approvazione scritta di TRANSFLUID. 3) Services included/excluded in the guarantee
a) In TRANSFLUID’S final decision, products or components,
3) Prestazioni incluse/escluse nella garanzia whose faults are covered by the guarantee, will be repaired or
a) Eventuali prodotti o componenti i cui difetti, ad insindacabile replaced at no extra cost, with the exception of the
giudizio di TRANSFLUID, sono coperti da garanzia, saranno subsequent points. The replaced parts will be covered from
riparati o sostituiti senza alcun addebito, salvo quanto the remaining period of the original guarantee, which stays in
stabilito ai punti successivi. Le parti sostituite saranno force for the product initially supplied (a new guarantee period
coperte dal residuo periodo della garanzia originale che resta will therefore not come into effect).
in vigore sul prodotto inizialmente fornito (non decorrerà
quindi un nuovo termine di garanzia).
TF 6401-I - rev. 0 TF 6401-GB - rev. 0
b) Sono esclusi dalla garanzia, e pertanto restano a carico del b) Excluded from the guarantee and remaining at the Buyer’s
Compratore, costi derivanti da: expense are the costs resulting from:
- rimozione del prodotto TRANSFLUID dal macchinario in cui - removal of the TRANSFLUID product from the machinery
è inserito e relativa rimessa in servizio; onto which it is fitted, and recommissioning;
- adeguato imballaggio ed oneri derivanti da trasporti di - suitable packing and charges resulting from the return
andata e ritorno del materiale; transport of the material;
- ripristino di lubrificanti in genere, tubazioni, cofanature - restoration of lubricants in general, piping, sound proof
insonorizzanti, carter, ecc; canopies, guards, etc.;
- qualsiasi altro costo non espressamente approvato per - all other costs not expressly approved in writing by
iscritto da TRANSFLUID. TRANSFLUID.
c) Per le operazioni di smontaggio/reinstallazione/messa in c) The Buyer can request the support of a specialised technician
servizio del prodotto, il Compratore potrà richiedere il to disassemble/re-install/recommission the product by
supporto di un tecnico specializzato inviando un regolare sending a standard purchase order. TRANSFLUID will invoice
ordine di acquisto. L’intervento sarà fatturato da TRANSFLUID the work, applying the current ASSIOT rates (Italian
applicando le correnti tariffe ASSIOT (Associazione Italiana Association of Gears and Transmission Elements
costruttori organi di trasmissione, affiliata EUROTRANS). Manufacturers, a member of EUROTRANS).
d) TRANSFLUID non potrà essere ritenuta responsabile per d) TRANSFLUID cannot be held liable for lost or reduced profit,
mancati o minori profitti, costi per macchinari sostitutivi, fermi costs for replaced machinery, still machinery, damage to
macchina, danni ad apparecchiature o proprietà causati da un equipment or property caused by failure of its products.
eventuale malfunzionamento dei propri prodotti.
4) Modalità di richiesta di prestazioni in garanzia 4) Conditions for requesting services under guarantee
a) Il Compratore, qualora intenda avvalersi della garanzia, dovrà a) If the Buyer intends to take advantage of the guarantee, he
informare TRANSFLUID per iscritto, entro 7 (sette) giorni dal must inform TRANSFLUID in writing within 7 (seven) days of
momento in cui si è evidenziato un difetto, comunicando: discovering a fault, stating:
- descrizione del prodotto; - product description;
- numero di serie (ove previsto), numero di specifica o codice - series number (where foreseen), specification number or
articolo; article code;
- riferimento alla data ed al documento di acquisto o - reference to the date and document of purchase or delivery;
consegna; - reasonable proof that the fault falls within the conditions of
- ragionevole prova che il difetto rientri nelle condizioni di guarantee, together with a detailed description of the
garanzia completata da una descrizione dettagliata irregularity or failure and where possible, supported by
dell’anomalia o malfunzionamento ed eventualmente photographs.
supportata da fotografie. In the event of failure after commissioning the product, the
In caso di malfunzionamento occorso dopo la messa in following must also be communicated:
servizio del prodotto, dovranno essere comunicati inoltre: - type of application;
- tipo di applicazione; - power and engine rpm (stating also the make and model for
- potenza e giri del motore (in caso di motore endotermico endothermic engines);
anche marca e modello); - diameter, type, number of races and position of pulley (if
- diametro, tipo, numero gole e posizione puleggia (se foreseen by the application);
l’applicazione lo prevede); - hours of operation.
- ore di funzionamento. b) TRANSFLUID will indicate whether the product must be
b) In base al prodotto coinvolto, al malfunzionamento segnalato, delivered or sent free port to an authorised centre or directly
all’urgenza di intervento, TRANSFLUID indicherà se il to its own plant depending on the product concerned, the
prodotto stesso dovrà essere consegnato o spedito in porto failure indicated and the urgency of the intervention.
franco ad un centro autorizzato o direttamente presso la c) On receiving the product, TRANSFLUID or the authorised
propria sede. distributor will carry out a thorough analysis; if the product is
c) Una volta ricevuto il prodotto, TRANSFLUID o il distributore deemed to be covered by the guarantee:
autorizzato provvederanno ad una approfondita analisi; - TRANSFLUID will repair or replace the parts needed to
se il prodotto sarà ritenuto coperto da garanzia: restore full and safe working at no cost;
- TRANSFLUID riparerà o sostituirà gratuitamente le parti If the product is NOT deemed to be covered by the guarantee,
necessarie al ripristino della piena e sicura funzionalità; TRANSFLUID:
se il prodotto NON sarà ritenuto coperto da garanzia, - will send a technical report explaining its decision;
TRANSFLUID: - will draw up an estimate for the repair;
- invierà un rapporto tecnico motivando la decisione; - will carry out the repair upon receipt of the order from the
- stilerà un preventivo di riparazione; Buyer.
- solo dopo aver ottenuto l’ordine dal Compratore, procederà d) The repaired products will be returned to the Buyer freight
con la riparazione. collect, by the same means of transport that was used for the
d) I prodotti riparati saranno restituiti al Compratore in porto arrival (unless stated otherwise).
assegnato, utilizzando lo stesso mezzo di trasporto con cui e) Should the Buyer decide not to accept the estimate for the
sono pervenuti (a meno che non sia diversamente repair, he must communicate his decision in writing, explicitly
specificato). asking for the parts to be scrapped or returned; the parts will
e) Qualora il Compratore decida di non accettare il preventivo di be sent in their current state.
riparazione, dovrà comunicare per iscritto la propria decisione
chiedendo esplicitamente la rottamazione o la restituzione
delle parti che saranno spedite nello stato in cui si trovano.
TRANSFLUID s.r.l. Via V. Monti, 19 20016 Pero (Milano) Italy Tel. +39-02.339315.1 Fax +39-02.33910699 e-mail: info@transfluid.it www.transfluid.it
■ ■ ■ ■ ■ ■
KPTO PILOT BEARING FAILURE GM041229
Rev. 1
HOW TO PREVENT AND CHECK Pag. 1/5
A radial force is generated on the
output shaft by pulley and belts
transmission. This load is
compensated by consequent
reactions on output bearing and pilot
bearing as shown on this picture.
Radial load depends on Engine

power and speed, pulley dimensions
and “X” dimension.
Transfluid can easily calculate
expected bearings life and shaft
safety factor but the following
information must be provided:
-Engine power and speed
-Pulley dia, groove type and number
-“X” dimension
-Unit serial number
-Working hours counter reading
If allowed radial load is exceeded,

the pilot bearing inner race (that is
originally interference fit) starts to
rotate over the shaft. The worn out
metal is washed away by the
lubrication oil flow. As shown on this
picture (taken after 800 working
hours with overloaded bearing) oil is
contaminated by black stripes (steel
and aluminium). Magnetic plugs
located on KPT sump will also trap
some metallic particles.
GM041229_GB.doc/GM - 14/01/2005
KPTO PILOT BEARING FAILURE GM041229
Rev. 1
This is the situation found on a
19KPTO after 800 working hours
with overloaded bearings.
The pilot bearing inner race can
manually slide out its seat.
It is possible to detect shaft toothing
wear caused by induced
misalignment (shaft bending +
bearing seat runout due to wear)
This pictures gives an idea about

how much material is gradually worn
out on both shaft and bearing race
inner dia.
On page bottom, left side, there are

two pictures showing a similar
failure. The first on the left was taken
after about 400 hours, the picture in
the middle was taken after about
1200 hours.
Picture on the right side shows a
pilot bearing seat detail of a brand
new shaft.
GM041229_GB.doc/GM - 14/01/2005
KPTO’s PILOT BEARING FAILURE GM041229
Rev. 1
This is another side effect of angular
misalignment induced by pilot
bearing failure. Inner impeller
toothing was completely worn out.
HOW CAN I INSPECT MY KPT

UNIT TO PREVENT BEARING
DAMAGE?
1) Check oil conditions from one of

the two unit sight glasses. If there
are black stripes like in this
picture or if oil is completely
black, you are running into
problems.
2) Drain oil and inspect both
magnetic plugs. Surely they have
trapped magnetic particles.
GM041229_GB.doc/GM - 14/01/2005
Rev. 1
3) Remove the pulley and mount a
dial indicator and a threaded bar
as shown on this picture at the
specified distance
38 mm
(1,5”)
4) Pull down with your hand and set

the dial indicator to zero.
5) Without rotating the shaft, pull up

with your hand and read the
maximum value.
6) Readings up to 0,23 mm (0,009”)
should be considered within
manufacturing limits (bearings C3
play and bearing seats
manufacturing tolerances). Larger
values may be due to a bearing
failure.
GM041229_GB.doc/GM - 14/01/2005
Rev. 1
7) Remove oil feeding and
lubrication pipes.
8) Remove output bearing carrier
screws and pull out the output
shaft assembly.
9) Inspect pilot bearing race press
on shaft. If it is damaged, collect
all necessary information and ask
Transfluid to run a bearing life
calculation.
WARNING
DO NOT START
ENGINE WHILE THE
OUTPUT SHAFT
ASSEMBLY IS
MISSING
If the calculated bearing life is too low, some important modifications should be considered:
- Mount the existing pulley closer to the bearing carrier.
- Increase pulleys diameter and reduce belts number.
- Do not overtension belts
NO
Pulley is mounted
far away from shaft
NO
shoulder. Small pulley dia.,
more grooves/belts
YES
Pulley is mounted YES
against shaft Larger pulley dia.,
shoulder. less grooves/belts
GM041229_GB.doc/GM - 14/01/2005
FORI DI PERDITA PER KSL & KPT TF 6246
BLEEDING ORIFICES FOR KSL & KPT Rev. 2
Il diametro dei fori è in mm.
Per situazioni differenti, consultare IST 04-01/01.
Orifices diameter mm.
For different situations, ask Transfluid.
La tabella include casi in cui il KPTB è usato con motore Diesel e l’elettropompa a 50 o 60 Hz.
Per velocità intermedie, usare il diametro corrispondente a quella più alta.
Table includes cases where KPTB could be used with Diesel engine and electric pump at 50 or 60 Hz.
For speed in between, use the higher speed diameter.
KSL - KPT velocità in entrata / input speed
DIMENSIONI E POMPA
SIZE & PUMP 1200 rpm 1500 rpm 1800 rpm 2000 rpm 2200 rpm
KPTO/U 15 * - 2.25 2 2 1.75 (1.5 std)
KPTB 15 & 3D66 50Hz 3 2.75 2.5 2.5 2.25
KPTB 15 & 3D66 60Hz 3.25 3 2.75 2.75 2.5
KPTO/U 17-19 * - 2.5 2.5 2.5 2.25 (2 std)
KPTB 17-19 & 3D80 50Hz 3 2.75 2.5 2.25 2
KPTB 17-19 & 3D80 60Hz 3.25 3 2.75 2.5 2.25
KPTB 17-19 & 3D135 50Hz 4 3.75 3.5 3.25 3
KPTB 17-19 & 3D135 60Hz 4.5 4 3.75 3.5 3.25
KPTO/U 21 * - 3.25 3.25 3.25 3 (2.75 std)
KSL-KPTB 21 & 3D135 50Hz 3.75 3.5 3.25 3 2.75
KSL-KPTB 21 & 3D135 60Hz 4.25 3.75 3.5 3.25 3
KPTO/U 24 * - 3 3 3 2.75 (2.5 std)
KSL-KPTB 24 & 3D135 50Hz 3.75 3.25 3 2.75 2.5
KSL-KPTB 24 & 3D135 60Hz 4 3.5 3.25 3 2.75
KPTO/U 27 * - 3.5 3.5 3.5 (3.25 std) -
KPTB 27 & 4D160 50Hz 3.75 3.5 3 2.75 -
KPTB 27 & 4D160 60Hz 4 3.75 3.25 3 -
KSL 27 & 4D220 50Hz 4.5 4 3.5 3.25 -
KSL 27 & 4D220 60Hz 5 4.5 4 3.75 -
KPTB 29 & 4D160 50Hz 3.5 3.25 2.75 - -
KPTB 29 & 4D160 60Hz 3.75 3.5 3 - -
KSL 29 & 4D220 50Hz 4.25 3.75 3.25 - -
KSL 29 & 4D220 60Hz 4.5 4.25 3.75 - -
KSL 34 & 4D300 50Hz 4.5 4 - - -
KSL 34 & 4D300 60Hz 5 4.5 - - -
KSL D34 & 4D300 50Hz 3.5 3 - - -
KSL D34 & 4D300 60Hz 3.75 3.25 - - -
* = per pompa incorporata / built-in pump
- Std significa standard; per ordini di magazzino, questo è il diametro da fornire.

- Il diametro std. può essere utilizzato a qualunque velocità purchè non sia specificato il tempo di svuotamento.
- Tutti i KSL & KPT sono forniti con tappi ciechi di ricambio in una busta di plastica.
- IL D34 KSL ha 8 tappi forati invece che 4.
- Std means standard; when ordered for stock, this is the supplied diameter.
- Standard diameter can be used at any speed if drain time is not specified.
- All KSL & KPT are supplied with blind plugs spare in a plastic bag.
- D34 KSL has 8 orifice plugs instead of 4.
TF6246 rev2
HQR1112
SECTION : Magnet
ISSUE: 01/2017

S-1

OPERATION MANUAL
PERMANENT MAGNETIC SEPARATORS
MODEL: RCY-QF100
STRIKER AUSTRALIA PTY LTD
S-2
Magnet Manual
Permanent Magnetic Separators
ISSUE:01/2016
Table of Contents

1. Notice items of operator's personal safety S-4
2. Structure and working principle S-4
3. Installation S-7
4. Commissioning S-12
5. Notices for operation S-14
6. Parameters and attached drawings S-15
7. Inspection reports S-16

S-3
Magnet Manual
ISSUE:01/2016
1. Notice for operators’ personal 2. Structure and working principle
safety
2.1 Summary
Magnetic separators can form very strong
magnetic field, so care must be exercised Attractive force can only happens on ferrous
and the potential danger should be known materials in the non‐equal magnetic field.
by the workers at all times while working The attractive force (F) is proportional
around the machine. The magnetic field is directly to the product of the magnetic
concentrated underside the separator, while intensity (H) and the magnetic gradient ( H/
weak magnetic force is available around. The L). We consider both of the two parameters
safety rules are as follows: above‐mentioned important in our design.
The technical standards all meet the
1) Magnetic field will damage the requirements in JB/T8711‐1998. The
pacemaker severely. People with standard models are suitable for removing
pacemaker can’t get close to the iron from low speed conveyor; Super‐strong
equipment unless magnetic field is models (T1, T2, and T3) are specially
ensured to be no affection. designed according to some special working
conditions with thick material, high conveyor
2) Don’t use iron appliance or tools near speed, big or very tiny iron.
the magnetic field, especially the
appliance with sharp ends. 2.2 Structure and features

3) Don’t take magnetic memory carriers With special magnetic circuit design, the
close to the equipment, such as magnetic curves can be fully concentrated
magnetic disk, tape, credit card and so under our equipments. This kind of
on. equipment has high magnetic gradient and
also high magnetic intensity at rated height.
4) Don’t take your watch or the appliance Even at the same magnetic intensity, the
with power supply close to the magnetic gradient of this kind of equipment
equipment. is superior. Ferrous iron in different shapes,
from 0.1kg to 35kg in weight can be caught.

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Please refer to the following form for more information about permanent magnetic separators:

Model Outline Drawing Features Application
RCY‐C (Overband) Continuous collecting For a large range of
and discharging, industrial fields.
reliable operation,
easy maintenance,
low noise, automatic
rectification of the
belt

RCYK‐C (Steel cladded) Steel cladded Specially for collecting
(Overband) belt，continuous steel scrap with sharp
collecting and ends
discharging; low
noise; reliable
operation and easy
maintenance;
automatic
rectification of belt

RCY‐PⅡ(Overband) Compact structure, For small working
small volume; place; for various
continuous collecting industrial fields
and discharging;
reliable operation and
easy maintenance;
automatic
rectification of belt.

RCYD‐C (Explosion‐ Inflaming retarding For working sites with
proof) (Overband) belt, explosion‐proof Explosive gas around
motor, continuous
collecting and
discharging; reliable
operation and easy
maintenance;
automatic

RCYD‐PⅡ (Explosion‐ Compact structure, For small working
proof type) small volume; place and with
(Overband) Inflaming retarding explosive gas around.
belt , explosion‐proof
motor, continuous
collecting and
operation and easy

maintenance.

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Model Outline drawing Features Application
RCY‐Q (Light‐duty) Compact structure, For small working
(Overband) small volume, light sites; for various
weight, continuous fields.
collecting and
operation and easy
maintenance;
automatic

RCY‐P (Manual Simple structure, For belt conveyor with
cleaning) reliable operation, belt width narrower
power‐saving. than 1m, for thin
material layer and
little iron tramp
included.

Term explanation:

1) Manual cleaning: Discharge iron by manual control.
2) Self cleaning (belt) means the separator composes of magnetic system, supporting frame,
belt, main drum, secondary drum, supporting pulley and electric reducer. The driver and
the reducer are combined. Automatic discharge realizes by driving the belt running
through the chain, chain gear driving belt and the scraper. It can also be called belt
magnetic separator.
3) Explosion‐proof: explosion‐proof sign is ExdI. The execution standard is GB3836.1‐2000 and
GB3836.2‐2000. The equipment got MA sign and explosion‐proof certificate authenticated
by the nation.

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3. Installation 1. Length of each suspension device

is L, decided by consumer.
3.1 Transportation and storage 2. Steel rod includes two types:
un‐welded (welded by customer)
1) Be transported in package with good and welded.
ventilation and rainproof. 3. Notice for choosing 2.2
2) Be stored in the dry warehouse with
good ventilation. 1) Rope clip must be assembled in the
same direction.
3.2 Package opening and checking 2) U shape bolt of rope clip must be
buckled from one side of the end,
1) Check if the equipment and cable and rig mount fixed from the side of
are in good condition working segment (re. the drawing)
2) The documents attached include: 3) Quantity and the distance of rope
clips is as the following chart
a. Packing list
b. Certificate of quality The dimension The lowest The distance
c. Appurtenance’s certificate and of rope clips quantity of between Rope
(diameter of rope clips of Clips (C)
instruction manual steel rope) each group
d. Instruction manual
e. Technical materials related to technical Note:
service and information feedback. 1) The angle between two suspension
devices must be less than 60°.
3.3 Suspension device 2) If the suspension space is limited,
shackle can be assembled with any
1) Suspension device for the main body of the following:
(re. attached parameter chart 2 ) Screw buckle, thimbles, steel rope or
2) Suspension device details (steel rope steel rod.
in 2.2 is a better choice).
3.4 Installation of main frame and traveling
trolley (re. parameter form 3)

3.4.1 Installation of manual cleaning type
(for model RCY‐P)
1) Cross belt installation: The separator is
installed above the middle of belt
conveyor, where the width of the
working space is about 10m to ensure
the equipment can move freely. No
barriers around, rated suspension height
≤H (re‐attached parameter page) The
direction of the rails must be vertical to
2.1 Chain 2.2 Rope 2.3 Steel rod the belt conveyor.
1. Screw buckle
2.Chain
3. Shackle
4.Steel rope clip
5. Steel rope
6. Thimble
7. Steel rod

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Overhead (Fixed Suspension)
Cross Belt (Fixed Suspension)

Overhead (Monorail & Single Trolley)

Note:
Cross Belt (Monorail & Single Trolley)
1) The suspended height can be adjusted
2) Overhead installation: The separator is according to the conveyor speed and
installed above the head of the belt material character. Better collecting
conveyor. The rated suspended height results can be realized at the lower
≤H (re‐attached parameter). The suspension height lower than H (re.
obliquity=15O‐30O The traveling trolley attached parameter page).
is installed right above the conveyor and 2) Make the space between trolley wheels
its direction must be the same to the and rail 3mm‐4mm by adjusting the filler
direction of the conveyor. Refer to the pieces before installation.
drawings below:

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3.4.2 Installation of belt magnetic
separator (model RCY‐PII, RCY‐C,
RCY‐Q)

1) Cross belt installation Cross Belt (Fixed Suspension)

The separator is installed above the middle
of belt conveyor, where the width of the
working space is about 10m to ensure the
equipment can move freely. No barriers
around, rated suspension height ≤H
(re‐attached parameter page).

The installation mode in Drawing a: the rails
are not needed. The separator can be
suspended on the ceiling or on the beam.
The distances between the four suspension
points must be the same to that between
the four lifting lugs, thus lifting lugs could
get homogeneous stress.

The installation mode in drawing b and c: for Cross Belt (Monorail & Single Trolley)
easy maintenance of the magnetic
separator, traveling trolley can be used; the
rail should be installed vertically to the
conveyor belt.

Cross Belt (Monorail & Double Trolley)

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2) Overhead installation: the magnetic

separator is installed above the head of
the conveyor. The rated suspension
height ≤ H (re. Attached parameter
page). Obliquity=15°~30° The installation
mode in Drawing d: the rails are not
needed. The separator can be
suspended on the ceiling or on the
beam. The distances between the four
suspension points must be the same to
that between the four lifting lugs, thus
lifting lugs could get homogeneous
stress. The installation mode in drawing
e and f: for easy maintenance of the
magnetic separator, traveling trolley can
be used; the rail should be installed
vertically to the conveyor belt.

Overhead (Fixed Suspension)

Overhead (Monorail & Single Trolley)

Overhead (Monorail & Double Trolley)

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Note: 3.5 Installation procedures

1) If the belt magnetic separator is installed 1) Choose installation place
horizontally and an obliquity of conveyor 2) Install rails. The length at the end of the
is available, the driver end should be in rail must be long enough for the
the same direction to the lower end of separator move. Keep 2m space of
the conveyor, and the obliquity of the either side of separator for installation
separator should be not over 5º (re. The and maintenance, and also enough
drawing below). space should be kept for discharging.
2) The suspension height can be adjusted 3) Install traveling trolley or suspension
according to the conveyor belt speed fastening device on the rails.
and the material character. Better 4) Install a manual lifter on the rail for
collecting results can be realized when lifting the separator.
the suspension height < H (re‐attached 5) Lift the separator to the proper height
parameter page) with steel rope and manual lifter.
3) If double rails are used or the equipment 6) Connect the separator and the traveling
is comparatively heavy ( heavier than 10 trolley or the fixed suspension points.
tons), double‐rail with trolley can be Place it at the height of H (re. attached
used. The installation direction of the parameter page). Better collecting
rails should be the same to the results can be realized if the suspension
installation requirements of the belt height is lower than H.
magnetic separator above mentioned.
The drawings are as follows: 3.6 Control cabinet installation
1) The installation place of the control
cabinet is subject to the condition of the
working spot. It should not be
weatherworn. Keep it safe and
convenient for operation.
2) Connect the cable extended from the
separator with the control cabinet. The
cable length between the power supply
and the control cabinet depends on
working spot.


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4. Commissioning 6) If acousto‐optic warning system is

4.1 The commissioning of manual‐ used, some problems can be
discharging magnetic separator after produced deliberately for checking if
installation (model RCY‐P) it is effective.
1) Check the reliabilities of the 7) Run Separator to see if the separator
connection on both ends of the runs reliably and stably, if departure
suspension device. of the belt exists. The unloading
2) Measure and adjust the suspension running time should be not shorter
height (no higher than H; re. than 2 hours. The equipment can’t
Attached parameter page). If incline be put into commissioning unless
installed, the obliquity α=15o~30 o everything is normal during the trial
should also be measured. process.
3) Observe the working situation of the 8) Observe the working situation of the
equipment and its catching and equipment and its attracting and
discharging ability. Put some discharging ability.
different shapes of ferrous scraps Put some different shapes of ferrous
into the material if necessary to test scraps into the material if necessary
the separator. to check the separator. Adjust the
suspension height and obliquity if
Adjust the suspension height and obliquity if necessary. (Don’t put too heavy or
necessary. (Don’t put too heavy or sharp sharp iron tramps)
iron tramps) 9) Check whether or not the departure
4) If no problems are found within 24 of the belt exists during running
hours during commissioning, normal under load, and whether oil leak
operation can be started. exists on the speed reducer.
4.2 The commissioning of belt magnetic 10) If no problems are found within 24
separator after installation (RCY‐PII, hours during commissioning, the
RCY‐C, RCY‐Q) equipment can be put into normal
1) Check the reliabilities of the operation.
connection on both ends of the 11) Overband magnetic separators
suspension devices. Four supporting mustn’t be started if under load.
points can be placed if the Start the magnetic separator first
equipment swings during and then start the conveyor. Check
commissioning. the connection parts. Check the
2) Measure and adjust the suspension connection conditions once for
height (no higher than H; re. three months.
Attached parameter page). If incline 12) The instruction of departure
installed, the obliquity α=15o~30 o adjustment is as follows:
should also be measured. Firstly, adjust the supporting base. If
3) If cross‐belt installed, measure all the bases can’t be adjusted more,
whether the undersurface of but the departure still exists, then
magnetic separator parallels with adjust the bearing base of the
the conveyor belt. secondary drum. Re the drawing
4) If overhead installation, the highest below:
point the material reaches should
aim at the center of the magnetic
system.
5) If acousto‐optic warning system is
used, some problems can be
produced deliberately for checking if
it is effective.

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1) Observe the separator as drawing A

indicates, if the belt departs to the left,
adjust the position of the supporting
rollers. If no more adjustment space is
available but the departure still exists,
adjust the bearing base of the secondary
drum.
2) If it departs to the right as drawing b
indicates, the adjustment method is
opposite to 1.
3) Notice: when the belt is stopped for
adjustment, don’t tread the belt. If the
departure is large, exchange any two
phases of the driver and the belt will
move to the opposite direction. As the
belt moves to the middle of the
separator, stop running, then exchange
any two phases of the driver, the belt
will run normally. If departure still exists,
adjust it according to the methods
mentioned above. When the departure
is solved, let it run for 2 hours. Observe
the running conditions and make
adjustment timely if the departure exists
again.

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4.3 Common trouble analysis

Trouble Possible reason Solving method Remark
Reduction of catching Suspension height
Adjust the suspension
and discharging and the obliquity
height or the obliquity
ability changed
Change on the
Re. Adjustment
parallel of the driving
Departure of the belt methods for Only for belt magnetic
drum ,the secondary
with load the departure of the separator
drum and supporting
belt
pulley
More violent
The loosing of the Fasten the connection
vibration, more noise
connection parts parts
caused.

5. Notices for operation
1) Start the separator without load. (start the separator first, then start the material conveyor)
2) Don’t disassemble the magnetic core.
3) If used in the open air, a shield is needed.
4) If used in coastal or damp area, the suspension device should be coated with solid lubricant
to avoid corrosion.

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6. Parameters and attached drawings

MODEL ADEAPTIVE BELT SUSPENSION MAGNETIC WEIGHT
WIDTH HEIGHT INTENSITY
RCY‐QF100 1000mm 250mm 460GS 1180kg


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7. Inspection Report

Equipment Name Magnetic Separator Speed Reducer N/A
Manufacturer
Equipment Model RCY－QF100 Motor Manufacturer STRIKER
Suspension
Serial NO. YC1006209 300
Height(mm)
Mfg. Date 2010/06 Item Inspected 4 Items
Inspection Criteria JB/T8711‐1998
Inspection Conclusion All the Items inspected met with the Inspection Criteria

Appendix to the Inspection Report

Inspection
Items Inspected Inspection Criteria Conclusion
Conclusion
Rotation must be Met with the Passed the Quality
All rotation parts
flexibly and smoothly Inspection Control of Striker
Must be even and
level‐off. Any
Expose surfaces of the
coming‐off, peeling‐ Met with the Passed the Quality
non‐manufacturing
off and tracks due to Inspection Control of Striker
metal parts
operation tools are
not allowed
Max. magnetic intensity
at the geometric center
≥380 (customer Passed the Quality
of the magnetic pole@ 385
request) Control of Striker
suspension height rated
(Gs)
Catching capacity Passed the Quality
≥365 372
(M16×50Bolt)(mm) Control of Striker
MAGNETIC INTENSITY
50mm 986GS 100mm 865GS 150mm 693GS 200mm 574GS
250mm 466GS 300mm 385GS


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SECTION : Remote
ISSUE: 01/2017

T-1
HQR1112
SECTION : Warranty
ISSUE: 01/2017
Table of Contents
21.1.1 Warranty U-2


U-1
HQR1112
SECTION : Warranty
ISSUE: 01/2017
21.1.1 Warranty Such components, accessories and

equipment are usually warranted by their
The equipment described in this manual is respective manufactures; in this case you
warranted to be free from any defect in are entitled only to such benefits as the
workmanship and material under conditions respective manufacturers may give under
of normal use and service in accordance their warranty.
with this manual.

The company’s obligation under this
warranty is limited to replacing or repairing
at the company’s works any part or parts
returned to it with transportation charges
prepaid, which the company’s examination
shall disclose to its satisfaction to have been
thus defective within twelve (12) months or
2000 hours of operation from the date of
delivery, whichever occurs first.

The company reserves the right to reject the
cost of fitting replacement parts.

This warranty shall not apply to any part or
parts, which shall have been altered or
repaired or purchased outside the company
nor to parts, which in the opinion of the
company have been subjected to misuse.

This warranty is in lieu of all other
warranties and conditions statutory or
otherwise expressed or implied of all other
obligations or liabilities on the company’s
part. In particular any liability for loss of time
to the user while the equipment is out of
commission, or for any labour charges or
other expenses or for any loss of profit or
consequential damage, loss or expense is
expressly excluded.

Normal wear and tear is excluded from this
warranty cover.
The company makes no warranty in respect
of components; accessories or equipment
not manufactured by it through they may
have been supplied with the original
equipment.

U-2

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STRIKER HQR1112

TRACKED IMPACTOR MANUAL

Unlimited Solutions For Limited Resources

1.2.1 General information A-2

1.3.1 Designated Use A-2

1.4.1 Copyright A-2

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1.1.1 Introduction 1.3.1 Designated Use

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2.2.1 Safety Notice B-3

2.3.1 Organisational Measures B-4

2.4.1 Basic personnel responsibilities B-4

2.5.1 Standard Operation B-5

2.6.1 Special work B-5

2.7.1 Hazardous/Flammable Materials B-6

2.8.1 Special dangers warning B-7

2.9.1 Hydraulic equipment B-8

2.10.1 Transport recommissioning B-8

2.11.1 Location of emergency stops B-9

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2.3.1 Organisational Measures 2.4.1 Basic Personnel Responsibilities

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2.5.1 Standard Operation 2.6.1 Special Work

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Always use provided safety and secure 2.7.1 Hazardous/Flammable Materials

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2.8.1 Special Danger Warnings Before carrying out any welding always

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2.9.1 Hydraulic Equipment 2.10.1 Transport Recommissioning

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2.11.1 Location Of Emergency Stops The manual has guidance for safety

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3.2.1 Identification and Control Location C-2

3.3.1 Other Functions C-2

3.4.1 Remote Control Unit C-3

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3.1.1 Serial Number Plate The remote control is located in a carry case

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4.2.1 Loading of Machine D-2

4.3.1 Plant Loading / Off Loading D-2

4.4.1 HQR1112 Operation D-3

4.5.1 HQR1112 Transport D-4

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4.1.1 Safety Information 4.3.1 Plant Loading/ Off Loading

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5.2.1 General Information E-2

5.3.1 Measures before set up E-2

5.4.1 General set up E-2

5.5.1 Daily Check Procedure E-3

5.6.1 Start Engine Procedure E-4

5.7.1 Plant Set up Procedure E-4

5.8.1 Machine set up E-5

5.9.1 Instruction Folding Hopper Wings E-6

5.10.1 Side Conveyor E-7