Operacion Servicio y Partes GT200 Cono Movil LS1200 PDF

GT200 Operation, Service, and Parts Manual
Track Plant Model and Serial Number

Plant Model: GT200
Plant Serial Number: T150277
Crusher Serial Number: C150908
Engine Serial Number: JSC25377
Clutch Serial Number: PT CLUTCH 115-91
Track Serial Number: STRICKLAND 133202
Manual Revision: 0
Factory Installed Liner Configuration
Mantle Liner: 450128SX

Bowl Liner 450127SX
Backing Material: 090037B 6EA BUCKETS
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Table of Contents
Table of Contents
Section 1: Introduction.............................................................................9
Operation, Service Manual, and Parts Book.................................................................................. 9
Address For Notices.............................................................................................................9
JCI Parts Ordering Information....................................................................................................... 9
GT200 Serial Number Plate Location........................................................................................... 10
1200LS Crusher Serial Number Plate Number Location..............................................................11
Track Plant Components...............................................................................................................11
Section 2: Safety..................................................................................... 13
Safety Overview............................................................................................................................ 13
Hazard and Advisory Statements................................................................................................. 13
Arc Flash Safety............................................................................................................................14
Lockout/Tagout.............................................................................................................................. 14
Lockout/Tagout Devices..................................................................................................... 17
Lockout/Tagout Kit..............................................................................................................19
Lockout/Tagout Procedure................................................................................................. 19
Safety Tips.....................................................................................................................................20
Safety Decals................................................................................................................................ 23
Track Plant Safety Decal Locations................................................................................... 30
Crusher Safety Decal Locations.........................................................................................32
Emergency Stop (E-STOP) Locations.......................................................................................... 33
Section 3: Setup......................................................................................35
Hoisting and Handling Safety....................................................................................................... 35
Machinery Installation Safety........................................................................................................ 36
Site Selection.................................................................................................................................37
Plant Leveling..................................................................................................................... 38
Track Plant Control Locations.......................................................................................................38
Initial Startup Inspections.............................................................................................................. 38
Hopper and Crushing Chamber Inspection........................................................................38
Hydraulic System Inspection.............................................................................................. 39
Lube Assembly Inspection................................................................................................. 39
Under Crusher Inspection.................................................................................................. 39
Conveyor Safety............................................................................................................................ 39
General Conveyor Information...................................................................................................... 41
Conveyor Belt Training..................................................................................................................41
Adjusting Belt Side Creep.............................................................................................................43
Conveyor Loading......................................................................................................................... 46
Remote Operation......................................................................................................................... 46
Remote Operation Safety...................................................................................................46
Tethered Remote................................................................................................................47
Wireless Remote................................................................................................................ 48
Transporting Machinery.................................................................................................................48
Moving the Plant.................................................................................................................48
Plant Travel Pre-Start Checks............................................................................................49
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Table of Contents
The Importance of Record Keeping and Your Warranty....................................................64
Section 4: Operation...............................................................................65
Crusher Safety...............................................................................................................................65
Control Panel.................................................................................................................................66
Hydraulic Controls......................................................................................................................... 67
Main Screen.................................................................................................................................. 68
Pre-Start Checks........................................................................................................................... 68
Plant Pre-Start Checks.......................................................................................................68
Conveyor Pre-Start Checks................................................................................................68
Crusher Pre-Start Checks.................................................................................................. 69
Engine Start...................................................................................................................................70
Crusher Starting Procedure.......................................................................................................... 70
Feed Conveyor Start..................................................................................................................... 78
Crusher Shutdown Procedure.......................................................................................................79
E-STOP Recovery......................................................................................................................... 81
Hopper Level Sensor.................................................................................................................... 82
Hopper Sensor Calibration Procedure............................................................................... 83
Engine Screen............................................................................................................................... 86
Engine Status and T4 Icons......................................................................................................... 87
Crusher Information Screen.......................................................................................................... 88
Clutch Information......................................................................................................................... 90
Fault History.................................................................................................................................. 91
Diagnostics.................................................................................................................................... 92
Active Engine Diagnostic Codes...................................................................................................92
Fault Codes................................................................................................................................... 93
Setting the Date and Time............................................................................................................94
Tech Mode.....................................................................................................................................95
Machine Set Points Access.......................................................................................................... 96
Machine Set Point Options................................................................................................ 98
Crusher Close Side Setting Adjustment Procedure-Decreasing the CSS.................................. 100
Crusher Close Side Setting (CSS) Adjustment Procedure-Increasing the CSS......................... 108
Section 5: Maintenance........................................................................ 119

Maintenance and Repair Safety..................................................................................................119
Depressurize Hydraulic System.................................................................................................. 122
Track Plant Maintenance Procedures.........................................................................................126
Lubrication and Fluid Chart.............................................................................................. 126
Daily Inspection Checklist................................................................................................ 128
Daily After Plant Startup...................................................................................................134
Engine Air Cleaner........................................................................................................... 134
Restriction Indicator.......................................................................................................... 135
Engine Fuel Level.............................................................................................................136
Hydraulic Oil Level........................................................................................................... 138
Hydraulic Restriction Indicator..........................................................................................139
Lube Oil Reservoir Fill Procedure....................................................................................139
Hydraulic Hoses and Connections................................................................................... 141
Hydraulic Cooler............................................................................................................... 154
Drive Cog Sheave Alignment and Belt Tension.............................................................. 154
Conveyor Maintenance................................................................................................................163
Conveyor Daily Inspection Checklist................................................................................163
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Table of Contents
Conveyor Weekly or Every 50 Hours of Operation Schedule..........................................163

Repairing a Broken Conveyor Belt.................................................................................. 164
Section 6: Plant Parts Book................................................................ 185

PLANT COMPONENTS.............................................................................................................. 186
GT200 FRAME............................................................................................................................ 190
FEED CONVEYOR MTG GT200DFLS.......................................................................................193
FEED CONVEYOR GT200DFLS................................................................................................ 194
FEED CONVEYOR WIPER GT200DFLS................................................................................... 198
FEEDER TAIL GUARD GT200DFLS..........................................................................................199
RETURN ROLLER GUARD GT200DFLS.................................................................................. 200
FEED CONVEYOR HOPPER GT200DFLS................................................................................201
TAIL PULLEY ASSEMBLY......................................................................................................... 205
UNDER CRUSHER CONVEYOR FOLD GT200........................................................................ 206
HEAD PULLEY ASSEMBLY GT200 UC-PPI............................................................................. 216
TAIL PULLEY ASSEMBLY GT200 UC-PPI................................................................................217
IDLER IMPACT 30DEG UC GT200........................................................................................... 217
IDLER IMPACT 45DEG UC GT200........................................................................................... 218
IDLER STL 45DEG UC GT200.................................................................................................. 219
IDLER STL 30DEG UC GT200.................................................................................................. 220
RETURN IDLER GUARD PPI GT200........................................................................................ 221
UNDER CRUSHER HOPPER GT200DFLS............................................................................... 222
WIPER UNDERCRUSHER CONVEYOR................................................................................... 224
ENGINE ASSEMBLY (CAT)....................................................................................................... 226
GT200 ENGINE SLED................................................................................................................ 240
GT200 ENGINE ENCLOSURE................................................................................................... 242
GT200 ENGINE SUPPORT CAT................................................................................................250
GT200 FUEL TANK.................................................................................................................... 251
GT200 HYDRAULIC TANK ASSY.............................................................................................. 253
STAIR ASSEMBLY GT200......................................................................................................... 256
GT200 WALKWAY HANDRAIL...................................................................................................258
GT200 HYDRAULIC VALVE ASSEMBLY.................................................................................. 260
GT200 HYDRAULIC ENCLOSURE............................................................................................ 272
LUBE FLOW METER ASSEMBLY............................................................................................. 275
CABLE ASSEMBLY FLOW METER...........................................................................................276
LUBE TANK ASSEMBLY............................................................................................................277
HOPPER FEED CRUSHER GT200DFLS.................................................................................. 280
CRUSHER DRIVE GT200.......................................................................................................... 282
GT200 DRIVE TAKEUP..............................................................................................................284
GT200 DRIVE GUARD............................................................................................................... 287
E-STOP BRACKET GT200.........................................................................................................288
HYDRAULIC SCHEMATIC GT200............................................................................................. 290
DECAL INSTALLATION GT200DFLS.........................................................................................292
GT200 DUST SUPPRESSION................................................................................................... 299
GT200 UPGRADE.......................................................................................................................303
SENSOR MOUNTING ASSY...................................................................................................... 305
GT200 BEACON ASSEMBLY.....................................................................................................306
BAGHOUSE CONNECT ADD FOR CAT................................................................................... 307
BAG HOUSE ASSEMBLY GT200DFLS..................................................................................... 308
BAG HOUSE ENCLOSURE GT200DFLS.................................................................................. 311
BAG HOUSE ELECTRICAL ASSEMBLY GT200....................................................................... 315
BAG HOUSE CONTROLLER GT200......................................................................................... 317
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Table of Contents
Section 7: Crusher Parts Book........................................................... 321

1200LS FACTORY INSTALLED COUNTER WEIGHT CONFIGURATION................................321
1200LS FACTORY INSTALLED MANGANESE CONFIGURATION.......................................... 323
1200LS SEAL AND HOSE KITS................................................................................................ 323
CRUSHER FINAL ASSEMBLY................................................................................................... 325
LOWER ASSEMBLY................................................................................................................... 327
BASEFRAME MACHINED.......................................................................................................... 332
PIN CLUTCH ASSY 10-PIN........................................................................................................334
WEDGE PLATE ASSEMBLY 1200 LS....................................................................................... 336
FLOATING PLATE W/ INSERTS................................................................................................339
CONE ASSY................................................................................................................................341
PINION ASSEMBLY....................................................................................................................343
UPPER ASSEMBLY....................................................................................................................345
ADJUSTING JACK ASSEMBLY................................................................................................. 349
ADJUSTING JACK ASSEMBLY................................................................................................. 350
TIR ASSEMBLY.......................................................................................................................... 351
TIR ASSEMBLY HOSE KIT........................................................................................................ 353
UPPER ASSEMBLY HOSE KIT................................................................................................. 354
DECAL LOCATION 1200LS....................................................................................................... 356
CONE LIFTING EYE ASSEMBLY.............................................................................................. 359
TIR CYLINDER............................................................................................................................360
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Introduction
Introduction
Operation, Service Manual, and Parts Book

This manual provides the information for an experienced operator to successfully and safely operate your
equipment. Please review this manual carefully to ensure you receive the most benefit from your machine.
Make sure that all personnel are aware of, and use, proper safety precautions when working with and/or
around the plant and related equipment. For information on service, contact your dealer or the manufacturer
service department. Please refer to your parts book for further manufacturer contact information.
Address For Notices

Any and all inquiries and/or warranty claims should be submitted in writing to JCI at the following address:
Johnson Crushers International, Inc.
86470 Franklin Blvd.
Eugene, Oregon 97405
Office: 541-736-1400 / Fax: 541-988-9401
Toll Free: 800-314-4656
Service Department: (866) 875-4058
Parts Sales Department: (888) 474-0115
JCI Parts Ordering Information

The JCI Parts Department is open from 7 AM to 5 PM Pacific Time. You can contact us in the following ways:
• *24/7 Phone (24 hours/7days a week, even holidays!): 1-888-474-0115
• Fax: 541-988-9487
• Email: parts @jcieug.com
How to Order Parts:
1. Follow your local and MSHA procedures to safely lock out/tag out the power source to your equipment.
See the Safety Section for specific lockout/tagout instruction for your machine.
2. Find the model number and serial number of your machine from the Serial Number Plate.
3. Locate the parts to be replaced by using the part lists and drawings in the parts book section.
4. Call your JCI dealer or use the JCI Parts contact information provided to order your parts. Provide the
following information:
What You Need to Order Parts:
• Serial number of the equipment. (ex. C140873 for a crusher).
• Model of the equipment. (ex. K200+).
• Part number(s) and quantity.
• Shipping information.
• Priority (next day air, ground, truck, etc.).
• Purchase order number. JCI also accepts Visa and MasterCard. Orders may also be sent out COD.
9
Introduction
Note: There is a $100 call in charge for emergency orders shipped outside of normal business hours.
Note: JCI can also supply you with parts for your Cedarrapids/ElJay® Rollercone™ crusher and 3-shaft
screens.
GT200 Serial Number Plate Location
The serial number plate for the GT200 is mounted to the frame on the right-hand side below the feeder.
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Introduction
1200LS Crusher Serial Number Plate Number Location
The serial number plate is mounted on the opposite side of the crusher drive assembly.
Track Plant Components

The GT200 plant is a remote-controlled, track-mounted crushing plant system. The plant consists of a feed
conveyor, a discharge conveyor, and a LS series crusher. The conveyors and tracks are hydraulically driven
and are operated by a bank of control valves mounted in an enclosure on the right-hand side of the plant. The
feed conveyor folds down to lower the height of the plant for travel.
The plant has a diesel engine that powers the hydraulic and electrical systems.
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Introduction
12
Safety
Safety
Safety Overview
It is the responsibility of the quarry management team to develop a comprehensive safety awareness
program, and to ensure that all quarry workers and support personnel receive appropriate safety training
as approved by federal, state, and local regulations. Safety is basically common sense. There are standard
safety rules, but each situation has its own peculiarities, which can not always be covered by rules. Therefore,
quarry personnel must continually watch for possible safety hazards and be prepared to take prompt
corrective action when necessary. Failure to observe the precautions contained in this chapter can result in
serious personal injury and even loss of life. As with most industrial work environments, a careful operator
is the best insurance against an accident. The complete observance of one simple rule would prevent many
unnecessary injuries and deaths each year.
The rule is:
“Never attempt to clean, lubricate, repair or adjust any machinery unless it is stopped and properly locked
out.”
Please note that this chapter is only intended as a brief review of basic quarry precautions and procedures.
The general guidelines included in the following paragraphs should not be considered in lieu of a quarry’s
official safety procedures, insurance company requirements, or applicable federal, state, and local
regulations.
Hazard and Advisory Statements
Hazard Warning Symbol

Hazard and advisory statements are emphasized throughout this manual.
The following safety alert symbol is used to bring attention to the specific advisory:
When you see the symbol, pay particular attention to the advisory that follows as your safety and that of
others is involved.
Hazard Statements
The Caution, Warning and Danger statements are hazard statements used to alert workers of unsafe
practices and potentially harmful or life-threatening situations. Each of these statements is preceded by the
Safety Alert Symbol.
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Safety
• CAUTION indicates a potentially hazardous condition that, if not avoided, MAY result in minor personal
injury.
• WARNING indicates a potentially hazardous condition that, if not avoided, COULD result in serious
personal injury or death.
• DANGER indicates a potentially hazardous condition that, if not avoided, WILL result in severe
personal injury or death.
Advisory Statements
The Note statements are advisory statements that relate to equipment operation, maintenance and service
procedures. They are used to draw attention to proper procedures and practices.
• NOTICE is used to draw attention to a procedure that must be observed to prevent machine damage or
malfunction.
• NOTE is a basic informational statement or helpful suggestion.
Arc Flash Safety
JCI Electrical systems and switch panels pose an Arc Flash and electrical
shock hazard. Refer to NFPA 70 for information about working with high voltage
electrical systems.
DANGER:
• Shock and Arc Flash Explosion Hazard
• Refer to NFPA 70 for information about working with high voltage electrical systems.
Lockout/Tagout
Who Must Use Lockout/Tagout?

Quarry owners, managers, and safety officers must be aware of OSHA’s “lockout/tagout” standard: CRF
Section 29 1910.147, The Control of Hazardous Energy. This standard is also recognized by MSHA. All
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Safety
mechanics, maintenance personnel, operators, and electricians must fully understand and comply with this
standard to ensure the safety of all employees.
What is Lockout/Tagout?
Lockout/tagout is a means to ensure that personnel who install, operate, repair, maintain, service or otherwise
disable machines, equipment, or electrical energy systems are protected from harm due to unexpected
energizing, or the release of stored energy by:
1. Lockout – Placing a disconnect switch, circuit breaker, valve, or other energy-isolating mechanism
in the off or safe position and securing it with a lock so the energy-isolating mechanism cannot be
activated.
2. Tagout – A prominent written warning (tag or label) placed on the energy-isolating mechanism
indicating the name of the individual placing the mechanism out-of-service, and stating that the energy
isolating mechanism cannot be activated until the tagout device is removed.
When Must Lockout/Tagout Occur?

Lockout/tagout must occur whenever service or maintenance is performed, and injury could occur due to the
unexpected startup of equipment, or the release of stored energy. In general, lockout/tagout procedures must
be performed under the following circumstances:
• Before working on electrical, hydraulic or pneumatic circuits or devices.
• Before clearing jammed mechanisms, machinery or equipment.
• Before removing guards or other protective devices.
• Whenever a machine or its controls will be left unattended.
When Can Lockout/Tagout Devices be Removed?

Lockout/tagout devices can only be removed after the following conditions are met:
• All guards and protective devices are properly reinstalled.
• All tools and repair equipment are removed from the equipment and the immediate area.
• All mechanics and other personnel are clear of the equipment and its immediate area.
• All personnel have been warned that the equipment is about to be restarted (sound warning horn or
activate warning lights).
After removing lockout/tagout devices, always use the normal startup procedure as described in the
operator’s manual for the machinery.
Lockout/Tagout Rules
• Always lockout/tagout any machinery before performing any adjustment, inspection, lubrication,
maintenance or repair procedures. Failure to observe this precaution may result in serious personal
injury or death.
• Your company’s lockout/tagout program may be somewhat different than described in this manual. If
so, be sure to completely follow your company’s official policies and procedures when lockout/tagout is
necessary. Consult your company’s safety officer if you have any questions.
• A lock must have only one user and one key. Anyone who installs a lock must keep the key in their
possession at all times. Except in an emergency situation, only the person that installs a lock is
authorized to remove it.
• To prevent accidental start-up, never give your lock or its key to another employee.
• Your key must open your lock only. Your key should not be capable of opening any other locks. Keys
for other locks should not be capable of opening your lock.
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Safety
• Except in an emergency situation, never attempt to remove anyone else’s lock. Do not allow others to
remove your lock.
• When disconnecting power, be sure that the circuit breaker handle (or other isolating device) is in the
OFF position. Accidentally locking a control in the ON position could result in serious personal injury or
death.
• If two or more people are working on a machine, a multiple lockout device must be used to prevent
accidental start-up in the event that one person finishes working before another.
• Each lock must have a tag. If two or more people are working on a machine, each person must attach a
separate tag to their lock. Never attach a lock without a tag.
• Never use tags alone. A tag should always be accompanied by a lock which prevents the isolating
device from becoming energized.
Additional Lockout/Tagout Requirements

• Be sure that the power is COMPLETELY turned off. A motor may be stopped and locked out. However,
interlocks, starters, and other supplemental electrical components may still be energized. Use a
voltmeter and/or ammeter to verify that all electrical circuits are completely dead.
• Always be sure that all peripheral equipment, such as feed conveyors, grizzly feeders and discharge
conveyors, is also tagged and locked out. Serious personal injury or death can result if any of these
items starts unexpectedly while the crusher is being serviced.
• Although lockout/tagout procedures are most commonly associated with electrical systems, be
aware that hydraulic, pneumatic and mechanical systems must also be tagged and locked out before
servicing. This may involve the lockout/tagout of valves, levers and other non-electrical devices.
• For machinery powered by internal combustion engines (diesel, gas, etc.), always disconnect batteries
and shut-off fuel supply before servicing the machinery. Lockout/tagout engine controls to ensure that
engine is not accidentally started while the machinery is being serviced.
• Always be sure that all hydraulic or air pressure is completely relieved before working on hydraulic or
pneumatic systems. Dangerous pressures can be present, even when equipment is turned off and
locked out.
• After maintenance or repairs are completed, always warn all employees that the machinery is about to
be restarted. Be sure no one is on or near the equipment before a lock and tag is removed.
• As a precaution, always activate a warning horn or light before restarting the machinery. This will
provide additional warning for personnel to stay clear of machinery that is about to be started.
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Safety
Lockout/Tagout Devices
TYPE A Battery Isolation Switch

1 Multiple User Lockout Device
2 Do Not Operate Tag
3 Padlock
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Safety
TYPE B Battery Isolation Switch

3 Padlock
4 Lock Out Hasp Designed for TYPE B Isolation Switch
Type C Main Power Disconnect
3 Padlock
Type D Main Power Disconnect
3 Padlock
A lock must be sufficiently durable, so it can withstand the environmental conditions (heat, cold, moisture,
etc.) around it. A lock must also be strong enough so that it cannot be easily removed or forced open. A tag or
label must be affixed to each lock to alert others that service work is in progress. Each tag or label must have
the following characteristics:
• Be sufficiently durable to withstand wear and abuse, even if used in dirty or damp environments.
• Be securely attached with a cable that is difficult to remove, cut or tear.
• Contain the name of the person that applied it.
• Contain a warning or other precautionary statement that briefly indicates why the machine is locked out
and what hazards could result if the equipment is started while service work is in progress.
When two or more people are working on a piece of equipment, a multiple lockout device must be used. This
allows each person to install their own lock, preventing accidental start-up.
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Safety
Lockout/Tagout Kit
The lockout/tagout kit contains all the necessary items to lock out your equipment. When you receive your
plant you should open the box and make sure it has all the items you need to properly lockout and tagout your
equipment.
Lockout/Tagout Procedure
OSHA has identified the following step-by-step lockout/ tagout procedure:
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Safety
1. Prepare for shutdown – Before shutting down a piece of equipment, know the type and magnitude of
the energy that powers it, the hazards of that energy, and how to control it. Warn all employees that the
machinery is about to be shut down.
2. Shut down the equipment – After warning all employees, shut down the machine, equipment, or
electrical system by the normal stopping procedure.
3. Control stored energy – Any potentially hazardous stored energy (electrical, mechanical, hydraulic,
pneumatic, etc.) that remains must be released, dissipated, restrained, or otherwise rendered safe. If
stored energy re-accumulates, monitor it until the possibility of accumulation no longer exists.
4. Isolate the equipment – Disengage all isolating devices, both primary and secondary, so that the
equipment is isolated from all of its energy sources (electrical, mechanical, hydraulic, pneumatic, etc.).
5. Apply lockout/tagout devices – Attach lockout tagout devices (according to your company’s safety
program) in such a manner that the isolating device (circuit breaker, control, etc.) will be held in a safe
or off position. Attach tags to alert others that the machinery is being serviced.
6. Verify that equipment is isolated – After warning all employees to stay clear, engage the start button
to confirm the machine is inoperable. Return the control to the off position before proceeding with
servicing.
Safety Tips
Know Your Machinery

• Read the manufacturer’s operation and maintenance manuals for all machinery and equipment that you
operate. Be sure that all hazard statements contained within the manuals are completely understood.
• Become familiar with the controls, functions and settings of each machine. Fully understand all phases
of each machine’s operation.
• Be sure that you completely understand and follow all startup and shutdown procedures as described
in the manufacturer’s manuals.
• Be familiar with the safety signs on your equipment, and the hazards against which they warn.
• Check the legibility of all safety signs every day. Order new signs from the machinery manufacturer if
they become illegible or worn.
Be Prepared for Emergencies

• Know the proper emergency shutdown procedures for the equipment you operate.
• Know where fire extinguishers are kept and how to use them. Be sure that fire extinguishers are
properly rated, and that they remain fully charged and ready for use at all times.
• Know the procedure for contacting emergency medical personnel. Keep a list of emergency phone
numbers handy at all times.
• Know where first-aid kits, stretchers and other emergency supplies are kept. Be sure that first-aid
supplies are properly maintained and ready for use.
• Make sure that a clear path to emergency equipment and exits is always maintained. Do not allow
equipment, spilled materials or other obstructions to get in the way.
• Know how to report accidents. Always report all accidents immediately to the appropriate supervisor.
Wear Personal Protective Equipment (PPE)

• Wear safety glasses or goggles whenever outside of an approved operator’s enclosure. Failure to wear
appropriate eye protection can result in permanent eye injuries and loss of sight.
20
Safety
• Wear appropriate ear protection when working within 50 feet of any operating quarry machinery, and in
other areas where noise levels are high. Prolonged exposure to high noise levels can cause permanent
hearing loss.
• Wear steel-toe safety boots, heavy-duty gloves and a hard hat. This equipment is mandatory in most
areas of the quarry.
• Use respirators in dusty locations and when working with hazardous substances. Prolonged exposure
to rock dust or chemical fumes can cause permanent respiratory illness.
• Other personal protective equipment may be necessary for your specific job assignment, such as a full
face shield and safety harness. Wear or use these items when necessary and as required by applicable
federal state and local regulations.
Observe Personal Safety Precautions

• Never wear loose or ragged clothing when working on or around rotating power equipment. Avoid
wearing necklaces, rings or other jewelry. These items can become caught or tangled in the machinery,
resulting in severe personal injury or death.
• Keep hair short, if possible. Keep long hair securely tied up to prevent it from becoming caught in the
machinery.
• Be especially careful whenever using wet walkways, platforms, or ramps. The combination of rock dust
and wet metal can create an extremely slippery surface. Keep all walkways and other access structures
clean, dry and free of grease or oil.
• Use walkways and ladders when working near machinery, or observing its operation. Use a safety
harness when necessary. Keep handrails and machine contact surfaces clean.
• To avoid back injuries, always use proper lifting techniques to safely lift heavy objects. Lift with your
legs and keep your back straight. Keep the materials or object close to your body. Have a co-worker
assist you if the load cannot be lifted safely by one person.
• Before starting the machinery, check that no personnel are inside, on, under or beside the equipment.
Unless absolutely necessary, do not allow anyone to be on or near the equipment while it is operating.
• Never attempt to catch falling materials or objects.
• Be aware of flammable liquids and other potential fire hazards. Do not smoke when refilling engines or
using cleaning solvents.
• Do not stand under equipment or components that are being hoisted or suspended. Never allow other
quarry personnel to do so.
• Before you assemble, operate, clean, lubricate, or adjust machinery, be sure to read and understand all
procedures contained in the machinery manufacturer’s manual.
• Be sure to operate quarry machinery in compliance with current OSHA and MSHA regulations, and all
applicable federal, state or local regulations.
Help Prevent Accidents

• Do not allow unauthorized personnel in or near the work area. Never allow unauthorized personnel to
operate, adjust, maintain or repair machinery.
• Allow only properly trained and experienced personnel to operate machinery. Be sure inexperienced
operators are carefully supervised at all times.
• Do not allow personnel to be near loading areas, or anywhere else that falling or ejected material could
hit them.
• Use extreme caution if the machinery must be operated for inspection or observation purposes. Stay a
safe distance from the machinery and wear appropriate personal protective devices.
• Before making repairs to the machinery, always clear all quarry material from the feed and discharge
devices (feeders, conveyors, chutes, etc.).
• In areas that present a danger of falling, use an appropriate fall protection device, such as a safety
harness and lifeline.
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Safety
• Always report any unsafe conditions or defective equipment to the appropriate supervisor.
Avoid Alcohol and Other Drugs

• Do not operate or work near quarry machinery when under the influence of alcohol or other drugs.
These substances can result in reduced alertness and impaired judgment. Serious personal injury or
death could result.
• Some prescription and non-prescription medications can cause drowsiness or other adverse side
effects. Do not operate or work near quarry machinery when under the influence of such medications.
Be Aware of Your Surroundings

• The quarry environment contains many situations that are potentially hazardous. Use extreme caution
to avoid being struck by haul trucks, loaders and other quarry mobile equipment.
• Be aware of idle machinery that could start up without warning. Stay clear of such machinery and the
immediate area.
• Be aware of overhead obstructions, such as conveyors, support structures or power lines.
Practice Good Housekeeping

• Do not store tools or equipment on walkways.
• Be sure that all walkways, platforms, stairs and ramps are kept free of spilled material and trash. A
buildup of material in these areas can cause slips and falls. Make repairs as required in areas where
spillage is present.
• Do not allow machinery to become buried under piles of spilled material. This will make the machinery
more difficult to inspect and may hide broken welds, loose fasteners and other serious problems that
could cause a safety hazard.
• Keep the areas around control panels and machinery free of spilled material. Free access must be
maintained at all times. In the event of an emergency, quick access to controls could prevent injury or
death.
• Clean up spilled fuel or oil immediately to eliminate slipping hazards. If necessary, use an oil absorbent.
• Always be sure that power is locked out and tagged before cleaning spilled material or oils. Never
clean-up these items while the machinery is operating.
Inspect And Maintain Machinery

• Always perform a safety inspection at the beginning of each shift. Refer to the machinery
manufacturer’s operation and maintenance manuals for detailed start-up inspection and maintenance
procedures.
• Test all warning devices before starting the machinery to ensure that they are working properly. Never
disable or bypass any alarm systems or interlocks.
• Be sure that any defective components or systems are properly repaired by a qualified technician
before the machinery is started. Immediately report any serious problems to the appropriate supervisor.
• Before performing inspections or maintenance, always lock out power and tag controls to the machine
drive, and to all feed and discharge equipment. Warn all personnel that the equipment is being
serviced. Refer to the Lockout/Tagout section of this chapter for additional information.
• Maintenance inspection procedures are included throughout this manual. Although maintenance is not
typically a safety concern, machinery that is regularly maintained and in proper working condition will
minimize the occurrence of safety hazards and emergency situations.
22
Safety
Safety Decals
Decal Meaning
WARNING: DO NOT EXCEED 55 MPH! — When towing

the equipment, do not exceed 55 MPH (96 KPH). Exceeding
the 55 MPH speed limit could result in tire failure or a serious
accident.
WARNING: HAZARDOUS VOLTAGE — The electrical

mechanisms pose a risk of serious burns or shock. You
must make sure that all components are shut off and
this equipment is properly locked and tagged out before
servicing the electrical system.
WARNING: CRUSH HAZARD — The trailer can roll

unexpectedly when the brakes are released, posing a crush
hazard. Always chock the wheels before releasing the
brakes. Read the manual for proper operation of the trailer
component.
WARNING: CRUSH HAZARD — This equipment drive

poses a crush hazard due to the belt drive. Lockout/tagout
the power source before removing the belt guard.
WARNING: LOUD NOISE HAZARD — This equipment’s

sound readings exceed 85dB and pose a noise hazard
while running. You must wear hearing protection when the
machine is operating.
WARNING: PINCH POINT — This equipment poses a pinch

hazard. You must keep feet and hands clear of the this
equipment while it is operating.
CAUTION: SLIP HAZARD — The walkways around this

equipment pose a slip hazard due to debris on the
walkways. Take care when working around this equipment
and watch your step.
23
Safety
Decal Meaning
WARNING: FALLING LOAD — This equipment is extremely

heavy and poses a crush hazard if it is lifted improperly. Use
the appropriately rated lifting device and rigging to raise. Lift
points are pointed out by this label.
WARNING: FALL HAZARD — This equipment is mounted

on a platform or trailer that is high off the ground. Falling
from this equipment could result in severe injury or death. Do
not allow anyone to climb on this equipment without proper
safety rigging and gear. Do not climb on this equipment
while it is operating.
WARNING: AVOID INJURY — This equipment poses a

severe injury risk if you do not read and understand
the operation and service manual before performing any
service.
WARNING: FALLING MATERIAL HAZARD — Operation

causes debris to become airborne and poses a risk of injury.
You must wear approved head protection while the machine
is operating. Stay clear of operating machinery.
WARNING: AVOID INJURY — Performing service on this

equipment while it is running poses risk of severe injury.
Do not service while it is operating. You must follow the
procedures to lockout and tagout the power source before
servicing.
CAUTION: USE RESPIRATORY PROTECTION —

Operation causes dust and debris to become airborne and
pose risk of respiratory injury. You must wear approved
respiratory protection while it is operating.
WARNING: AVOID INJURY — Operating this equipment

with the guards removed poses risk of severe injury. Do not
operate this equipment with any guards removed.
WARNING: WEAR EYE PROTECTION — This machine’s

operation causes debris to become airborne and poses a
risk of eye injury. You must wear approved eye protection
while the machine is operating.
24
Safety
Decal Meaning
WARNING: READ AND UNDERSTAND MANUAL

BEFORE OPERATING — This equipment poses severe
injury risk if you do not read and understand the operating
instructions.
WARNING: PINCH POINT — This equipment poses a pinch

hazard. You must keep feet and hands clear of the this
equipment while it is operating.
WARNING: CRUSH HAZARD — This equipment’s tailgate

is extremely heavy and poses a crush hazard. Stay clear
when opening the tailgate to access.
CAUTION: HOT SURFACE — During normal operation this

equipment’s wheel case temperature can exceed 180° F
(82° C). Do not touch or service until the wheel cases have
cooled.
CAUTION: EQUIPMENT DAMAGE — Do not run the

screen with the shipping brackets installed. Severe
equipment damage could occur if you attempt to operate
the screen with the shipping brackets installed. Read the
Operation Manual before running the screen.
WARNING: HIGH PRESSURE FLUID HAZARD — This

equipment’s hydraulic system poses a high pressure fluid
hazard. You must wear protective equipment when working
on this system. Follow the steps to relieve hydraulic
pressure and lockout/tagout before servicing.
WARNING: FLAMMABLE MATERIAL HAZARD — Diesel

fuel and hydraulic oil pose a flammable material hazard. Do
not smoke near this equipment. Do not allow open flame
near this equipment.
25
Safety
Decal Meaning
WARNING: STAY CLEAR OF MOVING MACHINERY —

Moving machinery can cause sever injury or death. You
must stay clear of the machinery while it is running. Make
sure that you follow the lockout/tagout procedures before
servicing.
WARNING: ROTATING SHAFT HAZARD — The conveyor

return idlers pose a rotating shaft pinch point hazard. Keep
away from the idlers when this equipment is operating.
Follow lockout/tagout procedures prior to servicing.
WARNING: ENTANGLEMENT HAZARD — Exposed

conveyor ends pose an entanglement hazard. Do not
operate the conveyor with the guards removed.
WARNING: HAND PINCH POINT HAZARD — Conveyor

folding points pose a pinch hazard that could cause
serious injury or death. Keep your hands clear while folding
conveyors.
WARNING: CRUSHING FORCE FROM ABOVE —

Unsupported conveyors pose a crushing hazard. You must
support the conveyor with an appropriately rated stand
before servicing the conveyor.
DANGER: STAY CLEAR MACHINE STARTS/STOPS

AUTOMATICALLY— You and all bystanders must remain
clear of this equipment while it is in operation. Make sure
that everyone understands your intention to move the
equipment or start a conveyor. Failure to keep bystanders
clear could result in severe injury or death.
DANGER: FALLING DEBRIS HAZARD — During operation

debris can be thrown into the air posing a risk of serious
injury or death. You must wear a hard hat in the vicinity of
this equipment while in is operation.
26
Safety
Decal Meaning
CAUTION: CORROSIVE MATERIAL AVOID CONTACT
WITH EYES AND SKIN — Take care when servicing the
battery as it contains battery acid. Battery acid is extremely
corrosive and will cause serious injury to your eyes and skin.
Always wear protective glasses, gloves and clothes when
working around the battery.
WARNING: STORED ENERGY HAZARD — This
equipment’s hydraulic system uses an accumulator to store
hydraulic energy. This poses a risk of injury due to explosive
decompression of the accumulator. You must relieve all
hydraulic pressure before servicing. Wear protective gear
and follow the lockout/tagout procedures.
WARNING: HIGH VOLTAGE HAZARD — This equipment’s

electrical system poses a risk of serious burn or
electric shock. You must take care when servicing the
electrical system. Follow all lockout/tagout procedures
before servicing.
WARNING: HIGH VOLTAGE HAZARD SHUT DOWN

BEFORE SERVICE — The electrical components in the
control panel pose a risk of serious burns or shock. You
must make sure that all components are shut off and
this equipment is properly locked and tagged out before
servicing the electrical components.
WARNING: MOVING PARTS HAZARD — This equipment

poses a crushing hazard if a person were to fall into the
crushing chamber from above while the crusher is running.
Do not allow anyone on or near the crusher opening while
it is operating.
WARNING: FALLING LOAD HAZARD — This equipment

is extremely heavy. You must use a properly rated lifting
device and rigging when lifting. Do not allow anyone near
or under while it is lifted. Read the operator’s manual for
information on the lifting points and appropriate lift rigging.
WARNING: ELECTRIC POWER SOURCE PRESENT —

The electrical components in the control panel pose a risk
of serious burns or shock. You must make sure that all
components are shut off and this equipment is properly
locked and tagged out before servicing the electrical
components.
27
Safety
Decal Meaning
DANGER: HAZARDOUS VOLTAGE. 480 VOLTS — The

electrical components in the control panel pose a risk
components.

components.

components.
WARNING: CRUSHING HAZARD — Stay clear of the area

under the screen when it is lifted off its supports. The screen
is extremely heavy and could cause severe injury or death
if it were to fall.
WARNING: PINCH POINT — The area between the upper

and lower crusher assemblies pose a pinch hazard. Stay
clear when the crusher is operating or when the hydraulic
power unit is energized. Read the manual.
WARNING: READ OPERATION MANUAL — Improper use

of the lift devise poses a hazard. Read and understand the
operating instructions before using the lift device.
WARNING: NO ENTRY WHEN MACHINE IS RUNNING

— Moving machinery can cause serious injury or death.
Stay clear of the screen access platform while the plant is
running.
28
Safety
Decal Meaning
components.
DANGER: HAZARDOUS VOLTAGE. Do not operate switch

under load. You must not move the switch to any position
while the plant is powered up. Severe injury or death could
occur due to high voltage electrical shock.
DANGER: HIGH PRESSURE HAZARD. Do not exceed

2300 psi (160 bar) while pressurizing the clamp cylinder. Do
not exceed 10000 psi (690 bar) while pressurizing the Jack
Cylinders. Severe injury or death will occur due to explosive
high pressure release.

2300 psi (160 bar) while pressurizing the TIR cylinder.
Severe injury or death will occur due to explosive high
pressure release.

3000 psi (207 bar) while pressurizing the hydraulic system.
Severe injury or death will occur due to explosive high
pressure release.
DANGER: SHOCK AND ARC FLASH HAZARD. Working

with high voltage electrical components poses a shock or
arc flash hazard which will result in serious burns or death.
You must be trained and comply with all relevant safety
regulations and precautions when working on the high
voltage electrical systems.
WARNING: CRUSHING HAZARD. Chock all tires on your
trailer before releasing the brakes. Trailer movement could
result in serious injury or death.
29
Safety
Decal Meaning
WARNING: STORED ENERGY HAZARD. The drive belt
tensioner is spring actuated and poses a stored energy
hazard that could cause severe injury or death. Read the
service manual before attempting to release the spring
tension.
Track Plant Safety Decal Locations
30
Safety
31
Safety
Crusher Safety Decal Locations
32
Safety
Emergency Stop (E-STOP) Locations

The E-STOP switches are mounted in several locations: the left-hand side, the right-hand side, the control
panel, and the hand-held remote control(s).
33
Safety
To actuate the E-STOP push in on the switch, which will shut down the entire plant operation. To reset the
switch, twist the button clockwise until it automatically pops out.
34
Setup
Setup
Hoisting and Handling Safety
General Precautions
• Do not allow personnel to work or walk under loads supported by a crane or hoist.
• Use appropriate lifting devices to secure the load to the crane.
• Use the correct lifting hooks to support the load.
• Use extreme caution when operating a crane near power lines or electrical equipment.
• Do not exceed the crane’s rated load capacity. Always subtract the weight of the hook block, slings,
chains, spreader bars and any additional equipment to determine the maximum load that can be safely
lifted.
Wire Rope
Wire rope requires careful use, handling and maintenance to ensure long life and safe operation. Always
observe the following precautions:
• Be sure to use the correct wire rope for the application.
• Be sure that the wire rope is inspected regularly following the manufacturer’s guidelines.
• Avoid sudden loading in cold weather. Never use frozen wire rope.
• Use suitable padding to protect wire rope from sharp corners or edges.
• Avoid dragging wire rope underneath loads or over obstacles.
• Never use wire rope that has been cut, badly kinked, frayed or crushed.
• Avoid reverse bends.
• Be sure that rope ends are properly sized.
• Use thimbles in eye fittings at all times.
Connecting Or Clamping Wire Ropes

When connecting or clamping wire ropes, use one of the following:
• Clamp and thimble connections combine both the clamp and thimble in one unit. Clamp and thimble
connections are capable of supporting 80% of the rated wire rope load.
• Cable clips are the most common way to secure a rope to a piece of equipment or to make an eye. The
cable clip or “Crosby Clip” is made of a U-bolt and saddle. If this type of clip is used to make an eye,
the use of a properly sized thimble is mandatory. If not, the cable may kink, forming a permanent weak
spot.
Chains
Chains require careful use, handling and maintenance to ensure long life and safe operation.
• Ensure that the correct size chain is being used for the application.
• Ensure that the chain is inspected regularly following the manufacturer’s guidelines.
• Avoid sudden or shock loading (DO NOT jerk load upright).
• Use suitable padding to protect the chain from sharp corners or edges.
• Avoid dragging the chain under loads or over obstacles.
• Use the proper fittings at all times.
35
Setup
• Inspect links to determine the amount of wear. Refer to manufacturer’s specifications for wear tolerance
ranges.
• Be sure that all connections between chain sections are completed with properly sized hardware and
lifting hooks.
WARNING: Always follow proper rigging procedures as provided by the chain

manufacturer. The angle of rigging may decrease the rated lifting capacity.
Fiber Or Synthetic Slings

Slings require careful use, handling and maintenance to ensure long life and safe operation.
• Ensure that slings are rated or coded for the hitch or application.
• Ensure that slings are inspected regularly, following the manufacturer’s guidelines.
• Slings may be safely used in a temperature range of 20 to 180° F (-6 to 82°C) without decreasing load
limits. For temperatures beyond this range or for wet/frozen slings, follow manufacturer’s instructions
for load reductions.
• Do not use synthetic slings in temperatures exceeding 180°F (82°C).
• Avoid sudden or shock loading (DO NOT jerk load upright).
Machinery Installation Safety
Foundations
Proper foundations and support structures are essential to ensure the safe and efficient operation of quarry
equipment.
• Crushing and screening machinery needs a firm foundation on which to operate. This does not need
to be a poured pad, but it must not be unstable ground. When selecting the location, be sure that the
entire area is as level as possible.
• Follow all manufacturer’s installation drawings and specifications when constructing the base pads for
permanent plants.
• If any questions arise regarding foundation requirements or modifications necessary for JCI machinery,
please contact the JCI Service Department.
• Customer-designed support structures for JCI equipment must meet JCI’s engineering standards. All
plans must be submitted in advance to the JCI Engineering Department for approval.
Guarding
• Quarry management is responsible for the proper installation and placement of guards to prevent
personnel from coming in contact with rotating or moving parts.
• In addition to the guards supplied with the machinery, additional guards and related safety equipment
may be required to comply with OSHA, MSHA and any applicable local regulations. The proper
fabrication, installation and placement of these items is quarry management’s responsibility.
• When fabricating guards, refer to MSHA’s Guide to Equipment Guarding at Metal and Nonmetal Mines.
Additional information can also be provided by the safety officer at your work site.
• Never remove guards until the machinery is stopped, power is locked out, and controls are tagged. Be
sure that guards are properly re-installed before reconnecting power.
36
Setup
Customer Modifications
• Do not modify quarry machinery in any way without prior approval from the manufacturer. Such
modifications may include (but are not limited to) changing machine speed or direction of rotation,
drilling additional holes and welding or bolting additional equipment to the machinery.
• All customer modifications to JCI machinery must be approved in writing by the JCI Engineering
Department.
Electrical Connections
WARNING: When installing any electrical equipment, be sure to completely

follow the manufacturer’s instructions. Failure to observe this precaution could
result in a dangerous electrical shock hazard.
• Be sure that all electrical equipment is properly grounded.

• Lay out the power lines, especially those for portable plants, so that contact with standing water is
minimized.
• Do not place power lines in an area where they will be driven over by transport vehicles or other quarry
equipment. If it is absolutely necessary to extend a power line across a traffic area, protect the cable
with properly rated bridging.
• Be sure that all auxiliary control panels or power supply panels can be securely locked out. This type of
panel is mandatory.
• Maintain adequate overhead clearance from power lines or other obstructions, particularly when
planning to use stacking conveyors for stockpiles.
• Be sure that electrical power supplies are located in an area that will be safe from accidental contact
during crushing operations.
• All JCI machinery is designed with electrical components of the proper size and voltage. Any
modifications to these components or to the power supply must be approved in writing by the JCI
Engineering Department.
• Be sure that all connections are in accordance with the National Electric Code and any applicable state
or local codes.
Site Selection
When selecting a suitable site for operation, many factors need to be taken into consideration. Selecting a site
without anticipating problems could lead to unsatisfactory operation and plant relocation could be required.
Some things to consider when selecting a site:
• Stability of the ground. If the ground is too soft or unstable, proper leveling and loading may be
impossible.
• The portable plant must be located so ample room is available. Leave plenty of room around the
portable plant, to facilitate access of loading equipment, assembly of portable plant components and
service personnel.
• Proper drainage is important to allow for runoff of normal rainfall.
• You may also want to consider prevailing wind direction and its effect on the operator or loading
personnel.
37
Setup
Plant Leveling
It is extremely important to make sure the plant is level before you run the crusher. Also, make sure the
ground is flat and that the plant is not parked so that one side is higher than the other so that the frame is
twisted or askew. Possible problems that could arise from improper leveling includes leaking around the
pinion, inaccurate lube oil level readings, and damage to the trust and radial bearings.
NOTICE: You must be sure to get the plant as level as possible. Running the plant unleveled will damage
the crusher.
Track Plant Control Locations
1 Electronics Compartment
2 Hydraulic Compartment/Conveyor Controls
3 Battery Isolation Switch
Initial Startup Inspections

Hopper and Crushing Chamber Inspection
Item Description Yes No
1 The cone head blocks have been removed and chamber is completely
empty.
2 The bowl liner is not in contact with the mantle anywhere (CSS>0)
3 Hopper is free of overhead obstructions that could prevent rotation of
bowl or cause interference during tramp iron events or chamber clearing.
See installation drawing for required overhead clearance.
4 Feed conveyors are properly placed to assure centrally distributed
material.
5 The hopper level sensor is properly installed and calibrated.
38
Setup

6 The maximum vertical drop from the highest feed conveyor to the top of
the cone is less than 7'[2.134M].
7 Mantle bolt protector cap is in place.
Hydraulic System Inspection

1 Oil level is at or near the full mark on the site gauge (hydraulic oil does not
have to be absolutely full)
2 Oil fill port on the inlet to the oil filter is capped and tight.
Lube Assembly Inspection

1 Lube oil level is at the FULL mark on the sight gauge (top off if required).
2 Lube oil fill cap is in place.
3 Breather is unobstructed.
4 Lube oil return line is connected and routing appears to be as per
recommended practice.
5 Lube oil cooler hoses are connected properly.
6 Lube oil supply line is connected properly.
Under Crusher Inspection

1 The crusher is mounted level in all directions.
2 All crusher supports and/or foundations are on solid ground and/or
supported on cribbing that is in solid condition.
3 All mounting bolts are tight.
4 Crusher discharge area is free of debris all the way from the CSS to the
conveyor belt.
5 Lube supply line is connected and properly placed so it is protected from
debris and vibration.
6 Crusher drive sheave and motor sheaves are free of built up dirt or
debris.
7 Belt guards are in place and sheaves are free to turn.
Conveyor Safety
• Do not allow anyone to operate the conveyor until he or she has read the owner’s manual and is
completely familiar with all safety precautions.
39
Setup
• Do not allow the following people to operate or maintain the conveyor:

Children
Persons unfamiliar with the equipment, or unfamiliar with safe operating and maintenance procedures
for the equipment.
Persons under the influence of alcohol, medications, or other drugs that can impair judgment or cause
drowsiness.
• Make sure everyone is clear of the conveyor before starting the belt, during operation, or maintenance.
Never allow anyone to ride on the conveyor!
• Do not leave conveyor unattended while in operation.
• Do not wear loose hanging clothes, neckties, or jewelry. Long hair is to be placed under a cap or hat.
These precautions will help prevent you from becoming caught in the moving parts of the conveyor.
• Do wear safety glasses, ear protection, respirators, gloves, hard hats, safety shoes, and other
protective clothing when required. Requirements for personal protective equipment will vary depending
upon conveyor placement and material to be conveyed. It is the responsibility of conveyor operators to
be certain they make use of all necessary personal protective equipment.
• Buildup of materials on pulleys or idlers will lead to belt misalignment or damage. When removing such
materials, the conveyor must be stopped and power controls must be locked out or tagged out.
• The conveyor should not be used to handle materials other than those which were specified as part
of its design and manufacture. It is the operator’s responsibility to be aware of the conveyor system
capacities and operate the conveyor accordingly.
• Make sure the operator’s area is clear of any distracting objects. Keep work areas clean, and free
of grease and oil to avoid slipping or falling. Periodically check all shields and structural members.
Replace or repair anything that could cause a potential hazard.
• When the belt is moving, the material travels at a speed sufficient to cause injury. Do not start
the conveyor until you are certain no one is exposed to the moving parts or to the material being
discharged from the end of the conveyor.
• When preforming maintenance work on structural parts or repairing any moving parts block all wheels
to prevent the conveyor from moving, and block any extended hydraulic cylinders to prevent them from
moving or retracting.
• If any safety devices are not functioning properly, do not use the conveyor. Remove it from service until
it has been properly repaired.
• Do not replace components or parts with other than factory-recommended service parts. To do so may
decrease the effectiveness of the unit and/or create a safety hazard.
• Do not lubricate parts while the conveyor is running.
• Before starting engines within enclosed areas, be certain ventilation is sufficient to avoid buildup of
exhaust fumes.
• Relieve any and all pressure before opening, repairing, or removing any air pressure lines, hydraulic
lines, valves, fittings or seals. In the event of an hydraulic line rupture, stay clear of the area until
pressure has been relieved. Clean up any spilled fluid before performing repairs in the area.
• It is the operator’s responsibility to be aware of equipment operation and work area hazards at all
times.
• Operators are responsible to know the location and function of all controls and indicators, including
electrical power panels, hydraulic controls, motor controls, incline indicators, fuel and oil level
indicators, belt scale controls, etc.
• Operators are responsible to know the location and function of all guards and shields including but
not limited to drive guards, pulley guards, and nip guards; and are responsible to make certain that all
guards are in place when operating the conveyor.
• Operators are responsible to be aware of safety hazard areas and follow instructions on warning,
caution, or danger decals applied to the conveyor. Safety hazard areas may include but are not limited
to:
40
Setup
Pinch points at fold hinge areas.

Pinch points at fold support areas.
Pinch points where locking pins are used.
Electrical control panels.
Moving parts hazards on drives.
Moving parts hazards where contact with belts and idlers is possible.
General Conveyor Information

A properly installed and trained conveyor belt will operate for many hours without problems. You must
make sure that the belt runs centered on all pulleys and idlers along the entire length of the conveyor. Once
your belt is properly trained and adjusted it will contact the horizontal roller on the troughing idlers. It is not
necessary to use side guide rollers to keep a properly installed and trained belt. The following tips will help
you keep your conveyors functioning properly:
• Belt carcass ruptures, pulley cover gouging, and belt striping usually indicates the material is spilling
over the edge of the conveyor.
• Excessive belt cover wear is usually indicative of leakage at the skirt boards.
• Run the conveyor empty then add your feed material.
• When shutting down, stop the feed unit then shut down your conveyors.
• Make sure your electronic controls are set for the proper start-up/shut-down sequence.
• Periodically, check your conveyor belt run out while loaded to make sure it is running true on the idlers.
• Run the conveyor empty for three or four rotations when conveying wet material to clean the belt.
Conveyor Belt Training

Conveyor belt training is the process of adjusting idlers and load conditions to achieve conveyor belt travel
over the center area of the troughing idlers, pulleys, and return idlers. A true conveyor belt path means that
the belt is tracking without creeping to one side or the other. The following steps will guide you through the
belt training process.
WARNING: Do not attempt to make any adjustments to the conveyor with it

running. Serious injury or death could occur if any part of your body was pulled
into the conveyor as is moves through the idlers.
Note: Do not attempt to adjust belt tracking by unequal adjustment of conveyor take-ups. The take-ups are
designed for adjusting belt tension across the idlers and for keeping the tail pulley square with the conveyor
frame.
41
Setup
1. Verify the conveyor frames are level crosswise. Gravity can force the belt to run to one side if the frame
is not level.
2. Check the tail pulley and the head pulley are square with the conveyor frame.
3. Mark a point, X, midway between the conveyor frame and measure a distance diagonally from X to the
conveyor frame, Y, and place a mark on the frame.
4. Measure the same distance on the opposite conveyor frame, Z, and place a mark on the frame.
5. This Line, YZ, is at a 90 degree angle to the mid point line on the conveyor that runs through X.
42
Setup
6. Clamp a straight edge along the YZ line and use this as your reference to check all idlers for square.
7. Make sure the tail pulley and all troughing and return idlers are square.
8. Run the conveyor empty to check for belt run-out, check both the material side and then the return side
of the belt.
9. Check the conveyor belt splice for square. Run the conveyor at a slow speed, if the belt creeps at the
splice, your splice may not be square with the edge of the belt.
Adjusting Belt Side Creep

The following steps will help make adjustments to the conveyor return-side idlers and the material-side idlers
when the conveyor belt is creeping to one side during operation.
Note: Do not attempt to adjust belt tracking by unequal adjustment of conveyor take-ups. The take-ups are
designed for adjusting belt tension across the idlers and for keeping the tail pulley square with the conveyor
frame.
Note: Make sure the belt splice is square. If the belt splice is not square it can cause belt creep and may
need to be replaced.
WARNING: Do not attempt to make any adjustments to the conveyor with it

running. Serious injury or death could occur if any part of your body was pulled
into the conveyor as it moves through the idlers.
43
Setup
1. Loosen the nuts that hold the return idlers in place. The idlers are slotted and adjustments can be made
easily.
1 Return-side Idler
2 Return Idler Mounting U-Bolts
2. Move the idler in small increments in the opposite direction the belt is moving.
3. Tighten the nuts that hold the return idlers in place.
4. Run the conveyor for at least three (3) passes to see if the belt is still creeping.
Note: If the belt is still creeping, adjust the material-side idlers.
5. Loosen the nuts that hold the material-side idlers in place.
6. Move the material-side idler in small increments in the opposite direction the belt is moving.
7. Tighten the nuts that hold the idlers in place.
8. Run the conveyor for at least three (3) passes to see if the belt is still creeping.
44
Setup
9. If the belt is still creeping, make more adjustments until the belt is running true.
Note: If you think of a steering wheel (see illustration) where the center of the idler is fixed,
adjustments can be made by rotating the idler ends around the circle. Run the conveyor between each
adjustment until the belt creep stops.
45
Setup
Conveyor Loading
Properly loading the conveyor will prolong the life of the belt. The ideal condition is to have the material pass
from the chute to the belt at almost the same speed and direction of travel as the belt with a minimal amount
of impact. Improper conveyor loading may also cause the belt to creep.
Remote Operation
Remote Operation Safety
WARNING: Only authorized personnel are permitted to operate the track-

mounted plant remote control system. Personnel must be specifically trained in
the safe use of the remote control system. Failure to adhere to these rules and
those of your operation site can result in death, serious injury, and damage to
equipment.
46
Setup
Introduction
Your remote control equipped vehicle is a powerful tool. As powerful as it is, it is imperative that you, the
operator, know how to use this tool safely. In preparation for use of the remote control system, you must read
and understand this operation manual and be familiar with the safe operation of your vehicle. Always adhere
to the safety guidelines outlined in this manual when using your remote control system. Before any use of the
plant, you must be trained in the safe operation.
Note: Your quarry site may have own rules and regulations governing the operation of the remote control
system which supersedes those of this manual. In addition, you must have received specific training in how to
use the remote control system prior to operation of this plant.
To ensure safe operation of your track plant, it is important that it is operated and maintained within
manufacturing specifications. Consult your service technician and operation manual for more information. It is
your responsibility to be sure that the plant has been properly maintained before operating it.
Preparing For Operation

The area in which the track plant is operated must be a controlled environment. A controlled environment is
defined as an area that is clear of people and equipment, and in which people will not have contact with the
plant during remote control operation. Operating the track plant in a controlled environment will reduce the
risk of death or injury and damage to property.
Note: The minimum distance from any part of the plant to the operator is 15 feet (5m) while it is in operation.
Tethered Remote
The track plant comes standard with a tethered remote, which allows you to move the plant and press
emergency stop. This hand-held device plugs into the electrical system by way of a cable, so it does not
require batteries.
47
Setup
Wireless Remote
The track plant also comes with a wireless, hand-held remote that allows you to move the plant and stop the
engine.
Transporting Machinery
• Be sure that the machinery is properly secured so that it cannot vibrate or move during transport.
Remove any dirt, stones or other loose material from the machinery.
• Install shipping brackets, wood blocking or other shipping materials as directed in the machinery
manufacturer’s manuals. Perform any shipment preparation procedures as indicated in the manuals.
• Plan your route carefully. Know the clearance height of the machinery. Be aware of bridges, power
lines and steep or uneven grades. Be aware of any other conditions which may present hazards or
obstructions.
• Be sure that all tractor-trailer components are working and in good condition. Test all systems (brakes,
steering, lights, etc.) for proper operation and/or adjustment before beginning the move. Check air
pressure in all tires and replace any tires that are worn or damaged.
• After the machinery has been transported, block the tires if the trailer will remain stationary for an
extended period of time.
Moving the Plant

The track-mounted crushing plant is designed to be moved around a site under its own power. To move the
plant you will need to read and understand the safety precautions explained in this manual as well as all site
safety regulations applicable to operating a crushing plant.
48
Setup
WARNING: You must make all bystanders aware that the plant is about to be
moved. Serious injury or death can occur if an individual is in the path of the
moving plant. As the operator, it is your responsibility to use the warning horn
while operating the plant.
NOTICE: You must install the cone travel blocks before moving the plant. Failure to install the travel blocks
in the crushing chamber will cause severe damage to the bearings and will void the crusher warranty.
Plant Travel Pre-Start Checks

1. Read and understand the operations manual.
2. Check the engine oil level.
3. Inspect the engine air cleaner and clean the intake evacuator valve.
4. Examine the engine radiator and hydraulic cooler fins for material build up.
5. Check the engine fuel level.
6. Check the hydraulic oil level.
7. Visually inspect the hydraulic hoses and connections.
8. Make sure the cone travel blocks are properly installed in the crusher.
9. Prepare all conveyors for traveling, which could include lowering or folding into travel mode.
10. Install conveyor shipping brackets or tie down conveyors, where applicable.
Transporting the Crusher

When the crusher is to be moved to a new crushing site, the cone head must be blocked to prevent damage
to the crusher bearings. The roller bearings are designed to handle heavy crushing loads but not the sharp
impact load caused from the cone head bouncing during transportation. Moves of even short distances can
cause brinelling marks leading to reduced bearing life. Use the cone travel blocks that came with the crusher
to block the cone head. If you do not have the original blocks you can make new ones by cutting two wedge
shaped wooden blocks, each about 30" long, from a 4 by 4.
Place the blocks side by side in the widest part of the opening between the cone mantle and the bowl liner,
and hammer the wedges in place.
49
Setup
1 Cone Travel Blocks Installed
Conveyor Shipping Bracket

Plants with a folding conveyor are shipped with a shipping bracket that must be removed before unfolding the
conveyor.
1. Remove the hardware securing the shipping bracket to the top half of the conveyor.
50
Setup
2. Swivel the bracket up towards the base of the conveyor.
3. Align the bracket hole with the drilled hole in the conveyor.
4. Secure with the hardware previously removed.
5. Repeat steps 1-4 on the opposite side.
6. Install the bracket before moving the plant.
Under Crusher Conveyor Fold/Unfold

1. Remove the red shipping bars if they are installed.
51
Setup
WARNING: Before starting the plant and activating the conveyors, alert all by
standers the plant will be starting and the conveyors are being moved and make
sure everyone is clear.
2. Start the engine. Turn and hold the key in the START position for 10 seconds.
3. Make sure the conveyor cylinder hydraulic valve is pulled out to provide hydraulic flow to the conveyor
hydraulic valves.
52
Setup
4. Pull the lever on the under-crusher conveyor hydraulic control valve to unfold the conveyor.
5. Push the lever on the under-crusher conveyor hydraulic control valve to fold the conveyor.
6. Install the shipping bars if necessary.
53
Setup
Feed Conveyor Lift/Lower
WARNING: Before starting the plant and activating the conveyors, alert all by
standers the plant will be starting and the conveyors are being moved and make sure
everyone is clear.
2. Make sure the conveyor cylinder hydraulic valve is pulled out to provide hydraulic flow to the conveyor
hydraulic valves.
54
Setup
3. Pull the lever on the feed conveyor hydraulic control valve to lift the feed conveyor.
4. Push the lever on the feed conveyor hydraulic control valve to lower the feed conveyor.
55
Setup
Plant Travel Position
1 Track Idler End

2 Track Sprocket End
When traveling up a grade, make sure that the track is driven idlers first. You should drive the track drive
sprocket first while traveling down a gradient.
Travel Procedure Using Tethered Remote
Before starting the plant and activating the tracks, alert all bystanders the plant is
starting and make sure everyone is clear.
1. Make sure the ESTOPS are reset.
56
Setup
2. Turn the battery isolation switch to the ON position.
57
Setup
4. Make sure the flow control valves are turned to maximum speed for both tracks.
5. Pull both the LH and RH track enable levers outward.
58
Setup
6. From the controller main page, access the Track Drive page.
7. Turn the remote selector to the TETHERED position.
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Setup
8. Press the Track Enable button on the remote.
9. Use the toggles (FWD/REV) to drive the tracks.
Travel Procedure Using Wireless Remote
WARNING: Before starting the plant and activating the tracks, alert all by standers the
plant is starting and make sure every one is clear.
1. Make sure the ESTOPS are reset.
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Setup
2. Turn the battery isolation switch to the ON position
61
Setup
4. Make sure the flow control valves are turned to maximum speed for both tracks.
5. Pull both the LH and RH track enable levers outward.
62
Setup
6. From the controller main page, access the Track Drive page.
7. Turn the remote selector to the WIRELESS position.
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Setup
8. Locate and become familiar with the wireless remote before moving the plant.
1 OFF BUTTON
2 RIGHT FORWARD
3 RIGHT REVERSE
4 ENGINE SHUT DOWN
5 LEFT FORWARD
6 LEFT REVERSE
9. Press the buttons on the remote to move the plant into position.
10. When the plant is in position shut down the engine.
11. Turn off the remote.
The Importance of Record Keeping and Your Warranty

A warranty statement is located in the front of the operations manual. In order to activate your warranty, you
must complete and forward the startup checklist to JCI within 30 days after you have started your equipment.
Otherwise the warranty will be automatically active and the warranty time period will begin with the date the
equipment was shipped from the factory. The startup checklist requires a signature from the customer and the
dealer representatives present at the startup. Refer to the Maintenance section for daily checks, lubrication
checks, and required hourly preventive maintenance inspections and procedures. If you have any questions
concerning your equipment, you can contact JCI Service and Warranty at 1-800-314-4656.
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Operation
Operation
Crusher Safety
WARNING: Do not allow personnel to be on or near the crusher during operation.

The crusher will shake violently should tramp iron be fed into the machine. Stay
clear of feed and discharge areas to prevent being injured or killed by fling or
falling rock.
WARNING: Never attempt to clear jammed material from the crushing chamber
while the crusher is operating. Serious injury or death could result if you are
pulled into, or fall inside, the crushing chamber.
WARNING: Never attempt to manually clear jammed material from the crushing
chamber while the upper frame is in the lowered (clamping) position. Any material
lodged in the chamber could release without warning, and may be propelled
upward through the feed opening. Serious injury or death could result.
• Verify that all personnel are clear of the crusher prior to starting. This includes verifying that no
personnel are under the crusher.
• Perform a complete inspection before starting the crusher. Be sure that the crushing chamber is clear.
Make sure the cone blocking is removed.
• Be sure that all guards and other safety devices are correctly installed and tightly secured before
starting the crusher. Stay clear of rotating or moving parts during crusher operation.
• Rock projected upwards through the feed opening can injure or kill. Do not look directly into the feed
opening while the crusher is operating. Use mirrors or closed-circuit cameras if close observation of the
feed arrangement is necessary for troubleshooting or evaluation purposes.
• Do not tamper with crusher alarm components. Never attempt to defeat electrical interlocks or to
disable crusher protective devices.
• Never place hands on cylinder rods. Stay clear of pinch-point area between the upper and main
frames.
• Never stand on hydraulic hoses or use them as steps. If hoses rupture, serious injury or death could
result. As required, use a safety harness during servicing.
• Always lockout/tagout power to the crusher drive motor, crusher oil lubrication system and crusher
hydraulic system before performing any inspection, adjustment, lubrication, maintenance or repair
procedures. Also lockout power to all crusher feed and discharge equipment. Be sure pressure is fully
relieved before servicing the hydraulic system.
• If the crusher is powered by a diesel engine, always disconnect batteries and shut-off fuel supply
before performing any inspection, adjustment, lubrication, maintenance or repair procedures. Lockout/
tagout engine controls to prevent the engine from being accidentally started while the crusher is being
serviced.
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Operation
• Support the crusher upper frame with hardwood blocking or steel safety spacers and shut off and
lockout and depressurize the hydraulic system before entering the crushing chamber for service work.
Never rely on hydraulic pressure to keep the upper frame raised. You could be crushed and killed if the
upper frame lowers unexpectedly.
• Always stop the crusher immediately if any gauges show abnormal readings, or if there is a sudden
obvious change in operation. Be alert for noises that might indicate trouble.
• Inspect, lubricate, maintain and repair the crusher in accordance with the instructions contained in this
manual and any additional manuals or documentation provided with the crusher.
• Inspect all warning signs and caution decals. If they become torn or not readable contact your local
dealer or JCI for replacement.
• On portable plants be sure that the trailer is properly blocked and level. All blocking must be suitable to
support the trailer dead load weight plus the crusher impact live loading.
• Avoid stopping the crusher with material inside the crushing chamber. In the event that the crushing
chamber is full of rock use the hydraulic clearing feature. Always inspect the crushing chamber and V-
seat after a clear for loose or jammed rock.
Control Panel
1 Display (HMI)
2 Panel Emergency Stop Button
3 Track Selector Switch
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Operation
4 Ignition/Start Switch
Hydraulic Controls
1 Flow Control Valve for U/C Conveyor and Left-Hand Track

2 U/C Conveyor (IN) / Left-Hand Track (OUT) Control Valve
3 Flow Control Valve for Feed Conveyor and Right-Hand Tack
4 Feed Conveyor (IN) / Right-Hand Track (OUT) Control Valve
5 Flow Control for Cone Lube Oil and Conveyor Lift Cylinders
6 Cone Lube Oil (IN) / Conveyor Lift Cylinders (OUT)
7 Jack Cylinder Needle Valve
8 Clamp Cylinder Needle Valve
9 Cone Clamp (IN) / Jack (OUT)
10 Cone TIR (IN) / Clear (OUT)
11 Under Crusher U/C Conveyor UP / DOWN
12 Feed Conveyor UP / DOWN
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Operation
Main Screen
1 Engine Information Screen

2 Plant Run Screen
3 Tracking Screen
4 Diagnostic Information
5 Plant Settings
6 Work-Lamps On/Off
Pre-Start Checks
Plant Pre-Start Checks
1. Read and understand the operation and service manual.
2. Inspect the engine air cleaner and clean intake evacuator valve.
3. Examine the engine radiator and hydraulic cooler fins for material buildup.
4. Check the engine fuel level.
5. Check the hydraulic oil level.
6. Visually inspect the hydraulic hoses and connections.
7. Make sure the baghouse travel cover has been removed.
Conveyor Pre-Start Checks

1. Check to be sure the feed conveyor gear reducer is filled to the proper oil level.
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Operation
2. Make sure that all conveyor guards are installed and functioning properly.
3. Visually inspect all hoses, lines and belts for leaks, wear and damage.
4. Check and remove all tools and any foreign objects from the belt, particularly on the return side where
they may get between the pulleys and belt. Grease on the belt should be removed immediately as it will
deteriorate the belt.
5. Make certain no parts of the plant have been locked out or tagged out. If they have, determine who
placed the lockouts, and have them remove the lockouts before starting the plant.
6. Walk completely around the conveyor, making certain no other personnel are under, on top of, or next
to the plant. Warn anyone nearby that you are starting the plant.
7. Make sure all shipping brackets and tie downs have been removed.
Crusher Pre-Start Checks

For optimum performance and maximum life as well as safety of personnel working around the crusher,
certain items must be checked on a daily basis. In the Maintenance section of this manual there is a checklist
and instructions on how to conduct the checks.
This section is intended only for daily, routine start-ups and addresses only those items necessary for starting
a crusher that is in good working order and has already been maintained and/or serviced and is ready for use.
1. Make sure the crusher shipping blocks are removed.
2. Check to make sure the hopper and crushing chamber are clear of rocks. Starting with anything
(including rocks) in the chamber can potentially cause cone brake problems.
3. Check the crusher discharge area for blockage or debris. Pay particular attention to unusual buildup on
the pinion tunnel and/or struts.
4. Inspect all guards. Make sure they are in place and are not damaged.
Note: Check for any unusual wear on the top of the wedgeplate guard or exposed portions of the cone
seal. Normally there should be no appreciable wear in this area, so if wear begins to appear, a root
cause analysis should be implemented right away to avoid costly, preventable damage.
5. Check the lube oil level in the reservoir sight glass. Top it off if required but do not overfill. The oil
should only be checked after the crusher has sat unused for an appreciable period of time (overnight is
ideal). Any time the lube pump has run, it takes a considerable period for the oil to return to its original
level.
6. Check crusher drive sheave for any accumulated dirt and clean if necessary. If dirt accumulates in
either sheave, it will cause vibration that is often mistaken for crusher imbalance.
7. Inspect the drive belt for damage or excessive wear. Check for proper belt tension.
8. Check all hydraulic and lubrication system hoses and connections for wear, leaks, or damage.
9. Check to make sure all hoses are connected properly.
10. Assess the condition of the baseframe tub liners. These are wear items that will erode over time.
11. Check the condition of the manganese liners. A daily inspection of the exposed portion of the parallel
zone will expose not only the general condition indicated by the thickness but also the development of
hooks in the liner or mantle, which can give clues to application problems and also to the presence of
missing chunks caused by uncrushable objects passing through the chamber.
12. Check the condition of bowl liner fit. Look for indications that the liner is loose or cracked or evidence of
water leaking between the liner and bowl, which indicates that a loose liner may be imminent.
13. Check the pinion shaft and seal area for leaks.
14. Check the rotation stop pin for proper alignment with the stop block shim.
15. Verify hydraulic oil level is near the full mark on the sight glass. It does not have to absolutely full.
16. Give the crusher an overall review looking for any changes since the day before, such as:
69
Operation
• Missing TIR cylinder rod coupler keeper rings

• Oil leaks at TIR cylinders, bowl clamp, bowl rotation motor, etc.
• Damaged TIR cylinders
• Accumulation of black powder under the rotation stops indicating that bowl float has occurred.
17. Verify that the bottom of the bowl drive ring is in the “Crushing Zone” defined by the decals on the gear
supports.
Engine Start
1. Turn the ignition key to the ON position and wait until the splash screen appears on the display.
NOTICE: Do not attempt to start the engine if there are any faults displayed or the wait to start lamp is
illuminated. If a problem occurs refer to the Fault Finding section.
2. Turn the ignition key to the START position. At this point the start delay siren will sound.
3. Hold the key in this position for 10 seconds, after which time the engine will begin to crank.
4. As soon as the engine starts, release the ignition key so that it returns to the ON position.
5. To stop the engine, turn the ignition key to the neutral/off position as shown.
Crusher Starting Procedure

1. Conduct all plant and crusher pre-start checks.
2. Follow the procedure to start the engine.
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Operation
3. Push in the TIR valve lever.
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Operation
4. Push in the clamp/jack lever.
5. Make sure both the TIR and clamp circuit pressure guages are set at 2500 psi.
72
Operation
6. Push the crusher lube/setup valve lever in for crusher lube.
7. Access the plant run screen.
73
Operation
8. Set lube flow control to 6 gals/min, which will show on the Plant Run Screen of the plant control unit.
NOTICE: Crusher Lube flow in excess of 6 GPM will cause lube oil leakage inside of the crusher.
9. Push the under crusher conveyor lever in to start.
10. Verify the under crusher conveyor belt is traveling at the proper speed. Set at position 7 on the flow
control knob.
Note: If the under crusher conveyor pressure shown on the Plant Run screen is below 300 psi, the
crusher will not start. If it is above 2500 psi, the feed conveyor will not start.
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Operation
11. Put the feed conveyor valve lever in the neutral position.
12. Press the clutch Start/Stop button to initialize the crusher start sequence.
The control system will then ramp the engine speed to 1000 rpm and monitor the conveyor pressure
(if the sensor is enabled). When the conveyor pressure is within operating values the system will then
monitor the lubrication oil flow. When the flow is above the preset start value, the horn will sound for 30
seconds and the engine RPM will ramp to the speed required to engage the clutch. When this engine
speed is set a signal is sent to the clutch control unit to engage. The control system will then wait until
the clutch has engaged. This will be indicated by the clutch start/Stop button turning green.
The button will begin to flash.
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Operation
When the clutch engages the engine will then ramp to the desired operating speed.
13. Set the flow control knob on the Feed Conveyor valve to three (3) on the dial, slow speed.
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Operation
14. Push in the Feed Conveyor valve lever.
Note: Things that can stop the feed conveyor:

• Material in the hopper is sensed by the hopper level sensor.
• Under crusher conveyor pressure is above 2500 PSI.
• Engine overload protection senses excessive engine load.
15. Push button #5 on the Plant Run screen to start the feeder.
16. Conduct post start checks.

17. Slowly increase feeder speed rate to desired speed. Try to maintain cone choke feed.
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Operation
Feed Conveyor Start

Once the engine is at operating speed (if the feeder option is enabled) the feed conveyor can be started by
pressing the feed conveyor Start/Stop button. The feed conveyor can be controlled by the hopper level sensor
or by a downstream signal if it is available.
1 When this icon turns yellow it indicates that a hopper level high signal has been detected. If it
turns red the feed conveyor will be stopped.
2 When this arrow turns red it indicates that a down steam fault signal has been detected and the
feed conveyor will be stopped.
78
Operation
1 Exit to Main Menu

2 Diagnostic Information
3 Engine Data
4 Hopper Level Sensor On/Off
5 Feed Conveyor On/Off
6 More Pages
1 Lubrication Temperature
2 Lubrication Flow
3 Engine Speed Error Value
4 Engine Speed
Crusher Shutdown Procedure

1. Turn off the feed conveyor. Let material clear from the crusher.
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Operation
2. Press the clutch button to start the crusher auto stop sequence.
3. Once material has completely cleared, pull the u/c conveyor valve lever to the neutral position to stop
the conveyor.
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Operation
4. Pull the cone lube/conveyor cylinder valve lever out to the neutral position.
5. Turn the engine start switch to the OFF position to shut down the engine.
E-STOP Recovery
1. Put all hydraulic valve levers in the neutral position.
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Operation
2. Reset all E-STOPS.

3. Address whatever problem caused the emergency stop.
4. Follow the procedure to start the engine, if desired.
Hopper Level Sensor

The crusher is shipped with a hopper level sensor and a mounting bracket, which provides considerable
adjustability, mounts on any shape hopper, and can be easily repositioned when moving a portable plant.
1 Hopper Level Sensor

2 Sensor Bracket
The pivoting sensor bracket provides protection against falling rocks and pivots in two directions to
accommodate alignment of the sensor. The hole required for the sensor is 1.20” [30mm]. A 157” [4m] cable
is provided and should be adequate for most feed hoppers. Longer/shorter cables can be provided as
optional equipment. One end of the sensor cable terminates at the sensor. The other end of the sensor cable
terminates at the junction box in the battery compartment.
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Operation
1 Hopper Level Sensor

2 Cable Input
The hopper level sensor may be enabled or disabled as required. If enabled, the sensor is used by the
system to determine if the feed conveyor should be stopped or started.
The control setup consists of configuring a sensor on delay period and a conveyor off period. If the sensor
detects a target within its sensing window for an uninterrupted time period equal to the on delay period, the
system disables the feed conveyor output for a time period equal to the conveyor off period. At the end of the
off period, the conveyor will be re-enabled. If the sensor still detects a target within its range, the process will
be repeated. If no target is detected, the conveyor will remain enabled. By requiring that the sensor detect
a target for an uninterrupted period of time, it is possible to avoid incorrectly confusing a full hopper with
individual rock(s) bouncing momentarily into the sensing window.
Hopper Sensor Calibration Procedure

Program the sensor to detect a window with a “near” and “far” limit. The far target detects the desired hopper
full level. Any time an object is within this window the output LEDs on the sensor will light up and a signal will
be sent to the control system. The system will interpret the signal to indicate that the hopper is full only if a
sustained uninterrupted signal is received for a time period equal to the configured on delay time.
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Operation
1 Sensing Window
2 Hopper Level Sensor (P/N 027521)
3 Near Target
4 Far Target Surface of Feed Material with Full Hopper
The key point to remember when setting up the sensing range is that the feed conveyor is enabled if the
sensor LEDs are off and the feed conveyor is disabled if the sensor LEDs are on.
Make the sensing window as large as practical. If the window is too small, it is possible to make the sensor
too sensitive and risk missing a full condition.
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Operation
1 Green Power ON/OFF LED

2 Yellow Analog Output LED
3 Analog Output Programming Pushbutton (Not Used)
4 Red Signal Strength LED
5 Yellow Discrete Output LED
6 Discrete (Switched) Output Programming Pushbutton
1. Choose the output for the first set of window limits (discrete) and push and hold the corresponding
button until the green Power LED goes OFF and the appropriate yellow Output LED turns ON (solid).
This indicates the sensor is waiting for the first limit.
Note: Program the “near” target first then the “far” target. The near target should be no closer than 12”
from the sensor.
2. Position a flat metal or wood object (target) for the first limit and briefly “click” the same button. This
will teach the sensor the first limit. The yellow Output LED will flash to acknowledge receiving the first
window limit; it is now waiting for the second limit.
Note: Press and hold the same button > 2 seconds (before teaching the second limit) to exit
PROGRAM mode without saving any changes. The sensor will revert to the last saved program.
3. Position the target for the second limit and “click” the button again. This will teach the sensor the
second limit. The yellow Output LED turns off and the green Power LED comes on; the sensor is now in
normal RUN mode.
4. When the sensor is programmed, test the sensor by holding a target in front of the sensor until the
sensor output LEDs light up. Move the target back/forth to find the distance where the LEDs first come
on. This is the “full” level. Move the target away. The LEDs should remain off everywhere within the
chamber lower than the “full” level.
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Operation
5. When the “full” level is acceptable, go to the HOPPER LEVEL SENSOR ADJUST configuration screen
and set up the on delay and conveyor off period.
Engine Screen
The engine speed can be controlled manually by pressing the Up and Down arrows on the engine and
tracking screens. During machine operation the engine speed is controlled automatically, manual control is
inhibited.
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Operation
Engine Status and T4 Icons
1 Exit to Main Menu

2 Increase Engine RPM
3 Decrease Engine RPM
4 To initiate a manual regeneration press and hold the manual DPF button
5 To inhibit the DPF system press and hold DPF inhibit button for 5 seconds.
1 The regeneration lamp notifies the operator that the after treatment system has not automatically
regenerated at the required time limit and requires an exhaust system cleaning.
2 The High Exhaust system Temperature (HEST) Lamp will illuminate during manual exhaust
system cleaning.
3 The Regeneration Disabled (Inhibit) Lamp indicates that Regeneration Disabled (Inhibit) Switch is
active, therefore automatic and manual (non-mission) exhaust system cleaning cannot occur.
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Operation
4 The Diesel Exhaust Fluid lamp signal controls an indicator lamp or LED that is used to alert the
machine operator that the diesel exhaust fluid is low and MUST soon be replenished.
5 The Wait to Start Lamp This lamp indicates that the Intake Air Heaters are performing a pre-heat
cycle during cold ambient conditions.
6 The Engine Stop lamp displays critical operator messages and engine diagnostic fault codes.
7 The Engine Warning Lamp displays messages that require prompt operator attention and engine
diagnostic messages.
Crusher Information Screen
1 Exit to Main menu. (Not available when crusher is in operation).

2 Press to run the start sequence.
3 Press to view engine data.
4 Switch work lamps on/ff.
5 Enable Feed Conveyor.
6 Press to enter next page.
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Operation
1 Engine Speed
2 Engine Load
3 Engine Fuel Rate
4 Lubrication Oil Flow
5 Lubrication Oil Temperature
6 Hydraulic Oil Temperature
7 Conveyor Pressure
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Operation
Clutch Information
1 Clutch Output Speed

2 Clutch Pressure
3 Engine Speed
4 SPN’s
5 FMI’s
6 Lockout Countdown
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Operation
Fault History
1 Exit to Information Page

2 Scroll through fault history
3 Scroll through fault history
4 Engine Fault History
5 Press and hold to clear fault history
6 Time and Date Adjustment
The last 25 machine faults are stored in controller memory. Use the up/down arrows to navigate through the
list. To clear the fault history press and hold button 5 for three seconds.
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Operation
Diagnostics
1 Exit to Main Menu

2 Language Select
3 Radio Remote Diagnostic Page
4 Control Unit Output Diagnostic Pages
5 Control Unit Input Diagnostic Pages
6 Navigates to Machine Fault History, Engine Fault History, Set Time and Tech Mode
Active Engine Diagnostic Codes

Engine fault codes are transmitted from the engine using the J1939 Protocol. These faults are not stored
by the machine controller. Only the currently active faults can be viewed. Refer to engine documentation for
description of codes.
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Operation
To clear the active fault list from the controller, turn the ignition off and on, or press and hold button 1. The list
will be refreshed with any currently active faults.
Fault Codes
FAULT CODE NUMBER DESCRIPTION
001 E-STOP PRESSED
002 RADIO STOP PRESSED
004 LOW HYDRAULIC OIL
005 HIGH OIL TEMPERATURE
006 HYDRAULIC OIL TEMPERATURE CRITICAL
007 HYDRUALIC OIL TEMPERATURE SENSOR FAULT
008 LUBRICATION OIL LEVE LOW
009 LUBRICATION OIL TEMPERATURE HIGH
010 LUBRICATION OIL TEMPERATURE CRITICAL
011 LUBRICATON OIL TEMPERATURE SENSOR FAULT
024 LUBRICATION OIL FLOW LOW
028 TRACKING HANDSET FAULT
029 REMOTE TRACKING HANDSET FAULT
030 PRODUCT CONVEYOR SPEED FAULT. FEED SHUTDOWN
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Operation
FAULT CODE NUMBER DESCRIPTION

031 PRODUCT CONVEYOR SPEED FAULT. CLUTCH SHUTDOWN
036 LOW CLUTCH PRESSURE
037 CLUTCH DISENGAGED WHILE PLANT IS RUNNING
038 UNABLE TO DISENGAGE CLUTCH
039 CONVEYOR PRESSURE SENSOR FAULT
040 CLUTCH FAULT
041 UNABLE TO ENGAGE CLUTCH
060 NODE 2 CAN OFFLINE
061 NODE 3 CAN OFFLINE
062 NODE 2 CAN FAULT
063 NODE 2 CAN FAULT
064 CLUTCH CONTROLLER OFFLINE
Setting the Date and Time

1. From the Fault History page, press the last button to enter the Date and Time page.
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Operation
1 Exit to Fault History Page

2 Press to edit selected value
3 Press to select next value to edit
4 Press to save
2. Press and hold the left arrow key for five seconds. The first digit on the left will turn green.
3. Change the value using the up/down buttons.
4. Use the right button to move to the next value.
5. Once the settings are complete press button 6 to save. The digit color will turn back to white.
Tech Mode
In Tech Mode, a log of sensor bypass occurrences and dates can be viewed.
You can also test output functions from the control system. Press the up or down button to select the desired
function. When the function is selected, press button 3 to switch the output on and off.
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Operation
1 Exit to Time and Date Page

2 Press to select desired output
3 Press to enable output
Machine Set Points Access

The set points menu contains all values and parameters used to set up and control the machine. These
values should only be changed with guidance and permission from JCI.
1. Access the machines set points:
a) Press the machine set points button on the Main menu.
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Operation
b) Enter the security code using the up/down buttons to change between digits.
c) Press button 5 to enter the selected value.

d) Once the correct code is entered, press button 5 to access the set points page.
2. Set the machine values:
a) Use the up/down arrows to select the desired value to adjust.
b) Press button 4 to begin adjustment.

c) Adjust the value using the up/down arrows.
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Operation
d) Press button 4 to store.
3. Set the machine options:

a) Use the up/down arrows to select the desired option.
b) Press and hold button 4 for three seconds to enable the selected option.
c) To disable the option, press and hold button 5 for three seconds.
4. To restore factory settings, press and hold buttons 2 and 3 together for three seconds.
Machine Set Point Options

ID Set Point Description Default Units Min Max Screen
#
0 Hydraulic Oil Enable ON ON/OFF 6101
Temperature Hydraulic Oil
Sensor Temperature
Sensor
1 Hydraulic Oil Enable ON ON/OFF 6101
Level Sensor Hydraulic Oil
Level Switch
2 Lubrication Oil Enable ON ON/OFF 6101
Temperature Lubrication Oil
Sensor Temperature
Sensor
3 Lubrication Oil Enable ON ON/OFF 6101
Level Sensor Lubrication Oil
Level Switch
98
Operation
ID Set Point Description Default Units Min Max Screen

#
4 Product Enable Product ON ON/OFF 6101
Conveyor Conveyor
Pressure Sensor Pressure Sensor
5 Feed Conveyor Enable Feed ON ON/OFF 6101
Enable Conveyor
Option
6 Hopper Enables Hopper ON ON/OFF 6101
Level Sensor Level Option
7 Up/Down Enables the ON ON/OFF 6101
Stream Up/Down
Stream Option
1 High Hydraulic Set Point for 170 °F 100 250 6100
Oil Temperature High Hydraulic
Oil Temperature
Warning
2 High Lubrication Set Point for 170 °F 100 250 6100
Oil Temperature High Lubrication
Oil Temperature
Warning
3 Maximum Engine Speed 1000 RPM 900 1250 6100
Engine for Clutch
Speed Clutch Engagement
Engagement
4 Minimum Lubrication 4 Gallons 3 6 6100
Lubrication Oil Flow to be
Oil Flow Greater than to
Enable Clutch
5 Maximum Conveyor 2000 PSI 500 2500 6100
Product Pressure Need
Conveyor to be Less than
Pressure for Normal
Operation
6 Minimum Conveyor 400 PSI 50 500 6100
Product Pressure Needs
Conveyor to be Greater
Pressure than for Normal
Operation
7 Maximum Engine’s 2150 RPM 800 2300 6100
Engine Speed Maximum
Operating
Speed
99
Operation
Crusher Close Side Setting Adjustment Procedure-Decreasing the CSS

1. Follow the safety procedures to start the engine if it is not already running.
2. Alert all bystanders that you will be changing the Close Side Setting.
3. Make sure that the crushing chamber is clear of all material and that the crusher is not running.
4. Lower the shim guard.
100
Operation
5. Put the clamp/jack valve lever in the neutral position.
101
Operation
6. Verify that the clamp cylinder needle valve is open by turning the knob counter-clockwise.
102
Operation
7. Turn the jack cylinder needle valve clock-wise to close the valve.
103
Operation
8. Pull out the clamp/Jack valve lever until the eight (8) clamp cylinders are fully retracted.
104
Operation
9. Turn the clamp cylinder needle valve clockwise to close it. The bottom shims should be loose.
105
Operation
10. Remove the appropriate number of bottom shims to achieve the desired close side setting. Be sure to
remove the same color and number of shims from all eight (8) cylinders.
106
Operation
11. Push the clamp/jack valve lever in; it will remain in that position. The upper assembly will lower onto the
bottom shims.
107
Operation
12. Place the removed shims on the upper shim stacks. Pull up on the cylinder rods to make room for the
additional shims.
13. Turn the jack cylinder needle valve counter-clockwise to open it.
14. Pull the clamp/jack valve lever out to the neutral position (center).
15. Turn the clamp cylinder needle valve counter-clockwise to open it.
16. Push the clamp/jack valve lever in to energize the clamp circuit.
17. Inspect the shim stacks to make sure they are all in and aligned, make sure all shims are stacked on
the top and bottom the same way for each cylinder. Make sure there are no loose shims.
18. Replace the shim guard.
19. Refer to the crusher start procedure to begin crushing operation.
Crusher Close Side Setting (CSS) Adjustment Procedure-Increasing the

CSS
1. Follow the safety procedures to start the engine if it is not already running.
2. Alert all bystanders that you will be changing the Close Side Setting.
3. Make sure that the crushing chamber is clear of all material and that the crusher is not running.
108
Operation
4. Lower the shim guard.
5. Put the clamp/jack valve lever in neutral.
109
Operation
6. Verify that the clamp cylinder needle valve is open by turning the knob counter-clockwise.
110
Operation
7. Turn the jack cylinder needle valve clock-wise to close the valve.
111
Operation
8. Pull out the clamp/Jack valve lever until the eight (8) clamp cylinders are fully retracted.
112
Operation
9. Turn the clamp cylinder needle valve clockwise to close it. The bottom shims should be loose.
113
Operation
10. Push in the clamp/jack valve lever.
114
Operation
11. Remove the desired shims from the top stacks. Be sure to remove the same number and size shim
from all eight (8) stacks.
12. Align the remaining top shim stacks and make sure they are properly placed in the cylinder.
115
Operation
13. Pull the clamp/jack valve out until the bottom stacks are loose.
116
Operation
14. Place the shims that were removed on the bottom stacks. Make sure they are aligned and pushed into
the stacks. Do this for all eight (8) stacks.
15. Push the clamp/jack valve lever in; it will remain in that position. The upper assembly will lower onto the
bottom shims.
16. Turn the jack cylinder needle valve clockwise to open it.
17. Pull the clamp/jack valve lever out to the neutral position (center).
18. Turn the clamp cylinder needle valve counter-clockwise to open it.
19. Push the clamp/jack valve lever in to energize the clamp circuit.
20. Inspect the shim stacks to make sure they are all in and aligned, make sure all shims are stacked on
the top and bottom the same way for each cylinder. Make sure there are no loose shims.
21. Replace the shim guard.
22. Refer to the crusher start procedure to begin crushing operation.
117
Operation
118
Maintenance
Maintenance
Maintenance and Repair Safety
WARNING: Always lockout/tagout power to machinery and conveying equipment

before performing any maintenance or repairs. Warn all personnel that the
machinery is being serviced.
General Precautions
• To help ensure safe machine operation, use only genuine Original equipment manufacturer (OEM)
replacement parts that are sold or approved by the machine’s manufacturer. Use of non-OEM parts
may adversely affect machine operation and could result in an a hazardous situation.
• Always tighten all fasteners to the proper torque as described in the repair procedures. When torque
specifications are not listed, use the values in the torque table at the back of this manual.
• Be sure all replacement fasteners are of the proper grade and specifications. Replace any worn or
damaged fasteners.
Electrical Systems
• Always read, understand and follow appropriate electrical system troubleshooting, maintenance and
repair instructions in the machinery manufacturers’ manuals.
• Allow only trained and licensed electricians to install, troubleshoot and repair electrical equipment. All
procedures must be in compliance with the National Electric Code and any applicable state or local
regulations.
• When servicing an electrical system, work with the power locked out and tagged. Always assume that
an electrical system is live until it has been locked out.
• Always tag and lockout power before removing cables with quick-disconnect plugs.
• Repair any obviously worn or damaged wires and connectors.
• Inspect power cables and connections daily for signs of wear, cracked insulation and worn or damaged
connectors. Repair or replace as required.
• Do not store tools inside electrical cabinets.
• Verify that all tools are grounded with a three wire plug or double insulated. Be sure that all extension
cords are grounded with a three wire plug.
Pressurized Systems
• Adjust, maintain and repair all pressurized systems only in accordance with the instructions contained
in the manufacturer’s manuals provided with the machinery.
• Never attempt to work on a pressurized system while it is pressurized or in operation.
• Before performing maintenance or repairs on any pressurized system:—Cycle the controls through
all operating positions to relieve any trapped pressure.—Check that ALL pressure is relieved from
the system. The pressure gauge must read zero (0) PSI.—Lockout and tagout all controls. Be sure
electrical power is properly locked out and tagged.
• Allow time for hot hydraulic oil to cool before performing any maintenance or repairs. Hot oil can cause
burns.
119
Maintenance
• Before loosening fittings or removing components, always recheck that ALL pressure is relieved from
the system. The pressure gauge must read zero (0) PSI.
• Never attempt to loosen a hydraulic fitting while a hydraulic system is pressurized. You could be injured
or killed by a stream of high pressure oil.
• Never have your face near, or stand directly in front of a hydraulic line when cracking a fitting, even
after system pressure has been relieved. Always assume that the line has pressure.
• Use a piece of cardboard to check for hydraulic oil leaks, not your hand. Escaping fluid under pressure
can penetrate the skin, resulting in serious personal injury.
• Clean-up any spilled hydraulic fluid. Hydraulic fluid is extremely slippery, and can be especially
dangerous if spilled on an elevated walkway or platform.
• Repair any leaks immediately. Always relieve system pressure and lockout/tagout power before
tightening fittings or making repairs.
• Never attempt to adjust pressure relief valves to above the machinery manufacturer’s recommended
settings. Serious personal injury and/or equipment damage could result. Do not operate any hydraulic
or air system with obviously worn or damaged, or leaking components. Always replace any defective
components immediately.
• Never place hands on hydraulic cylinder rods while equipment is in operation. Do not step on the
hydraulic relief cylinder hoses when climbing on the crusher.
• Refer to manufacturer’s instructions when recharging hydraulic accumulators or checking accumulator
pressure. Allow only trained hydraulic system technicians to depressurize, recharge or repair hydraulic
accumulators.
Welding On Machinery
• Be sure to provide adequate ventilation when welding inside enclosed areas to prevent the buildup
of hazardous fumes. Special concern should be exercised when welding chromium, manganese,
cadmium, copper, cobalt, lead and nickel, as these materials are considered to be potentially
carcinogenic.
• Be sure to wear the proper welding shield, welding gloves and clothing. Do not wear synthetic fabric
clothing or clothing which could be easily ignited by sparks.
• Always follow all standard safety procedures when welding. Be sure that all systems are shut down,
power is locked out, and controls are tagged. Provide welding screens to protect other employees
working in the area.
• Relieve all hydraulic pressure before welding near hydraulic components and lines. Cover hydraulic
components to protect them from weld spatter and sparks.
• Do not weld near flammable liquids or hydraulic oils.
• Welding lifting eyes or hooks to manganese steel castings is strongly discouraged, and should be
done only if absolutely necessary. Always use a stainless steel or manganese weld rod. Never allow
personnel to walk or work underneath castings being lifted or supported.
• Never ground the welder so that the electrical power will flow through bearings, hydraulic components
or electrical equipment. Serious damage could result.
• Be sure all compressed gas cylinders are stored upright, chained and capped. Turn-off all cylinders
when not in use.
Clearing Jammed Material
WARNING: To prevent serious personal injury or death, never attempt to

remove jammed material while the machinery is in operation.
120
Maintenance
WARNING: Never stick any part of a person’s body into the crushing chamber
when the upper assembly is raised.
• If material becomes jammed in the machinery:

Immediately stop the machinery.
Lockout/tagout power. Warn others that the machinery is being serviced.
Follow the instructions in the operation and maintenance manual of the affected equipment.
• Always remove all jammed material before restarting the machinery. To prevent damage, never attempt
to restart a stalled machine without first removing the jammed material.
• Never use dynamite or other explosives to clear jams. Explosives are dangerous and can injure or kill
personnel. Damage to machinery could also occur.
Hazardous Materials
• Be aware potentially hazardous chemicals or materials. Such items can be harmful if they are
improperly used, stored, mixed transported, if they are inhaled, swallowed or allowed to contact the
skin.
• Consult your employer’s hazard communications plan for instructions regarding the proper handling
and use of hazardous materials. Read and understand the labels attached to the product containers.
Always follow the instructions carefully.
• Consult the manufacturer’s material safety data sheet (MSDS) for potential hazards and appropriate
medical procedures should an accident occur.
• Store hazardous materials only in approved containers. Be sure containers are clearly labeled.
• To avoid potential health hazards, persons in regular contact with hydraulic oils must be aware of the
importance of thorough hygiene, and the proper methods for handling mineral oils.
• Mineral-based hydraulic oils act as solvents on the natural oils of the skin. Frequent and prolonged skin
contact can cause dermatitis or severe irritation.
• Always wear suitable protective clothing when handling hydraulic oil.
• Be sure protective clothing and proper wash-up facilities are available to all personnel that may come in
contact with mineral-based hydraulic oils.
• Always dispose of used rags or paper towels in the correct and safe fashion.
Disposal Of Excess Fuels, Lubricants And Liquids

Quarry personnel are responsible for the proper disposal of unused fuels, used lubricating oils, used hydraulic
oils, and other toxic materials. DO NOT dispose of these materials in an unapproved manner. Follow all
applicable federal, state and local regulations.
• Store flammable liquids in a safe place, away from quarry machinery and personnel. Use approved
safety containers and be sure that they are clearly marked. Containers must be covered when not in
use.
• Keep flammable liquids away from sparks, open flame, and other ignition sources. Do not smoke
around flammable liquids. Always obey posted “no smoking” signs.
• Be familiar with the locations of fire extinguishers throughout the quarry. Be sure they remain
accessible at all times, and are not blocked by obstructions.
• Do not use gasoline or other flammable liquids to clean tools or parts. Use only approved non-
flammable solvents.
121
Maintenance
• Always shut-off engines before refueling. Ground fuel spout against the filler neck to prevent static
electricity. Never smoke while refueling.
• Use only approved safety containers for storing and transporting small quantities of flammable liquids.
Keep containers covered when not in use.
Depressurize Hydraulic System
WARNING: Before starting the plant and activating the conveyors, alert all
bystanders the plant will be starting and the conveyors are being moved and make
sure everyone is clear.
1. Make sure the feed conveyor is in the lowered position.
122
Maintenance
2. Make sure the under crusher conveyor is in the neutral position or has the shipping bars installed.
WARNING: There still may be residual pressure trapped in the hydraulic hoses
due to the counter balance hydraulic valve in the feed conveyor system. When
working on the hydraulic lines to the feed conveyor wear proper PPE.
123
Maintenance
3. Use a wrench to depressurize the hydraulic systems by opening the Jack Cylinder Valve, the Clamp
Cylinder Valve and the TIR Cylinder Valve.
124
Maintenance
4. Install lockout/tagout device.
125
Maintenance
Track Plant Maintenance Procedures

Lubrication and Fluid Chart
ITEM DESCRIPTION TYPE OF LUBRICANT FREQUENCY AMOUNT

1 Feed Conveyor Tail Pulley NLGI Grade 2 Every 50 Hours 1 pump to maintain
Pillow Block Bearings Multipurpose Grease slight leakage at the
such as Mobile grease seals
126
Maintenance

XHP 222 or Mobilux
EP 2
2 Under Crusher Tail Pulley NLGI Grade 2 Every 50 Hours 1 pump to maintain
Conveyor Pillow Block Multipurpose Grease slight leakage at the
Bearings such as Mobile grease seals
XHP 222 or Mobilux
EP 2
3 Crusher Lube Oil Mobilgear 600 XP150 500 hours or 17 Gallons/64 liters
more frequently
depending on use
and sampling or
observation
4 Hydraulic System/Hydraulic Exxon Humble H46 2000 Hours 150 Gallons/568 liters
Fluid ISO 46
5 CAT Diesel Engine Oil (Cat Diesel Engine Oil-Ultra Every 10,400 liters 32 Quart/30 liters
DEO) Low Sulfur Cat DEO- (2750 gallons) of
ULS (SAE 15W-40, fuel or 250 service
SAE 10W-30) Cat hours or 6 months
DEO-ULS SYN (SAE
5W-40) Cat Cold
Weather DEO-ULS
(SAE-0W-40) Diesel
Engine Oil Cat DEO
(SAE 15W-40 SAE
10W-30) Cat DEO SYN
(SAE 5W-40)
6 Diesel Fuel Red Dyed Diesel Fuel As Needed 190 Gallon/719 Liter
7 Drive Belt Tensioner Pillow NLGI Grade 2 Every 50 Hours 1 pump to maintain
Block Bearings Multipurpose Grease slight leakage at the
XHP 222 or Mobilux
EP 2
8 Feed Conveyor Planetary 90 Weight gear oil with 500 hours Until oil comes out oil
Gearbox EP additives level check hole.
9 U/C conveyor Fold Pivot NLGI Grade 2 Every 50 Hours 1 pump to maintain
Point Multipurpose Grease slight leakage at the
XHP 222 or Mobilux
EP 2
10 Engine Coolant PREFERED Cat SERVICE LIVE Maintain the coolant
ELC (Extended (*1)(*2) Cat ELC level within 13mm
Life Coolant) or a - 965,606 km (0.5 inch) below the
commercial extended (600,000 mi), 12000 bottom of the pipe
life coolant that meets Hrs, or 6 years. for filling, or withing
the Caterpillar EC-1 (*3) Commercial 13mm (0.5 inch) to
spec. ACCEPTABLE coolant that meets the proper level on
- A Cat DEAC the Caterpillar EC-1
127
Maintenance

(Diesel Engine spec - 482803 the sight glass (if
Antifreeze/Coolant or km (300,000 mi) equipped)
a commercial heavy- 6000 hrs or 6
duty coolant that meets years. (*4) CAT
“ASTM D4985”, or DEAC - 321,869
ASTM D6210” spec km (200,000 mi)
3000 hrs, or 3
years. Commercial
Heavy-Duty coolant
that meets “ASTM
D6210 - 241,402
km (150,000 mi),
3000 hrs, or 2
years. Commercial
Heavy-Duty coolant
that meets “ASTM
D1985” - 241402
km (150,000 mi),
3000 hrs, or 1 year.
(*1) Use the interval that occurs first.

(*2) Refer to Caterpillar Operation and Maintenance Manual C9 Industrial Engine, “Maintenance Interval
Schedule” in order to find the correct interval for replacing the water temperature regulator.
(*3) Cat ELC Extender must be added at 6000 service hours or one half of the service life of the ELC.
(*4) An extender must be added at 3000 service hours or one half of the service life of the coolant.
Daily Inspection Checklist
WARNING: Always lockout/tagout the equipment and depressurize the hydraulic

systems prior to conducting these inspections.
ITEM DESCRIPTION YES NO

1 Check the engine oil level.
2 Check the engine coolant level.
3 Drain the fuel water separator.
4 Inspect the engine/radiator drive belt.
5 Inspect the engine air cleaner system for restriction.
6 Check the engine fuel level.
7 Check the hydraulic oil level.
8 Inspect the hydraulic cooler hoses and connections.
128
Maintenance

9 Make sure all hydraulic lines are routed correctly, free from rips, punctures
and bulges, and have solid connections. Use a piece of wood or cardboard
as a backstop to pinpoint leaks.
10 Make sure all conveyor guards are installed and functioning properly.
11 Make sure all tools and foreign objects are removed from the conveyor
belts before starting.
12 Inspect the track undercarriage. Check for leakage on all track idlers.
13 Inspect the track drive motor seal and all hydraulic connections.
14 Inspect the track front idler system. Check for excessive roller wear.
15 Check battery for corrosion or damage. make sure battery terminals are
free of corrosion and other debris.
16 Check the gear reducer oil levels on the conveyors.
17 Check inside the crusher for missing or worn counterweights.
18 Check the condition of the crusher manganese.
19 Check the under-crusher discharge area for obstructions.
20 Check stop blocks for cracks or sheared bolts.
21 Check for material buildup under the plant and remove.
22 Check all oil lines for signs of damage and fittings for leaks
23 Check all grease lines. Make sure they are properly routed, free of rips,
punctures and bulges and connected securely.
24 Check the conveyor belts for proper tracking, damage and excessive wear
during the shift.
25 Check for loose fittings. Make sure all nuts, bolts, and other connections
are secure.
Engine Oil Level

1. To accurately check the oil level, stop the engine and allow for the oil to drain off engine internal parts
(at least 20 minutes). This eliminates the possibility of overfilling.
2. Lockout/tagout the plant, following all local rules and regulations.
129
Maintenance
3. Make sure that the area around the dipstick is clean and the plant is level.
1 Engine Oil Dipstick

4. Push the dipstick completely down and pull out.
5. The oil level must be between the ADD and FULL marks on the dipstick. If the oil level is below the
ADD mark, add oil to raise the oil level up to the FULL mark on the dipstick.
1 ADD Mark
2 FULL Mark
Note: Do not add engine oil until level is below the ADD mark on the dipstick. A major cause of engine
oil consumptions is overfilling the crank-case.
Note: Failure to promptly add oil when indicated may result in serious engine damage due to piston
and bearing seizure.
6. Follow the instructions in the engine manual to add oil.
130
Maintenance
7. Replace dipstick.
Engine Coolant Level
WARNING: Explosive release of fluids from a pressurized cooling system can

cause serious burns.
1. Turn engine off and wait until it is cold or cool enough to touch with bare hands.
NOTICE: Never add cold coolant to a hot engine, as it may crack the cylinder head or engine block. Do NOT
operate the engine without coolant even for a few minutes.
3. Slowly loosen cap to the first stop to relieve the pressure before removing completely.
131
Maintenance
4. Check engine coolant level.
5. Add coolant if necessary.

NOTICE: See the engine manual for the proper coolant specifications. Do NOT use any sealants that are
not recommended by your engine manufacturer.
6. Install coolant cap.
Fuel Water Separator

On your plant, the primary fuel filter also acts a fuel/water separator. It should be checked before starting the
engine prior to each shift.
132
Maintenance
2. Open the drain valve on the bottom of the fuel filter and drain the water from the fuel filter.
1 Fuel Water Separator Drain Valve

3. Close the drain valve.
Engine Drive Belts

2. Inspect engine drive belts for excessive wear or damage.
133
Maintenance
3. Replace or re-tension belts as necessary.
Daily After Plant Startup

1 Check hydraulic pressure
2 Check the hydraulic system filter restriction indicator.
3 Check the close side setting.
4 Check the conveyor load and make sure it is centered.
5 Check the feed rate and conveyor speed for desired output.
6 Check the feed conveyor to make sure the crusher is choke fed
7 Listen to the crusher for any unusual sounds.
8 Check for bowl float.
9 Check the temperature. (Normal temperature is 185°F/85°C)
Engine Air Cleaner

NOTICE: Always service the air filter system with the engine stopped. You can damage the engine severely
with dust and debris.
Note: An adequate supply of clean, filtered air is necessary to maintain correct fuel/air ratios, resulting in a
cleaner burning engine.
Free flow of air to the intake must not be restricted in any way. The maximum pressure drop through the
intake system, at full throttle and no load (approximately 2200 RPM) should not exceed specified engine
manufacturer’s recommendations.
Check the air intake evacuator valve by squeezing the valve to allow debris to fall from the valve. Check the
valve periodically if operating in dusty conditions.
134
Maintenance
Air Filter Evacuator Valve
1 Air Filter Evacuator Valve
Restriction Indicator
Periodically during your shift, check the air intake restriction indicator, which is located in the engine
compartment. A clear area, or service indicator window, around the middle of the indicator will fill with a yellow
plug that rises to the red area on the indicator. When the plug reaches the red area, the filter requires service.
After the filters have been cleaned or replaced, reset the indicator by depressing the button on the bottom of
the indicator.
135
Maintenance
1 Restriction Indicator Reset Button
Engine Fuel Level

Check the fuel level daily as part of the pre-start checks. Fill the fuel tank as necessary.
1. Make sure the engine is off. Lockout/tagout the equipment following all local rules and regulations.
2. Check the fuel level on the fuel tank sight gauge, located next to the fuel filler on the tank.
3. Unlatch the rubber fitting securing the fuel filler cover.
136
Maintenance
4. Lift the fuel filler cover.
CAUTION: Take care when opening the fuel filler. The tank is pressurized and
fuel could spray out as the cap is removed. Keep your face clear when removing
the cap.
5. Remove the fuel filler cap.
137
Maintenance
NOTICE: Since the fuel tank is pressurized during normal plant operation, the air pressure will be released
when you remove the cap.
6. Slowly add fuel, being careful not to overfill.
7. Install the fuel filler cap.
8. Lower the fuel filler cover.
9. Latch the rubber fitting to secure the cover.
10. Clean up any spilled fuel.
Hydraulic Oil Level

1. Depressurize the hydraulic system.
2. Lockout/tagout the equipment.
3. To accurately check the oil level, stop the engine and crusher and allow the oil to drain off internal parts
(at least 20 minutes). This eliminates the possibility of overfilling.
4. Check the sight gauge, located on the hydraulic tank.
Note: Hydraulic oil should be clearly visible in the top glass.

5. If necessary, add hydraulic oil.
138
Maintenance
Hydraulic Restriction Indicator
The hydraulic restriction indicator is located on top of the hydraulic tank. When the hydraulic fluid is at normal
operating temperature the hydraulic restriction indicator should be in the green. If the oil is cold the indicator
may be in the yellow or red. Operate the equipment for one (1) hour and as the hydraulic fluid warms the
indicator should move to the green. If the restriction remains in the yellow or red, the bypass has activated
and the hydraulic filter needs to be change or damage can occur.
Lube Oil Reservoir Fill Procedure

Check and/or add oil when the crusher has been stopped long enough that any oil remaining in the crusher is
able to return to the reservoir.
1. Check the oil in the sight glass.
139
Maintenance
NOTICE: Do not fill when the crusher is running. It is normal for the level to be below full when the crusher
is running. Overfilling or filling with the crusher running will not damage the crusher, but could cause an
overflow and/or fill the breather with oil, causing it to clog prematurely.
2. Clean the area around the fill opening thoroughly before removing the fill cap to avoid introducing dirt
directly into the reservoir. Verify that dirt will not be knocked into the opening once the cap is removed.
3. Verify that the spout on oil dispensing equipment and/or buckets, funnels, etc. are clean.
4. Remove fill cap.
5. Top off oil, but do not overfill.
140
Maintenance
6. Replace fill cap.

7. Clean up any spilled oil.
Hydraulic Hoses and Connections
WARNING: Follow all local safety regulations with respect to working around
energized electrical and hydraulic circuits. Familiarize yourself with how these
circuits operate before working on them. Never disconnect any hose until you
are certain the hydraulic system is depressurized. Serious injury or death can
occur from exposure to high pressure oil.
Check all plumbing lines and connections for leaks and replace as necessary. Check all hydraulic hoses for
leaks, bulging, tears, bucking, and replace as necessary.
Plant Maintenance Schedules

Weekly or Every 50 Hours of Operation
ITEM INSTRUCTIONS
Track Undercarriage Inspect all components for leakage, excessive wear,
and excess dirt buildup.
Batteries Inspect condition.
Radiator and Cooler Core Inspect condition. Clean.
Conveyor Head Pillow Block Bearings One pump of grease to maintain a slight leakage at
the seals.
Conveyor Take-up Bearings One pump of grease to maintain a slight leakage at
the seals.
Monthly or Every 200 Hours of Operation
ITEM INSTRUCTIONS
Hydraulic Tank Breather Replace breather filter.
Hydraulic Oil Test oil sample.
Track Drive Gearbox Oil Check level.
Every 500 Hours of Operation
ITEM INSTRUCTIONS
Track Gearbox Oil Change oil.
Conveyor Gear Reducers Change oil.
Clutch Check bolted connections and hydraulic connections.
Lube Oil Change oil.
Lube Oil Filter Change filter.
141
Maintenance
Every 1,000 Hours of Operation
ITEM INSTRUCTIONS
Hydraulic Oil Filter Change the filter.
Hydraulic Oil Change.
Yearly or Every 2,000 Hours of Operation
ITEM INSTRUCTIONS
Hydraulic Oil Change oil and filter.
Track Gearbox Oil Change oil.
Conveyor Pivot Pins One to two pumps of grease yearly. Also whenever
moving the conveyor position.
Every 5,000 Hours of Operation
ITEM INSTRUCTIONS
Clutch Inspect and service.
Track Checks
Track Undercarriage
Inspect the track mounting hardware for damage and cracking. Clean excess debris from the track.
Front Idler Unit

• Inspect the spring and tension system for damage, debris buildup, and excessive wear.
• Check the seal of the front idler and tensioning system.
• Check for excessive wear on the front idler and sliding blocks.
142
Maintenance
Batteries
Each week the batteries should be checked and cleaned.
WARNING: When working around batteries, avoid any sparks and/or flame.
Hydrogen gas given off by batteries is explosive.
• Ensure that the battery tops are kept clean and free of dirt and electrolyte.
• Check that all terminals and connectors are clean and tight.
• Replace any wire or cable with damaged insulation.
• Make sure that the battery box cover is secured before vehicle is placed in operation.
• Clean battery with a weak solution of baking soda and warm water. Ensure that no cleaning solution
reaches electrolyte in battery.
• Fill all battery cells with distilled water to inside top of battery.
• Check electrolyte level.
WARNING: Avoid contact with electrolyte. Acid burns! Personal injury can
result.
• Check and record battery voltage level.

• Check battery hold-downs for tightness, and clean if needed with solution used on battery. Ensure
integrity of hold-downs, and replace if in doubt.
Note: Frequency of battery maintenance dependent on type of battery (i.e. conventional, low-maintenance,
or maintenance-free).
143
Maintenance
Radiator and Cooler Care
• Check the engine radiator and hydraulic oil cooler for damage, wear, and dirt buildup.
• Clean the radiators periodically to keep dirt buildup from closing off the fins.
• Check the hoses and tubing that attach to the radiators for damage, leaks, or excessive wear.
Lube and Hydraulic Reservoir Air Breather Change Procedure

In normal service, replace the breathers once a year even if they appear to be serviceable.
The lube oil reservoir air breather is located inside the lube compartment.
144
Maintenance
The hydraulic breather is located on top of the hydraulic tank, behind the hydraulic filter.
1. Relieve all hydraulic pressure.

3. Inspect the area around the breather frequently to verify that the bottom surface is free to draw in clean
air.
Note: If the breather becomes completely covered with dirt, consider remotely mounting to a cleaner
location. If remotely mounted, keep the hose run as short as possible.
145
Maintenance
4. Remove the breather from the reservoir. If the breather is basically clean, it can be considered
serviceable. If there is some doubt, remove the breather and blow into the pipe-threaded port. There
should be little resistance. If it is difficult to blow into the breather, replace it.
5. Install the breather onto the reservoir. You may choose to use a filter strap to secure it.
Lube Oil Sample Procedure

Tools and supplies needed:
• Clean rags
• Sampling tube (P/N:083074)
• Small clean bottle with tight lid
• 7/16” [25.4mm] wrench
Some guidelines to follow when taking oil samples:
• Test often.
• Test between oil changes to detect trends.
• Look at the viscosity. Change before viscosity changes by 20%.
• Look at silica, iron, and copper. Compare against maximum values in the lube oil analysis chart and/or
look for trends.
• Look at particle count. If changes are detected, take a second look at silica, iron, and copper to see if
the particle count change corresponds with a change in one of these contaminant/wear elements.
• If any values are flagged by the test lab, find out why. If in doubt, change oil.
NOTICE: When taking an oil sample be very careful to prevent contamination of the sample.
1. With the lube pump running, clean the area around the sampling port, located by the lube pump in the
upper left corner of the lube unit.
2. Remove the protective cap (7/16” [25.4mm] wrench required) and clear away any debris.
146
Maintenance
3. Attach the brass fitting to the sampling tube provided in the box of auxiliary parts delivered with the
crusher.
4. Attach the sampling tube to the oil sampling port.
5. Prior to collecting the sample, allow a small amount of oil to flow into a spare container to flush away
any contamination.
147
Maintenance
6. Open the clean sample container and fill with lubricant.
7. Install the protective cap on the oil sampling port.

8. Send the sample to your local supplier or analysis lab or contact the JCI Service department to arrange
to have the sample analyzed. JCI can also supply sampling containers, spare sampling tubes, ports,
etc.
Track Drive Gearbox Oil

1. Park the plant on a flat level surface.
3. Clean the gearbox and surrounding area so that you can read the writing on the gearbox. Also so that
you will not introduce contaminants into the box when you check the oil.
4. Position the track gearbox so that it is oriented as shown.
148
Maintenance
1 Oil Fill Level Plug

2 Oil Drain Plug
5. Remove the “Oil Fill Level” plug and look inside the gearbox. The oil level should be at the bottom of
the plug threads. Add oil if necessary.
6. Replace the plug and use a new washer.
Lube Oil Change Procedure
WARNING: The hydraulic system operates at high pressures. Do not attempt

to perform any service without depressurizing the system. Serious injury could
result from high pressure oil.
Guidelines:
• Replace the factory installed Mobilgear 600XP 150 oil 200 hours after initial startup. Following this
initial change, replace the oil every 500 hours, or more often if oil samples indicate.
• The life of synthetic oil such as Mobilgear SHC150 may be extended beyond the recommended 500
hours but should be monitored by oil sample analysis and should not exceed 1,000 hours.
• Higher viscosity oil and synthetic oil offer additional protection when running at elevated temperatures,
but do not offer significant protection against thermal breakdown when run at temperatures exceeding
180°F (82°C). If running at temperatures higher than this maximum cannot be avoided, then oil
changes may be needed more frequently. Monitor changes in viscosity by oil sample analysis.
149
Maintenance

3. Locate the drain plug, underneath the lube reservoir.
4. Place a container under the reservoir drain.

5. Remove the drain plug from the reservoir and drain the oil.
6. Install the reservoir drain plug.
7. Add new oil to the lube oil reservoir.
8. Change the oil filter.
Lube Oil Filter Change Procedure

Change the filter when the plug on the oil filter restriction indicator reaches the red zone. Also change the filter
at every lube oil change.
2. Lockout/tagout the crusher and power supply.
150
Maintenance
3. Locate the lube oil filter.
4. Unscrew the filter.
5. Inspect filter for any contamination and dispose properly.

6. Remove new filter from packaging.
7. Apply a light coat of oil to the o-ring.
151
Maintenance
8. Remove the protective paper.
9. Install onto the filter head.

10. Clean up any spilled lube oil.
11. After re-pressurizing the hydraulic system, check for leaks around the oil filter.
Hydraulic Oil Fill Procedure

1. Locate the hydraulic filter.
152
Maintenance
2. Remove the breather to relieve any presser built up in the tank.
3. Clean the area around the filter.

4. Remove filter cover and hardware.
5. Remove the filter element inside the filter.

6. Add oil. Use only pre-filtered hydraulic oil.
7. Insert the filter element.
8. Install the breather.
153
Maintenance
Hydraulic Oil Change Procedure
WARNING: The hydraulic system operates at high pressures. Do not attempt

to perform any service without depressurizing the system. Serious injury could
result from high pressure oil.

3. Locate the hydraulic tank drain plug underneath the plant.
4. Place a container under the drain to catch the oil.

5. Remove the drain plug from the tank and drain the oil.
6. Change the oil filter.
7. Install the drain plug.
8. Add new oil to the tank.
Hydraulic Cooler
Inspect the hydraulic cooler for damage or leaks. Keep the cooler clean from excess dirt buildup.
When the plant is operating, periodically check to make sure the fan is operating. The thermostat for
the cooler is set at 115°F so if the hydraulic tank or the hoses are hot to the touch, make sure the fan is
functioning properly.
Drive Cog Sheave Alignment and Belt Tension

Verify Drive Cog Sheave Alignment Procedure
The best tool to measure any misalignment is a laser alignment device. You can also use a straightedge such
as a long level, a ruler, a straight length of metal, or a string.
154
Maintenance

2. Lockout/tagout the crusher and plant.
WARNING: The drive belt guard weighs over 450 lbs. You must use a lifting
device rated for the weight of the guard. Never allow anyone under a lifted belt
guard. Serious injury or death could occur if the lifting device failed.
3. Remove the belt guard.

Angular Misalignment
Parallel Misalignment
155
Maintenance
4. Verify that the sheaves are aligned.
156
Maintenance
Parallel Misalignment Adjustment Procedure

1. Make sure the cog sheaves are aligned correctly.
2. To adjust parallel misalignment, loosen the bolts on the engine cog sheave bushing and push or pull
the cog sheave/bushing until it is aligned with the crusher cog sheave.
3. When the cog sheaves are aligned, torque the bolts to 141 ft-lb (192 Nm).
157
Maintenance
4. Use a hammer and a drift to set the bushing and the cog sheave by hitting the bushing on the large
side opposite the split in the bushing. Hit bushing on both sides of the screw. Do not hit close to the
outside of the bushing to avoid damage.
5. Repeat steps working towards the split line.
6. Re-torque the bolts and repeat hitting the bushing until torque no longer turns the screws after
hammering.
7. Install the belt, if removed.
WARNING: Do not operate the plant without a drive guard. Serious injury or
death could occur.
1 Incorrect
2 Correct
3 Incorrect
8. Make sure when the belt is installed that it is positioned and tracks correctly.
158
Maintenance
Setting the Cog Belt Tension Meter

1. Press the POWER key.
2. If this is the first time you have used your meter, the screen will appear as below. If this is not the first
time, the last settings used will appear.
3. Press the “MASS” key.
159
Maintenance
4. The “MASS” window will be shown.
NOTICE: After ten (10) hours of operation, use the “USED BELT SETTING.”
MASS WIDTH SPAN NEW BELT USED BELT DEFLECTION

SETTING SETTING 74-81 LBS
(34-37 KG)
7.9 90 910 48-51 HZ 41-43 HZ .56 IN. (14MM)
5. Enter the “MASS” value from the above chart on the keypad. This entry will be in grams per meter.
Ensure the decimal is in the correct place in the display panel. If your entry is incorrect, press “MASS”
again and the cursor will return to the starting position.
6. Press the “WIDTH” key.
7. The “WIDTH” screen will be shown.
8. Enter the “WIDTH” value from the above chart on the keypad. Ensure the decimal is in the correct place
in the display panel. If your entry is incorrect, press “WIDTH” again and the cursor will return to the
starting position.
9. Press the “SPAN” key.
160
Maintenance
10. The “SPAN” screen will be shown.
11. Enter the “SPAN” value from the above chart on the keypad. This entry will be in grams per meter. If
your entry is incorrect press “SPAN” again and the cursor will return to the starting position.
Using the Cog Belt Tension Meter

3. Remove the belt guard.
4. Make sure the meter is on and the proper, mass, weight and span settings are displayed.
5. Press the “Hz” key. You are now ready to use the meter to determine your belt tension.
6. Press the “MEASURE” key, the green LED will begin flashing.
161
Maintenance
7. Hold the sensor 0.4 inch (1cm) or closer to the belt.
Note: Do not touch the belt with the sensor.

8. Strike the belt with a large wrench. The meter will display a measurement in Hz.
9. Repeat the above step three (3) times to ensure accuracy.
10. If the measurement is lower than the range listed in the belt setting chart, tighten the belt by turning tall
four (4) of the engine sled jack screws equally to maintain alignment of the cog sheaves.
11. If the measurement is higher than the range listed in the belt setting chart, loosen the belt by turning the
all four (4) of the engine sled jack screws equally to maintain alignment of the cog sheaves.
12. Perform the steps until the correct tension is achieved.
13. Install hard shims as needed to fill space between frame and engine sled.
14. Tighten the four engine sled jam nuts.
15. Tighten the left and right engine sled adjustment bolts.
16. Install drive guard.
17. Position a person to watch the belt as the plant runs.
162
Maintenance
NOTICE: If the belt does not track correctly, immediately shut down to prevent damage to the belt.
18. Run the plant to verify belt tension and proper belt alignment.
19. Shut down the plant.
20. Remove the drive guard.
21. Verify the belt tension and visually inspect the belt for proper alignment. Make adjustments as
necessary.
22. Install the drive guard.
NOTICE: Follow the procedures to isolate electronics and electrical system prior to welding.
23. Tack weld the hard shims.
Conveyor Maintenance
Conveyor Daily Inspection Checklist
OPERATOR’S SERVICE
INSPECTION ITEM OKAY
INITIALS REQUIRED
Check the gear reducer oil levels.
Make sure all guards are in place and are
working properly.
Inspect all conveyor belts for damage and
excess wear.
Make sure all tools are removed from
conveyors.
Check all hydraulic hoses for damage or
leaks.
Periodically during your shift check the
conveyor tracking. Adjust as necessary.
Conveyor Weekly or Every 50 Hours of Operation Schedule

ITEM INSTRUCTIONS
Tighten only if there is slippage on drive pulley or
enough sagging between idlers to allow spillage.
Belt Tension This is especially important when a belt scale is
used, as a sagging belt could produce incorrect
readings and affect end product specifications.
Drive Pulley Lagging Inspect and replace as needed.
Bearings on Conveyor Shafts Check for proper torque settings.
Bushings in All Belt Conveyor Pulleys Check for proper torque settings.
Taper-lock Bushings in Drive Sheave Check for proper torque settings.
Check for tears and other damage. Repair and
Belt
eliminate causes.
163
Maintenance
ITEM INSTRUCTIONS
Belt Fasteners Inspect for wear and replace as needed.
Level Across Conveyor Frame Check at different points and correct as needed.
Check and adjust to prevent side spillage, and to
Skirt Boards prevent material from falling between the tail pulley
and the belt.
Keep clean to ensure safe viewing distance legibility.
Safety Labels
Contact JCI for replacement decals if needed.
Ensure they contact the belt and run free under load.
Troughing and Return Idlers
Shimming may be necessary if a belt scale is used.
Head and Tail Pulley Hubs Check for tightness.
Gear Reducers Check oil levels.
Scraper Blades Check serviceability and adjust.
Radial Travel Tire Inflation Make sure does not exceed 100 psi
Repairing a Broken Conveyor Belt

This will guide you through the proper method of repairing a broken conveyor belt. Refer to the below sections
to correctly repair a broken conveyor belt.
• How to Measure for Proper Conveyor Belt Length
• How to Square the Ends of the Conveyor Belt
• How to Drill and Skive the Conveyor Belt
• How to Attach the Belt Ends
Measuring a Conveyor Belt Procedure

164
Maintenance
3. Make sure the take-ups are retracted all the way.
4. Wrap a tap measure around the conveyor take up at one end and pulley at the other end in the middle
of the idlers.
5. Add four (4) to six (6) inches / ten (10) cm to fifteen (15) cm to your measurement to allow for needed
training adjustments. This total is your proper cut length.
Squaring the Ends of the Conveyor Belt

You can maximize the belt splicing life when both ends of the belt are properly squared prior to fastener
installation:
• Fasteners will last longer when the belt is aligned correctly.
• The belt will require less maintenance and downtime.
• It will distribute tension evenly across the splice.
• The belts will run straighter.
• There will be less belt and splice wear.
• There will be less load spillage and cleanup from load shifting.
• It will help promote even top plate wear.
165
Maintenance
How to Square the Ends of the Conveyor Belt

1. Measure the width of your belt and mark the center points at intervals of three (3) to five (5) feet for a
distance of fifteen (15) to twenty (20) feet from the splice.
2. Mark the center with either a straight edge or chalk line using the marks from the above step.
166
Maintenance
3. Using a square, draw a line perpendicular to your average center line across the belt width.
4. For even greater accuracy in preparing your squaring line (on belts with worn edges) after completion
of step 3, mark two lines (B and C) equal distance from the center line in the area where the splice will
be installed. Lines B and C must be parallel to the center line.
167
Maintenance
5. Measure back from the intended splice area to a distance approximately equal to three times the belt
width. At this point drive a nail or an all on the center line. Using the nail or aw i as a pivot point, swing
an arc, marking the belt across its entire width.
6. Where this arc intersects the two smaller lines (B and C) marked parallel to the belt center line, align
a steel straight edge through these points and trace the line across the width of the belt. The resulting
line is the true square.
7. Cut the belt at this line using one of the belt cutters. (Refer to the instruction for using the Flexco 840
belt cutter.)
168
Maintenance
8. Repeat the above steps on the other end of the belt.
How to Drill and Skive the Conveyor Belt

1. Place a board on top, near the middle of the rolled out belt.
2. Fold both ends of the belt back on to its self and meet the ends on the board.
Note: Ensure the belt is “rubber” side up.
169
Maintenance
3. Place the bolt template with the lugs tight against the end of the belt.
170
Maintenance
4. Nail the bolt template in position through the belt to the board.
5. Use the Flexco drill bit (p/n HP1) to bore the holes through both ends of the template.
171
Maintenance
6. Take the drilling template off and pull one end of the belt out of the way.
172
Maintenance
7. Place the skiving template (p/n 990941) on the belt by inserting the aligning pins in the holes you
drilled.
8. Use a router with a 1-2” X 1” straight flute carbide tipped bit to create the skives.
173
Maintenance
9. Repeat moving the template and router skives until both end are complete.
Attaching the Belt Ends

Once the belt ends are squared, drilled and skived the belt ends are ready to be joined together.
1. Cut a chamfer at the edge of each belt end. This will help prevent the edge of the splice from catching
on any part of the conveyor structure or rollers. The chamfer is cut two (2) inches from the end at a
15-20 degree angle.
174
Maintenance
2. If needed, assemble bottom plate. Insert two (2) bolts and attach clip.
3. You may insert all the bolts in the holes of one side of the belt or you may start at once end or middle of
the belt and insert one bolt in each end of the belt.
4. Place top plates over bolts. If needed use a bolt horn. Start nuts on bolts by hand.
175
Maintenance
5. Cut Flexco-lok Tape 3 1/2 times the width of the belt and feed the tape under the top plates and under
the bottom plates then back under the top plates.
176
Maintenance
6. Pull the tape tight and hold in position by tightening a fastener at each end with Flexco part number
HW1. Then tighten all other plates. Make sure the points on the plates do not puncture the tape.
Tighten all nuts uniformly.
7. Hammer the plate points into the belt with a block of wood if needed.
177
Maintenance
8. Once the plate teeth are imbedded, tighten the nuts so the plates are below the top of the belt.
9. Break off excess bolt ends using a bolt breaker.
178
Maintenance
10. Grind the bolts smooth to finish.
Using the Flexco 840 Belt Cutter

The Flexco 840 belt cutter is a single operator self contained belt cutting device.
179
Maintenance
1 Base
2 Locking Pins
3 Clamp Bar Handles
4 Clamp Bar
5 Wrench
6 Blade troth
1. Ensure the blade in the belt cutter is at one end.
180
Maintenance
2. Roll the belt back a few feet from the cut mark and place the belt cutter.
3. Roll the belt back and position the belt over the belt cutter base.
181
Maintenance
4. Place the clamp bar on the belt cutter.
5. Place the locking pin in the belt cutter, and then push down the clamp bar handles to secure the belt.
182
Maintenance
6. Turn the wrench to move the blade through the blade troth and cut the belt.
7. Remove the belt from the belt cutter.
183
Maintenance
184
Plant Parts Book
185
Plant Parts Book
Plant Parts Book
PLANT COMPONENTS
Reference Number: 710940 Revision: 0
186
Plant Parts Book
ITEM QTY PART DESCRIPTION COMMENTS

NUMBER
1 1 710940 GT200 PLANT ASSY
10 1 700442 INSTALL GT200
20 1 710941 FRAME GT200DF
40 1 709744 FEED CONVEYOR MTG GT300DF
41 1 709597 FEED CONVEYOR GT200DFLS
42 1 043373 PULLEY TAIL FEEDER GT200
187
Plant Parts Book

NUMBER
43 1 709826 TAIL PULLEY ASSY GT200 FD-PPI
50 0 709750 UC CONVEYOR FOLD GT200DFLS NOT ORDERED
51 1 709809 UC CONVEYOR FOLD GT200
52 1 711233 UNDER CRUSHER HOPPER GT200DFLS
54 1 709749 WIPER UC CONVEYOR GT200DFLS
100 1 711130 GT200 ENGINE ASSY (CAT)
101 0 710922 GT200 HYD ASSY ENG T3 NOT ORDERED
102 0 710922 GT200 HYD ASSY ENG T3 NOT ORDERED
103 0 710923 GT200 HYD ASSY ENG T4F NOT ORDERED
104 0 711223 TANK FRAME DEF CUMMINS NOT ORDERED
110 1 710927 FUEL TANK GT200DFLS
120 1 710928 HYD TANK GT200
130 1 711212 BAG HOUSE ASSEMBLY GT200
131 0 711248 BAGHOUSE CONNECTION GT200DFLS NOT ORDERED
132 1 711249 BAGHOUSE CONNECT ADD FOR CAT
133 1 711225 BAG HOUSE GT200 AIR
134 1 200921 ASSY-ELECT BAG HOUSE GT200
140 1 710921 STAIR ASSY GT200DF
141 1 710930 HANDRAIL
142 2 065200 BATTERY 4D 12V 1000 CCA
150 1 710933 GT200DF HYD VALVE ASSY
160 1 710929 GT200DF LUBE ASSY
170 1 711350 HOPPER FEED CRUSHER GT200DFLS
180 1 710935 CRUSHER DRIVE GT200
190 1 028259 GT200DFLS ELECTRICAL CAT T3
191 0 028258 GT200DFLS ELECTRICAL CUMMNS T4 NOT ORDERED
192 0 711282 E-STOP BRACKET GT200 NOT ORDERED
193 1 028358 GT200 ELECT UPGRADE CUMMNS
194 1 711282 E-STOP BRACKET GT200
220 1 710945 SCHEMATIC GT200 HYD
230 1 710932 GT200 HYD ASSY
240 1 710939 GT200 DECAL KIT
188
Plant Parts Book

NUMBER
250 1 710938 GT200 DUST SUPPRESSION
270 1 708363 ASSY T30UIPB SENSOR MOUNTING
271 1 027521 SENSOR ULTRASONIC T30UIPB
273 1 711640 GT200 UPGRADE
303 1 713028 LIFTING LUGS GT200
304 0 065019 PRECLEANER - 8 DIA X 1300 CFM NOT ORDERED
305 0 065299 PRECLNR ADAPTR SYKLONE 8OD/7ID NOT ORDERED
189
Plant Parts Book
GT200 FRAME
Reference Number: 710941 Revision: C
190
Plant Parts Book

NUMBER
17 2 710941-017 LINER
77 1 710941-077 LINER
100 2 707977 MNT EAR 1.0 DIA 1.00 PL
101 1 043357 CRAWLER LH STRICKLAND DL385V-U
102 1 043358 CRAWLER RH STRICKLAND DL385V
103 2 707381 STEP TRACK MOUNTED
105 1 087196 VALVE DUAL COUNTER BALANCE-NEW
106 1 711295 HOSE HOOP WELD-ON
500 4 070158 CAPSCREW HEX 5/8 11NC X 2-1/4
501 40 070703 CAPSCREW HEX M24-3.0X90MM 10.9
502 20 070624 CAPSCREW HEX 1-1/2 X 4-1/2 GR5
600 4 078000 WASHER HT 5/8 YELLOW ZINC
601 4 078014 WASHER LOCK 5/8
603 20 078045 WASHER LOCK 1-1/2
191
Plant Parts Book

NUMBER
604 20 078058 WASHER HT 1-1/2 YELLOW ZINC
605 40 078099 WASHER LOCK 24MM
700 2 076148 NUT 1/2-13NC PLAIN
701 13 076050 NUT HEX 5/8-11NC G5 PLAIN
702 24 076051 NUT 3/4-10NC G5 (PLAIN)
703 24 076095 NUT 1-1/2-6NC PLAIN
704 40 076198 NUT HEX M24 X 3.0 CLASS 10
705 4 076025 NUT 5/8-11NC
192
Plant Parts Book
FEED CONVEYOR MTG GT200DFLS
Reference Number: 709744 Revision: A
193
Plant Parts Book

NUMBER
15 2 706966 MOUNTING EAR-LINKAGE GT200
16 2 089117 CYL HYD 4 BORE 34 MONARCH
20 8 070023 CAPSCREW HEX 3/4 10NC X 2-1/4
21 8 070191 CAPSCREW HEX 1-1/2 6NC X 6 G5
27 8 076000 NUT NYLOCK 3/4-10 NC
28 8 076056 NUT NYLOCK 1-1/2-6 UNC
FEED CONVEYOR GT200DFLS
194
Plant Parts Book
195
Plant Parts Book
196
Plant Parts Book

NUMBER
30 48.4 070349 ALLTHREAD ACME 1-1/4-5
45 1 709745 WIPER FEED CONVEYOR GT200DFLS
46 1 702732 GUARD TAIL FEEDER GT200DFLS
47 2 702749 GUARD RETURN ROLLER GT200DFLS
50 1 049305E 1050 X 10820 TOUGHFLEX SW630/2
51 1 043372 PULLEY HEAD FEEDER GT200
52 1 043373 PULLEY TAIL FEEDER GT200
53 2 AMS-C08885 MTRH YOUNG YMSS-125
54 2 AMS-C08981 BRG PB-2.500 BORE RDR TSF
55 12 AMS-C08999 ROLLER, 1 1/2 TRACKING JIMWAY
56 2 AMS-C08909 GEARBOX 24:1 805W2
57 2 043371 L1280 DISK RETURN ROLLER
58 12 043374 IMPACT BAR 1500MMX100MMX55MM
59 6 043375 IMPACT BAR 1240MMX100MMX55MM
60 4 070688 U-BOLT 3/8 X 1.25 X 2.25
61 12 070059 CAPSCREW HEX 1/2 13NC X 1-3/4
62 32 070038 CAPSCREW HEX 5/8 11NC X 2
63 4 070079 CAPSCREW HEX 5/8 11NC X 3 G5
64 24 070676 CAPSCREW SOC M16-2.0 X 35MM
65 4 070083 CAPSCREW HEX 7/8 9NC X 2-1/2
73 36 078014 WASHER LOCK 5/8
74 24 078098 WASHER NORD-LOCK 5/8
80 8 076009 NUT NYLOCK 3/8-16NC
81 12 076005 NUT NYLOCK 1/2 13NC
82 28 076050 NUT HEX 5/8-11NC G5 PLAIN
83 4 076064 NUT NYLOCK 7/8-9NC
84 6 076073 NUT ACME 1-1/4-5
197
Plant Parts Book

NUMBER
85 24 076063 NUT 7/8-9NC
FEED CONVEYOR WIPER GT200DFLS

NUMBER
10 1 043416 URETHANE BAR 1" X 4" X 36"
11 2 090663 SPRING, DIE 1.25OD .625ID X 4L
20 10 070059 CAPSCREW HEX 1/2 13NC X 1-3/4
21 4 070018 CAPSCREW HEX 1/2 13NC X 2-1/2
22 2 070612 CAPSCREW HEX 5/8 11NC X 8.00
23 2 070045 CAPSCREW HEX 3/4 10NC X2-1/2 Z
30 14 076005 NUT NYLOCK 1/2 13NC
198
Plant Parts Book

NUMBER
31 4 076174 NUT 5/8-11NC GALV RH
32 2 076000 NUT NYLOCK 3/4-10 NC
FEEDER TAIL GUARD GT200DFLS

NUMBER
10 20 070027 CAPSCREW HEX 1/2 13NC X 1-1/4
11 20 078025 WASHER LOCK 1/2
199
Plant Parts Book

NUMBER
13 20 076148 NUT 1/2-13NC PLAIN
15 8 070055 CAPSCREW HEX 1/4 20NC X 3/4
16 8 078015 WASHER FLAT 1/4
17 8 076026 NUT NYLOCK 1/4-20NC
20 2 079157 SPRING LATCH LH
21 2 079241 SPRING LATCH RH
RETURN ROLLER GUARD GT200DFLS

NUMBER
10 4 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
12 4 076005 NUT NYLOCK 1/2 13NC
200
Plant Parts Book
FEED CONVEYOR HOPPER GT200DFLS
201
Plant Parts Book
202
Plant Parts Book

NUMBER
35 2 709598-035 LINER
36 1 709598-036 LINER
203
Plant Parts Book

NUMBER
37 2 709598-037 LINER
38 1 709598-038 LINER
39 1 709598-039 LINER
50 358 042663 RUBBER SKIRT 3/8 X 3"
51 36 042663 RUBBER SKIRT 3/8 X 3"
55 2 049312 HEAD PULLEY SKIRTING GT200DFLS
70 28 070027 CAPSCREW HEX 1/2 13NC X 1-1/4
71 30 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
72 6 070529 CAPSCREW HEX 1/2 NC X1-1/2 PLN
73 33 070528 CPSCRW HX 1/2 13NC X 1-3/4 PL
74 10 070234 BOLT CARRIAGE 1/2 13NC X 1 1/2
75 34 070010 CAPSCREW HEX 5/8 11NC X 1-3/4
76 6 070383 CAPSCREW HEX 1 8NC X 2 1/2 G5Z
81 28 078025 WASHER LOCK 1/2
83 26 078014 WASHER LOCK 5/8
84 12 078030 WASHER HT 1 YELLOW ZINC
90 79 076005 NUT NYLOCK 1/2 13NC
91 28 076148 NUT 1/2-13NC PLAIN
92 10 076001 NUT NYLOCK 5/8-11 NC
93 2 076051 NUT 3/4-10NC G5 (PLAIN)
94 6 076059 NUT NYLOCK 1-8 NC
95 2 076025 NUT 5/8-11NC
96 2 070184 CAPSCREW HEX 5/8 11NC X 1-1/2
97 2 070003 CAPSCREW HEX 3/4 10NC X 1-1/2
98 2 078026 WASHER LOCK 3/4
204
Plant Parts Book
TAIL PULLEY ASSEMBLY

NUMBER
1 1 709829 TAIL PULLEY SHAFT FD GT200-PPI
2 1 042354 PULLEY WING 12 X 44 XT 35
3 2 060131 BUSHING XT-35 2-15/16
205
Plant Parts Book
UNDER CRUSHER CONVEYOR FOLD GT200
206
Plant Parts Book
207
Plant Parts Book
208
Plant Parts Book
209
Plant Parts Book
210
Plant Parts Book
211
Plant Parts Book
212
Plant Parts Book

NUMBER
90 2 042663 RUBBER SKIRT 3/8 X 3"
91 1 042135 RUBBER SKIRT 3/8 X 4"
92 2 042663 RUBBER SKIRT 3/8 X 3"
93 2 042663 RUBBER SKIRT 3/8 X 3"
94 2 042663 RUBBER SKIRT 3/8 X 3"
95 2 042663 RUBBER SKIRT 3/8 X 3"
96 2 042663 RUBBER SKIRT 3/8 X 3"
110 1 709770 TAKEUP 2-1/2 PB RDR
111 1 709025 UC CONV FOLD GT CONE SHAFT
112 2 709024 UC CONV FOLD GT LINK WELDMENT
113 1 709023 UC CONV FOLD GT PIVOT WELDMENT
213
Plant Parts Book

NUMBER
120 1 709824 HEAD PULLEY ASSY GT200 UC-PPI
121 4 AMS-C08999 ROLLER, 1 1/2 TRACKING JIMWAY
122 2 042299 JACK RATCHET CLEVIS ENDS
125 1 AMS-C08886 use 043536
126 1 AMS-C09003 use 043601
130 4 AMS-C08981 BRG PB-2.500 BORE RDR TSF
131 2 089118 CYL HYD 3 BORE 28 HCW3028
132 1 087196 VALVE DUAL COUNTER BALANCE-NEW
133 1 709823 TAIL PULLEY ASSY GT200 UC-PPI
136 1 049306E 900MM X 21660MM EP500/3
151 1 070688 U-BOLT 3/8 X 1.25 X 2.25
152 112 070027 CAPSCREW HEX 1/2 13NC X 1-1/4
153 86 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
155 79 070048 CAPSCREW HEX 1/2 13NC X 2 G5 Z
156 4 070037 CAPSCREW HEX 1/2 13NC X 2-1/4
157 2 070624 CAPSCREW HEX 1-1/2 X 4-1/2 GR5
160 10 070078 CAPSCREW HEX 5/8 11NC X 1-1/2
161 12 070010 CAPSCREW HEX 5/8 11NC X 1-3/4
162 4 070038 CAPSCREW HEX 5/8 11NC X 2
163 4 070167 CAPSCREW HEX 5/8 11NC X 2-3/4
164 4 070036 CAPSCREW HEX 3/4-10 X 2 G5 ZNC
166 2 070559 CAPSCREW HEX 1 8NC X 2-3/4 G5
167 14 070119 CAPSCREW HEX 1 8NC X 3 G5
168 4 070368 CAPSCREW HEX 1 1/4-7NC X 4 1/2
169 2 070362 CAPSCREW HEX 1-1/2 6X 3-1/2G5
175 2 076150 NUT 1/4-20NC PLAIN
176 2 076009 NUT NYLOCK 3/8-16NC
177 157 076148 NUT 1/2-13NC PLAIN
178 124 076005 NUT NYLOCK 1/2 13NC
179 26 076001 NUT NYLOCK 5/8-11 NC
214
Plant Parts Book

NUMBER
180 4 076000 NUT NYLOCK 3/4-10 NC
181 14 076059 NUT NYLOCK 1-8 NC
182 4 076054 NUT NYLOCK 1-1/4-7NC
183 4 076056 NUT NYLOCK 1-1/2-6 UNC
186 2 078015 WASHER FLAT 1/4
187 2 078022 WASHER LOCK 1/4
190 157 078025 WASHER LOCK 1/2
192 4 078014 WASHER LOCK 5/8
195 24 078026 WASHER LOCK 3/4
196 2 078027 WASHER LOCK 1
200 1 709806 IDLER IMPACT 30DEG UC GT200
201 3 709805 IDLER IMPACT 45DEG UC GT200
202 10 709807 IDLER STL 45DEG UC GT200
203 1 709808 IDLER STL 30DEG UC GT200
204 3 042255 IDLER C4-RRD-36SB
205 2 702753 GUARD RETURN IDLER PPI GT200
215
Plant Parts Book
HEAD PULLEY ASSEMBLY GT200 UC-PPI

NUMBER
1 1 709828 HEAD PULLEY SHAFT UC GT200-PPI
2 1 042525 PULLEY LAGGED 10 X 38 XT-30
3 2 060130 BUSHING XT-30 2-15/16
216
Plant Parts Book
TAIL PULLEY ASSEMBLY GT200 UC-PPI

NUMBER
1 1 709827 TAIL PULLEY SHAFT UC GT200-PPI
2 1 042491 PULLEY WING 8 X 38 XT-30 HUB
3 2 060130 BUSHING XT-30 2-15/16
IDLER IMPACT 30DEG UC GT200
217
Plant Parts Book

NUMBER
1 1 709804 IDLER FRAME 30DEG UC GT200
2 1 043584 IDLER CENTER IMPACT 20.5
3 2 043585 IDLER WING IMPACT 7.5
4 2 043588 RETAINER CLIP PPI TROUGH IDLER
5 2 042674 END CLIP IDLER CEMA-C PRECISIO
6 2 070550 HEX FLANGE SCREW TAP 10-32-3/8
IDLER IMPACT 45DEG UC GT200

NUMBER
2 1 043584 IDLER CENTER IMPACT 20.5
3 2 043585 IDLER WING IMPACT 7.5
218
Plant Parts Book

NUMBER
IDLER STL 45DEG UC GT200

NUMBER
2 1 043582 IDLER CENTER STL 20.5
3 2 043583 IDLER WING STL 7.5
219
Plant Parts Book
IDLER STL 30DEG UC GT200

NUMBER
2 2 043583 IDLER WING STL 7.5
3 1 043582 IDLER CENTER STL 20.5
220
Plant Parts Book
RETURN IDLER GUARD PPI GT200

NUMBER
10 4 070027 CAPSCREW HEX 1/2 13NC X 1-1/4
11 4 076005 NUT NYLOCK 1/2 13NC
221
Plant Parts Book
UNDER CRUSHER HOPPER GT200DFLS

NUMBER
10 1 711233-010 LINER
11 1 711233-011 LINER
222
Plant Parts Book

NUMBER
12 2 711233-012 LINER
20 22 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
21 2 070059 CAPSCREW HEX 1/2 13NC X 1-3/4
26 12 078025 WASHER LOCK 1/2
30 10 076148 NUT 1/2-13NC PLAIN
31 12 076005 NUT NYLOCK 1/2 13NC
223
Plant Parts Book
WIPER UNDERCRUSHER CONVEYOR

NUMBER
10 2 079146 CLEVIS ROD END .625NC ZINC
11 1 079148 PIN, SPLIT SPRING, 5/16 X 1.5
12 2 090663 SPRING, DIE 1.25OD .625ID X 4L
224
Plant Parts Book

NUMBER
13 1 079147 PIN WIRE LOCK LYNCH 1/4 X 2.25
14 1 042566 BELT SCRAPER BLADE 36 MARTIN
20 4 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
21 4 076005 NUT NYLOCK 1/2 13NC
22 6 076025 NUT 5/8-11NC
24 4 078020 WASHER FLAT 5/8
225
Plant Parts Book
ENGINE ASSEMBLY (CAT)
226
Plant Parts Book
227
Plant Parts Book
228
Plant Parts Book
229
Plant Parts Book
230
Plant Parts Book
231
Plant Parts Book
232
Plant Parts Book
233
Plant Parts Book
234
Plant Parts Book
235
Plant Parts Book

NUMBER
1 1 711368 GT200 ENGINE SLED
2 1 711369 GT200 ENGINE ENCLOSURE
236
Plant Parts Book

NUMBER
3 1 711129 GT200 ENGINE SUPPORT CAT
5 1 066003 ENGINE CAT C9 325 HP T3 GT200
6 1 065770 RADIATOR AKG GT200/300
7 1 065774 FAN SUCT 37 X 8 BLADE
8 1 065965 PTO HPTO12VG
9 1 085087 FILTER ASSY DONALDSON HMK03
10 1 089101 TANK HYD 15 GAL PT-TECH
11 1 065585 COUPLER HPTO RINGFEDER AC6.5
12 1 086221 PUMP L25C 1.53CUIN
13 1 086232 PUMP P197-12-12-5 CW
14 1 086231 PUMP HONOR 2GG2U18L
15 2 546289 VALVE COOLER BYPASS
16 1 711284 FUEL FILTER BRACKET CAT
21 25.55 054119 TUBE ALUMINUM 7 OD X 16GA
22 22.25 054116 TUBE EXHAUST 5 ID X FLEX
23 1 065737 MUFFLER 11.84 X 31.63 X 5ID
24 1 065275 FILTER AIR 7 X 7
25 1 065145 CAP RAIN 5 OD
26 1 065265 ELBOW INTAKE RBBR RED 5-7" ID
27 1 065292 ELBOW INTAKE RED RBBR 5-4"
28 1 065137 HUMP HOSE 7 ID
29 2 065764 ELBOW RUBBER 2.5" ID 90 DEG
30 1 065797 ELBOW INTAKE 4-3 X 90 SILICONE
31 2 065007 HOSE HUMP HI-TEMP 4 OD
32 1 065552 HUMP HOSE 3 ID HI TEMP
33 1 065796 REDUCING INSERT 2.5 OD TO 2 ID
34 3 065025 ELBOW EXH 90 5.000 OD OD
35 1 065799 TUBE RAD HOT GT200DF
36 1 065802 TUBE CAC CLD GT200DF
37 1 065800 TUBE RAD CLD GT200DF
38 1 065919 TUBE CAC HOT GT200DF
39 1 065979 TUBE INTAKE 5"OD-90L GT200DFLS
237
Plant Parts Book

NUMBER
40 2 026106 ISO MT 1/2"X13 9376K136
41 1 065251 KIT INDICATOR AIR FILTER
42 4 065026 CLAMP EXH BAND 5.000
43 2 065738 MOUNT EXH 11.84 RND
44 2 065140 CLAMP UBOLT TUBE 5 OD
45 2 065276 BAND MOUNTING AIR CLEANER 16 O
109 2 070056 MACH SCREW RD HD #8-32NC X 3/4
110 8 070066 CAPSCREW HEX 5/16-18NC X3/4
111 6 070547 CAPSCREW HEX M10-1.5 X 30MM
112 8 070032 CAPSCREW HEX 3/8 16NC X 1-1/4
113 6 070042 CAPSCREW HEX 3/8 16NC X 1-1/2
114 2 070236 CAPSCREW HEX 3/8 16NC X 3 1/2
116 12 070531 CAPSCREW HEX7/16 14NCX1-1/4 G8
117 7 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
118 2 070705 CAPSCREW HEX 1/2 13NCX2-1/4 G8
119 12 070078 CAPSCREW HEX 5/8 11NC X 1-1/2
120 12 070038 CAPSCREW HEX 5/8 11NC X 2
122 4 070383 CAPSCREW HEX 1 8NC X 2 1/2 G5Z
124 6 070532 CAPSCREW HEX1/2 13NCX 1-1/2 G8
125 2 070059 CAPSCREW HEX 1/2 13NC X 1-3/4
126 5 070050 ALLTHREAD 1/2 13NC
129 2 076104 NUT NYLOCK 8-32 UNC
130 16 076009 NUT NYLOCK 3/8-16NC
131 7 076005 NUT NYLOCK 1/2 13NC
132 8 076025 NUT 5/8-11NC
133 12 076001 NUT NYLOCK 5/8-11 NC
134 4 076059 NUT NYLOCK 1-8 NC
135 2 076024 NUT 1/2-13NC
140 8 078016 WASHER FLAT 5/16
141 4 078023 WASHER LOCK 5/16
238
Plant Parts Book

NUMBER
142 2 078017 WASHER FLAT 3/8
144 6 078018 WASHER FLAT 7/16
145 6 078001 WASHER LOCK 7/16
147 2 078019 WASHER FLAT 1/2
148 2 078078 WASHER FENDER 1/2" NOM 1.75 OD
152 2 078024 WASHER LOCK 3/8
153 6 078025 WASHER LOCK 1/2
239
Plant Parts Book
GT200 ENGINE SLED

NUMBER
37 16.5 703026 BELTING 42 GR2 3 PLY 3/16CV
40 2 711288 ELECTRICAL SUPPORT 20
240
Plant Parts Book

NUMBER
52 5 070059 CAPSCREW HEX 1/2 13NC X 1-3/4
53 12 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
54 2 070042 CAPSCREW HEX 3/8 16NC X 1-1/2
61 4 078026 WASHER LOCK 3/4
63 5 078078 WASHER FENDER 1/2" NOM 1.75 OD
64 4 078017 WASHER FLAT 3/8
70 21 076000 NUT NYLOCK 3/4-10 NC
71 4 076051 NUT 3/4-10NC G5 (PLAIN)
72 17 076005 NUT NYLOCK 1/2 13NC
73 2 076009 NUT NYLOCK 3/8-16NC
74 4 076024 NUT 1/2-13NC
241
Plant Parts Book
GT200 ENGINE ENCLOSURE
Reference Number: 711369 Revision: B
242
Plant Parts Book
243
Plant Parts Book
244
Plant Parts Book
245
Plant Parts Book
246
Plant Parts Book
247
Plant Parts Book

NUMBER
200 6 090242 BUMPER 1 D 3/8 H 5/16-18 THD
248
Plant Parts Book

NUMBER
201 3 091093 LATCH, CUP, NON-LOCKING
202 8 091020 HINGE LIFT OFF BOLTED
300 1 200111 BRKT SOLENOID FT/DS QSB4.5/6.7
301 32 070717 CAPSCREW BHS 5/16-18X1 S/S
501 2 070066 CAPSCREW HEX 5/16-18NC X3/4
502 6 070008 CAPSCREW HEX 3/8 16NC X1G5
503 22 070032 CAPSCREW HEX 3/8 16NC X 1-1/4
504 1 070042 CAPSCREW HEX 3/8 16NC X 1-1/2
505 49 070027 CAPSCREW HEX 1/2 13NC X 1-1/4
506 54 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
600 12 078015 WASHER FLAT 1/4
603 11 078025 WASHER LOCK 1/2
700 6 076026 NUT NYLOCK 1/4-20NC
701 2 076150 NUT 1/4-20NC PLAIN
702 14 076027 NUT NYLOCK 5/16-18NC
703 32 076205 NUT NYLOCK 5/16-18NC S/S
704 29 076009 NUT NYLOCK 3/8-16NC
705 70 076005 NUT NYLOCK 1/2 13NC
706 40 076148 NUT 1/2-13NC PLAIN
249
Plant Parts Book
GT200 ENGINE SUPPORT CAT

NUMBER
30 8 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
50 8 076005 NUT NYLOCK 1/2 13NC
250
Plant Parts Book
GT200 FUEL TANK

NUMBER
7 2 042135 RUBBER SKIRT 3/8 X 4"
8 2 042135 RUBBER SKIRT 3/8 X 4"
251
Plant Parts Book

NUMBER
21 1 040097 CAP FILL AND VENT 4"
22 1 040098 NECK FILL 4.25" OD X 4"H
23 1 040154 GAUGE FUEL MECH D-2"-32"
26 2 090185 HINGE LIFT OFF WELDABLE 4
27 1 042228 LATCH FLEX DRAW SOUTHCO LARGE
50 2 070038 CAPSCREW HEX 5/8 11NC X 2
51 2 070167 CAPSCREW HEX 5/8 11NC X 2-3/4
60 5 078020 WASHER FLAT 5/8
61 1 078014 WASHER LOCK 5/8
70 3 076001 NUT NYLOCK 5/8-11 NC
252
Plant Parts Book
GT200 HYDRAULIC TANK ASSY
253
Plant Parts Book

NUMBER
8 2 090047 MATERIAL GASKET NEOPRENE .125
254
Plant Parts Book

NUMBER
18 5.5 042135 RUBBER SKIRT 3/8 X 4"
19 4 042135 RUBBER SKIRT 3/8 X 4"
20 8 052013 PL .187 X 72W
25 1 089046 GAUGE SIGHT LEVEL 10" CENTERS
32 1 085019 FILTER BREATHER
33 1 085107 FILTER HYD RTF48TT25G10B/S2/V
50 16 070027 CAPSCREW HEX 1/2 13NC X 1-1/4
51 2 070167 CAPSCREW HEX 5/8 11NC X 2-3/4
52 2 070038 CAPSCREW HEX 5/8 11NC X 2
60 16 078019 WASHER FLAT 1/2
61 6 078020 WASHER FLAT 5/8
70 12 076024 NUT 1/2-13NC
71 4 076001 NUT NYLOCK 5/8-11 NC
255
Plant Parts Book
STAIR ASSEMBLY GT200
256
Plant Parts Book

NUMBER
8 1 065136 LINER BOX BATTERY
50 6 070641 BOLT CARRIAGE 3/8-16NC X 1
51 9 070004 BOLT CARRIAGE 5/8 11NC X1-1/2
52 6 070010 CAPSCREW HEX 5/8 11NC X 1-3/4
62 4 078017 WASHER FLAT 3/8
70 4 076149 NUT 3/8-16NC PLAIN
71 6 076009 NUT NYLOCK 3/8-16NC
72 12 076001 NUT NYLOCK 5/8-11 NC
257
Plant Parts Book
GT200 WALKWAY HANDRAIL
258
Plant Parts Book

NUMBER
51 10 070701 BOLT CARRIAGE 5/8 11NC X 2-3/4
52 2 070535 BOLT CARRIAGE .5NC x 2.75
70 2 076005 NUT NYLOCK 1/2 13NC
71 10 076001 NUT NYLOCK 5/8-11 NC
259
Plant Parts Book
GT200 HYDRAULIC VALVE ASSEMBLY
260
Plant Parts Book
261
Plant Parts Book
262
Plant Parts Book
263
Plant Parts Book
264
Plant Parts Book
265
Plant Parts Book
266
Plant Parts Book
267
Plant Parts Book
268
Plant Parts Book
269
Plant Parts Book

NUMBER
1 1 710931 GT200 HYD ENCLOSURE
2 1 087033 VALVE BODY B10-2-A8T
3 1 087046 VALVE RELIEF CARTRIDGE
4 1 083016 SAMPLER PLUG
5 1 085094 FILTER HEAD HMK04 SEE TEXT
6 1 085095 FILTER ELEMENT P170950
7 1 060696 MTRH 1.20 CU-IN HONOR
8 2 087161 VALVE D05 DBL SOL 24V DIN
9 2 087114 SUBPL D05 BACK PORTED ALUM
11 3 089016 GAUGE 0-5000 PSI LOWER MOUNT
12 1 086182 PUMP TRANSFER PERMCO M3000A
13 3 087309 VALVE NIMCO CV691
14 1 087319 VALVE 2 SECTION NIMCO CV112
15 1 087310 VALVE 2 SECTION NIMCO CV112
16 1 087134 HEADER BLOCK DAMAN AH0000616S
17 1 087314 INTENSIFIER HYD PRESSURE
18 1 707649 HEADER BLOCK, MACHINED SAE #10
50 4 070130 CAPSCREW HEX 5/16 24NF X 3/4
51 6 070361 CAPSCREW HEX 5/16-18NC x 3 G5
53 2 070042 CAPSCREW HEX 3/8 16NC X 1-1/2
54 4 070519 CAPSCREW SOC 3/8 16NC X 2-1/4
60 4 078023 WASHER LOCK 5/16
61 16 078016 WASHER FLAT 5/16
62 4 078020 WASHER FLAT 5/8
64 7 078024 WASHER LOCK 3/8
70 4 076001 NUT NYLOCK 5/8-11 NC
71 6 076027 NUT NYLOCK 5/16-18NC
72 8 076009 NUT NYLOCK 3/8-16NC
80 1 711283 LUBE FLOW METER ASSEMBLY
270
Plant Parts Book

NUMBER
81 3 087001 VALVE RELIEF 3/8
82 1 087172 VALVE CHECK PILOT TO OPEN
83 1 090093 GUAGE 10000 PSI 1/4 NPT
86 6 078015 WASHER FLAT 1/4
87 2 076026 NUT NYLOCK 1/4-20NC
88 2 070661 CAPSCREW SOC 10-32NC X 2-1/2
89 2 076094 NUT NYLOCK 10-32
90 2 078061 WASHER FLAT #10
91 2 065558 CLAMP UBOLT TUBE 3.0 DIA
271
Plant Parts Book
GT200 HYDRAULIC ENCLOSURE
272
Plant Parts Book
273
Plant Parts Book

NUMBER
13 50 042373 SEAL DOOR
18 88.5 042373 SEAL DOOR
30 8 091020 HINGE LIFT OFF BOLTED
31 4 042371 LATCH, OVER-CENTER, LOCK, BLK
50 8 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
51 32 070717 CAPSCREW BHS 5/16-18X1 S/S
52 22 070461 MACHSCREW RD HD 10-32 X 0.500
61 22 078068 WASHER LOCK #10
70 8 076005 NUT NYLOCK 1/2 13NC
71 32 076205 NUT NYLOCK 5/16-18NC S/S
78 4 076046 NUT #8-32NC
79 2 070387 MACHSCREW FLAT HD 8-32 X .75
80 8 070604 BOLT CARRIAGE 1/4 20NC X 3/4
81 34 078015 WASHER FLAT 1/4
82 21 076026 NUT NYLOCK 1/4-20NC
84 4 076009 NUT NYLOCK 3/8-16NC
86 4 070032 CAPSCREW HEX 3/8 16NC X 1-1/4
91 4 078016 WASHER FLAT 5/16
92 2 076027 NUT NYLOCK 5/16-18NC
94 3 076149 NUT 3/8-16NC PLAIN
274
Plant Parts Book
LUBE FLOW METER ASSEMBLY
275
Plant Parts Book

NUMBER
5 1 060921 COUPLING JAW L070 .625 X .157
6 1 020445 SENSOR PROX AB-871TM-DH8NP18-D
7 1 200913 CABLE ASSY FLOW METER
10 4 070055 CAPSCREW HEX 1/4 20NC X 3/4
11 4 078015 WASHER FLAT 1/4
12 4 076026 NUT NYLOCK 1/4-20NC
CABLE ASSEMBLY FLOW METER

NUMBER
1 1 028279 CABLE TURCK RK4.4T-2
2 1 028237 DEUTSCH 3 PIN REC DTM04-3P
3 1 028238 DEUTSCH 3 PIN WEDGE WM-3P
4 4 027712 DEUTSCH PIN 20 NICKEL
276
Plant Parts Book
LUBE TANK ASSEMBLY
277
Plant Parts Book
278
Plant Parts Book

NUMBER
14 1 083896 ELBOW 2-1/2 SCH 40 90DEG WELD
15 1 083975 NIPPLE KING MALE 2 1/2 WELD
16 1 085019 FILTER BREATHER
17 6 076007 HUCKBOLT COLLAR 3LC-2R-24
18 1 089046 GAUGE SIGHT LEVEL 10" CENTERS
19 1 089135 HEATER ARTIC FOX
20 1 705354 GASKET NEOPRENE 8 DIA.
50 6 070167 CAPSCREW HEX 5/8 11NC X 2-3/4
51 6 070527 CAPSCREW HEX 3/8 16NC X1G5 PLN
52 3 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
60 12 078020 WASHER FLAT 5/8
70 6 076001 NUT NYLOCK 5/8-11 NC
71 6 076009 NUT NYLOCK 3/8-16NC
72 3 076148 NUT 1/2-13NC PLAIN
279
Plant Parts Book
HOPPER FEED CRUSHER GT200DFLS
280
Plant Parts Book

NUMBER
20 8 052076 PL .250 F400
30 14 070059 CAPSCREW HEX 1/2 13NC X 1-3/4
32 16 070234 BOLT CARRIAGE 1/2 13NC X 1 1/2
40 44 076005 NUT NYLOCK 1/2 13NC
50 1 049441 RUBBER SKIRT NOT SHOWN
281
Plant Parts Book
CRUSHER DRIVE GT200
282
Plant Parts Book

NUMBER
1 1 710937 GT200 DRIVE TAKEUP
2 1 710936 GT200 DRIVE GUARD
3 1 060893 BUSHING KEYLESS B122215
4 1 060894 SPRKT 14MM 140T 90W B122215
5 1 060895 BUSHING KEYLESS B121090
6 1 060897 SPRKT 14MM 56T 90W B121090
7 1 060873 BELT SYNCH DR 14MGT 3136X90MM
10 4 070191 CAPSCREW HEX 1-1/2 6NC X 6 G5
11 4 078045 WASHER LOCK 1-1/2
12 4 078036 WASHER FLAT 1-1/2
283
Plant Parts Book
GT200 DRIVE TAKEUP
284
Plant Parts Book
285
Plant Parts Book

NUMBER
22 1 711818 DRIVE CRUSHER JACKING BOLT
30 2 060642 COLLAR SHAFT 2 PC, 2.4375 BORE
31 1 710947 PULLEY IDLER CRUSHER DRIVE BLT
32 1 090609 SPRG .5625 X 2.875 X 7 X 1.2 P
33 2 042071 BRG-P2B-SCM-108 1-1/2
43 4 070158 CAPSCREW HEX 5/8 11NC X 2-1/4
286
Plant Parts Book

NUMBER
54 1 078025 WASHER LOCK 1/2
60 4 076005 NUT NYLOCK 1/2 13NC
61 4 076001 NUT NYLOCK 5/8-11 NC
62 2 076000 NUT NYLOCK 3/4-10 NC
71 3 076148 NUT 1/2-13NC PLAIN
72 3 076095 NUT 1-1/2-6NC PLAIN
73 3 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
GT200 DRIVE GUARD
287
Plant Parts Book

NUMBER
10 20 070027 CAPSCREW HEX 1/2 13NC X 1-1/4
11 4 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
16 16 078025 WASHER LOCK 1/2
20 8 076005 NUT NYLOCK 1/2 13NC
21 20 076148 NUT 1/2-13NC PLAIN
E-STOP BRACKET GT200

NUMBER
288
Plant Parts Book

NUMBER
4 2 076009 NUT NYLOCK 3/8-16NC
289
Plant Parts Book
HYDRAULIC SCHEMATIC GT200
290
Plant Parts Book

NUMBER
1 1 710932 HYDRAULIC HOSE ASSY DUE TO THE COMPLEXITY,
CALL JCI FOR HOSES AND
FITTING INFORMATION
1 1 710923 GT200 HYD ASSY ENG T4F
291
Plant Parts Book
DECAL INSTALLATION GT200DFLS
292
Plant Parts Book
293
Plant Parts Book
294
Plant Parts Book
295
Plant Parts Book

NUMBER
1 1 090296 PL SERIAL NUMBER APT PENDING
296
Plant Parts Book

NUMBER
2 4 090467 DECAL LUBE POINT
3 2 090486 DECAL ISO6202/6115/6041 HRG/EP
4 4 090490 DECAL ISO5018 FALL HZD
5 1 090508 DECAL ISO1040 WRNG HIGHPRESS
6 3 090493 DECAL ISO6143 LOTO
7 2 090494 DECAL ISO6115 USE MASK
8 2 091030 DECAL GT200 SM
9 2 090497 DECAL ISO6202 EYE PROTECTION
10 4 090498 DECAL ISO6126 READ OPS MANUAL
11 3 090502 DECAL ISO 1024 HOT SUR CAUTION
12 5 090509 DECAL ISO6020 NO OPEN FLAME
13 4 090513 DECAL ISO1098 HAND PINCH POINT
14 4 090515 DECAL ISO6045 DRG AUTO STOP
15 2 090516 DECAL ISO DIESEL FUEL
16 1 090519 DECAL ISO6023 CORROSIVE MATL
17 2 090511 DECAL ISO1154 ARM ENTANGLMENT
18 2 090523 DECAL ISO5066 CRUSHER MOVING
PARTS
19 2 090524 DECAL ISO HYD FILTER
20 2 090526 DECAL USE ISO 46 OIL
21 1 091116 DECAL WELD INSTR GT200
23 2 090520 DECAL ISO4021 EXPL DECOMP
24 2 090765 DECAL KPI-JCI AMS
25 2 090483 DECAL SHIPPING WEIGHT
26 2 091029 DECAL GT200 LRG
27 4 090510 DECAL ISO6062 STAY CLEAR
28 2 090512 DECAL ISO1014 HAND ENTANGLEMENT
29 7 090514 DECAL ISO5008 CRUSH FROM ABOVE
30 6 090495 DECAL ISO6061 USE GUARDING
31 2 090491 DECAL ISO6041/6127 WRNG RTM
32 2 090540 DECAL ISO LUBE OIL
33 2 090527 DECAL USE ISO 150EP OIL
297
Plant Parts Book

NUMBER
34 2 090566 DECAL ISO CTR OF GRAVITY
36 1 091025 DECAL ISO5029 WRNG STORED ENER
37 1 091090 DECAL GT200 HYD CTLS HI PRESSR
38 1 091069-006 UNDER CRUSHER CONVEYOR - IN /
LEFT HAND TRACK - OUT
38 3 091069-009 FLOW CONTROL
38 1 091069-008 FEED CONV. - UP / DOWN
38 1 091069-007 UC CONVEYOR - UP / DOWN
38 1 091069-005 FEED CONVEYOR - IN / RIGHT HAND
TRACK - OUT
38 1 091069-004 CONE CLAMP IN / JACK - OUT
38 1 091069-003 CONE TIR - IN / CLEAR OUT
38 1 091069-002 CONE LUBE - IN, CONVEYOR
CYLINDERS - OUT
38 1 091069 DECAL GT200 HYD CONTROLS
39 1 091040 TRAVEL PROCEDURE
40 1 091114 DECAL PARTS SALES CONTACT
298
Plant Parts Book
GT200 DUST SUPPRESSION
299
Plant Parts Book
300
Plant Parts Book
301
Plant Parts Book
302
Plant Parts Book

NUMBER
10 1 711252 GT200DFLS DUST SUPP. FITTINGS
50 2 070501 CAPSCREW HEX 1/4 20NC X 3 1/4
51 2 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
52 2 070529 CAPSCREW HEX 1/2 NC X1-1/2 PLN
53 4 070014 CAPSCREW HEX 5/8 11NC X 2-1/2
60 4 078015 WASHER FLAT 1/4
70 2 076026 NUT NYLOCK 1/4-20NC
71 4 076005 NUT NYLOCK 1/2 13NC
GT200 UPGRADE
303
Plant Parts Book

NUMBER
1 1 087114 SUBPL D05 BACK PORTED ALUM
2 1 087191 VALVE D05 SGL SOL 24V DIN RH
3 1 708363 ASSY T30UIPB SENSOR MOUNTING
4 1 027521 SENSOR ULTRASONIC T30UIPB
6 1 711641 GT200 UPGRADE HOSE KIT
7 1 027994 TXDR WIKA PRESS 0-3000
15 1 711727 GT200 BEACON ASSEMBLY
20 2 070519 CAPSCREW SOC 3/8 16NC X 2-1/4
40 2 076009 NUT NYLOCK 3/8-16NC
304
Plant Parts Book
SENSOR MOUNTING ASSY

NUMBER
10 9 070010 CAPSCREW HEX 5/8 11NC X 1-3/4
12 9 076001 NUT NYLOCK 5/8-11 NC
305
Plant Parts Book
GT200 BEACON ASSEMBLY

NUMBER
9 1 040020 GROMMET RUBBER WIRE
10 2 070642 BOLT CARRIAGE 3/8-16NC X 1-1/4
15 2 076009 NUT NYLOCK 3/8-16NC
306
Plant Parts Book

NUMBER
16 2 076005 NUT NYLOCK 1/2 13NC
BAGHOUSE CONNECT ADD FOR CAT

NUMBER
2 1 065137 HUMP HOSE 7 ID
3 2 065033 CLAMP T-BOLT 7.38-7.78
307
Plant Parts Book
BAG HOUSE ASSEMBLY GT200DFLS
308
Plant Parts Book
309
Plant Parts Book

NUMBER
2 1 711213 BAG HOUSE ENCLOSURE GT200DFLS
3 2 087147 VALVE DIAGHRAGM 1 X 24VDC
6 4 065369 FILTER ELEMENT 6X60 BAG HOUSE
7 1 040211 AIR COMPRESSOR 24VOLT
10 2 040110 GROMMET 1" PIPE - LIP STYLE
11 1 040115 RELAY-24V AIR COMPRESS 002-240
12 1 040112 PRESSURE SWITCH 002-105
13 1 090455 DECAL BAGHOUSE BOTTOM PLATE
20 1 711312 ELECTRICAL SUPPORT BRKR GT200
51 2 070099 CAPSCREW SOC 1/4 20NC X 3/4
60 4 078022 WASHER LOCK 1/4
310
Plant Parts Book
BAG HOUSE ENCLOSURE GT200DFLS
311
Plant Parts Book
312
Plant Parts Book
313
Plant Parts Book

NUMBER
42 10 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
43 22 070027 CAPSCREW HEX 1/2 13NC X 1-1/4
44 6 070038 CAPSCREW HEX 5/8 11NC X 2
314
Plant Parts Book

NUMBER
45 6 070184 CAPSCREW HEX 5/8 11NC X 1-1/2
50 4 078015 WASHER FLAT 1/4
60 6 076150 NUT 1/4-20NC PLAIN
61 2 076026 NUT NYLOCK 1/4-20NC
62 4 076169 NUT NYLOCK 3/8-16NC S/S
63 28 076148 NUT 1/2-13NC PLAIN
64 4 076005 NUT NYLOCK 1/2 13NC
65 3 076001 NUT NYLOCK 5/8-11 NC
66 9 076050 NUT HEX 5/8-11NC G5 PLAIN
BAG HOUSE ELECTRICAL ASSEMBLY GT200

NUMBER
1 1 200922 BAG HOUSE CONTROLLER GT200
6 1 028287 CB 15A PANEL MOUNT MID RANGE
315
Plant Parts Book

NUMBER
10 2 028293 BOOT BAT ALTERNATOR #12 RED
11 1 027885 BATTERY CABLE POST 3/8"
20 1 027930 CONN METRIPAK 630 2 PIN 18-20
21 3 027931 CONN METRIPAK 630 F TERM 18-20
22 1 027932 CONN METRIPAK 630 FUSE COVER
23 1 026886 FUSE 5A ATO/ATC 46205
31 1 027927 DEUTSCH 12 PIN DTM06-12SB
32 1 027928 DEUTSCH 12 PIN WEDGELOCK WM12S
33 12 027929 DEUTSCH DTM CAVITY PLUG
34 12 027206 DEUTSCH SOCKET SIZE 20
36 2 027409 DEUTSCH 2 PIN PLUG DT06-2S
37 2 027411 DEUTSCH 2 PIN WEDGELOCK W2S
38 6 027382 DEUTSCH SOCKET 16 NICKEL 16-20
40 2 020516 CORD GRIP 1/2" .25-.375 CGB193
41 24 027803 CORD 16/2 SJO
42 2 027410 DEUTSCH 2 PIN RECEPT DT04-2P
43 2 027412 DEUTSCH 2 PIN WEDGELOCK W2P
44 6 027366 DEUTSCH PIN 16 NICKEL 16-20AWG
50 240 027690 WIRE 18 MTW BLACK
51 120 027933 WIRE 18 MTW RED
52 120 027934 WIRE 18 MTW WHITE
53 120 027935 WIRE 18 MTW ORANGE
54 120 027937 WIRE 18 MTW BROWN
55 300 026795 WIRE 10 MTW BLK
56 300 026797 WIRE 10 MTW RED
316
Plant Parts Book
BAG HOUSE CONTROLLER GT200
317
Plant Parts Book

NUMBER
1 1 027922 ENCL 6X6X4 NEMA4 POLY
2 1 027923 ENCL PNL 6X6 HOFFMAN
3 8 020182 DIN MOUNTING RAIL DIN #3
4 2 026601 SCREW PANHEAD #10-32 1/2"
318
Plant Parts Book

NUMBER
5 2 078061 WASHER FLAT #10
10 1 020512 TERM BLOCK END STOP
11 1 200527 PLC LOGO 12/24RC 200526
12 1 026883 TERM BLOCK FUSE ATC
13 1 026651 FUSE 1A ATO/ATC 46201
14 3 020504 TERM BLOCK TIE AB1492-JD3C
15 2 026479 TERM BLOCK SEP PLT
16 1 026898 TERM BLOCK CENTER JUMPER 2P J3
17 1 027558 RELAY JUMPER 4 PIN WIDE WAGO
20 1 027924 DEUTSCH 12 PIN DTM FLANGE MNT
21 1 027925 DEUTSCH 12 PIN FLANGE GASKET
22 6 027929 DEUTSCH DTM CAVITY PLUG
23 15 027420 DEUTSCH PIN 20 GOLD
24 1 027419 DEUTSCH 12PIN WEDGELOCK WM-12P
27 1 028221 INDICATING LIGHT GRN 24VDC
30 60 027690 WIRE 18 MTW BLACK
31 24 027691 WIRE 18 MTW BLUE
32 60 027933 WIRE 18 MTW RED
33 24 027934 WIRE 18 MTW WHITE
34 24 027935 WIRE 18 MTW ORANGE
35 24 027936 WIRE 18 MTW YELLOW
36 24 027937 WIRE 18 MTW BROWN
37 24 027692 WIRE 18 MTW GREEN
319
Plant Parts Book
320
Crusher Parts Book
Crusher Parts Book
1200LS FACTORY INSTALLED COUNTER WEIGHT CONFIGURATION

NUMBER
1 1 450034 CWT LEADING
2 1 450035 CWT LIGHT
321
Crusher Parts Book

NUMBER
10 1 450035 CWT LIGHT +2 1/4” SHIM p/n 450089
11 1 450035 CWT LIGHT +2 1/4” SHIM p/n 450089
12 1 450035 CWT LIGHT +2 1/4” SHIM p/n 450089
PART NUMBERS COUNTER WEIGHT

450034 CWT LEADING
450035 CWT LIGHT
450088 SHIM CWT 1/8
450089 SHIM CWT 1/4
322
Crusher Parts Book
1200LS FACTORY INSTALLED MANGANESE CONFIGURATION
ITEM QTY PART NUMBER DESCRIPTION COMMENTS

1 1 450128SX MANTLE
2 1 450127SX LINER
3 6 090037B MANGANESE BACKING MATERIAL NOT SHOWN
1200LS SEAL AND HOSE KITS
SEAL KITS

NUMBER
1 1 450079 KIT SEAL CLAMP CYL
2 1 450004 KIT SEAL CLAMP CYL
323
Crusher Parts Book

NUMBER
3 1 450013 KIT SEAL JACK CYL NEW STYLE
4 1 450679 SEAL KIT TIR CYLINDER
HOSE KITS

NUMBER
1 1 450683 TIR ASSEMBLY HOSE KIT
2 1 450717 KIT HOSE UPPER ASSEMBLY
324
Crusher Parts Book
CRUSHER FINAL ASSEMBLY

NUMBER
1 1 450703 LOWER ASSY
2 1 450704 UPPER ASSY
325
Crusher Parts Book

NUMBER
3 1 450141 GUARD SHIM
4 2 540130 LEG SHIM GUARD
5 1 450076 SEAL SHIM GUARD (NO DRAWING)
6 8 450148 CPLR BOLT ADJ 2 SPLITS
7 8 450358 WASHER ALIGNING CLAMP CYL
8 8 084001 O-RING 6227-30
9 8 084065 O-RING PARK 2-329 2.375 OD
10 8 450162 WASHER BOLT ADJ
11 8 450184 KIT SHIM STACK- P/S USE 450196
12 1 450718 DECAL LOCATION 200LS
13 1 090034 WRENCH ALLEN 7/8 NOT SHOWN
14 1 450030 WRENCH CLAMP CYL NOT SHOWN
15 1 450132 WRENCH MANTLE NUT STD NOT SHOWN
17 4 546338 SHIM 16 GA BASEFRAME MNTG NOT SHOWN
18 1 456531 CONE LIFTING EYE - SEE TEXT NOT SHOWN
19 1 456532 CONE LIFTING EYE ASSY SEE TXT NOT SHOWN
20 1 083074 NEEDLE OIL SAMPLER W/TUBING NOT SHOWN
326
Crusher Parts Book
LOWER ASSEMBLY
327
Crusher Parts Book
328
Crusher Parts Book
329
Crusher Parts Book

NUMBER
1 1 450659 BASEFRAME MACHINED
2 1 546840 PIN CLUTCH ASSY 10-PIN
3 1 456538 CLUTCH GUIDE RING 10-PIN
4 4 070130 CAPSCREW HEX 5/16 24NF X 3/4
5 4 070255 CAPSCREW SOC 3/8 16NC X 1-1/2
6 1 406015 CVR BRAKE HOUSING
330
Crusher Parts Book

NUMBER
7 28 078025 WASHER LOCK 1/2
8 1 450043 RING SEAL BASEFRAME
9 1 450243 ASSY PL WEDGE 1200 LS
10 1 450166 THRUST PLATE
11 6 070152 CAPSCREW HEX 1-14NF X 3
12 1 406087 SHAFT CONE BRAKE
13 2 406110 BRAKE SHAFT KEY
14 1 406109 CONE BRAKE PLATE
15 1 450497 FLOATING PLATE W/ INSERTS
17 28 070027 CAPSCREW HEX 1/2 13NC X 1-1/4
19 1 450694 CONE ASSY
20 1 450709 PINION ASSY
21 8 070010 CAPSCREW HEX 5/8 11NC X 1-3/4
22 8 078014 WASHER LOCK 5/8
23 1 450693 PINION TUNNEL ACCESS COVER
24 2 080032 PLUG MAGNETIC 1
25 2 070141 SETSCREW SOC 5/8 11NC X 5/8
26 1 083508 FS0304-C-12
27 1 083556 FS2503-12-12
28 4 450068 PIN PUSH BASEFRAME
29 4 084009 O-RING 6227-27
30 3 540129 ROLLER SHIM GUARD
31 3 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
32 8 450069 BOLT ADJ CONNECT QUICK
33 8 450148 CPLR BOLT ADJ 2 SPLITS
34 8 540226 RETAINER ADJ BOLT
35 8 450126 WASHER BOLT ADJ
36 8 084065 O-RING PARK 2-329 2.375 OD
37 1 083249 PLUG PIPE 2 1/2 NPT SQ HEAD
331
Crusher Parts Book
BASEFRAME MACHINED

NUMBER
1 1 450660 CASTING BASEFRAME
2 12 540242 CLAMP RING PAD GUSSET
332
Crusher Parts Book

NUMBER
3 1 450707 ROCK SHELF RING
4 4 450708 STRUT GUARD
5 1 406069 PLATE WEAR TUNNEL PINION
6 1 406281 SPINDLE BASEFRAME
7 1 450249 NUT SPINDLE
8 1 450699 CLAMP RING
9 10 456344 PLUG 1.625 DIA X 0.500
10 20 070151 SETSCREW SOC 1/2 13NC X 3/4
333
Crusher Parts Book
PIN CLUTCH ASSY 10-PIN

NUMBER
1 1 546841 BLOCK DRIVE 10-PIN
334
Crusher Parts Book

NUMBER
2 1 546842 BLOCK RATCHET 10-PIN
3 10 546641 PIN DRIVE
4 1 546460 WASHER THRUST
5 10 090442 SPRG COMPRES C0600-0490-1750
6 10 070540 CAPSCREW BUTTON 1/2-13NCX1
7 1 079052 RING RET SMALLEY WS-250
MUST BE REMOVED FOR
8 1 079124 RET RING SMALLEY WHM-162 INSTALLATION IN 1400LS
CRUSHER.
335
Crusher Parts Book
WEDGE PLATE ASSEMBLY 1200 LS
336
Crusher Parts Book

NUMBER
1 1 450634 WEDGE PLATE MACHINED
337
Crusher Parts Book

NUMBER
2 1 450059 GEAR RING SPIRAL
3 1 450007 RING SEAL UPPER WEDGE PL
4 1 450008 RING SEAL LOWER WEDGE PL
5 1 456156 BRG RADIAL
6 3 450228 RETAINER RADIAL UPPER
7 1 406017 BRG THRUST
8 1 450023 BRG LOWER THRUST
9 11 450035 CWT LIGHT
10 1 450036 CWT HEAVY
11 4 450088 SHIM CWT 1/8
12 4 450089 SHIM CWT 1/4
13 8 070025 CAPSCREW HEX 3/4 16NF X 2-1/2
14 6 070027 CAPSCREW HEX 1/2 13NC X 1-1/4
15 12 070083 CAPSCREW HEX 7/8 9NC X 2-1/2
16 12 078034 WASHER LOCK 7/8
17 1 450134 BAND WEAR WEDGE PL SEAL RG
338
Crusher Parts Book
FLOATING PLATE W/ INSERTS

NUMBER
1 1 450168 CASTING PL FLOATING
2 2 450312 PL FLOATING UPPER INSERT
339
Crusher Parts Book

NUMBER
3 2 450313 PL FLOATING LOWER INSERT
4 16 070039 CAPSCREW SOC 3/8 16NC X 3/4
5 2 450498 PL FLOATING UPPER INSERT
340
Crusher Parts Book
CONE ASSY
341
Crusher Parts Book

NUMBER
1 1 450695 CONE WITH STEM
2 1 456156 BRG RADIAL
3 1 456132 RETAINER BRG RADIAL CONE
4 4 070032 CAPSCREW HEX 3/8 16NC X 1-1/4
5 1 456304 BAR TORQUE
6 2 079268 PIN, TORQUE BAR
7 2 070189 CAPSCREW SOC 7/8 9NC X 1-3/4
8 1 450018 RING SEAL CONE
10 1 540103 FOAM 1X2X44
11 1 450056 WASHER MANTLE
12 1 456188 BOLT MANTLE
13 1 450257 PIN .500 X 1.000
14 1 450053 MANTLE NUT CAP, 45 INCH
15 1 070105 CAPSCREW SOC 1-1/4 7NC X2-1/2
342
Crusher Parts Book
PINION ASSEMBLY

NUMBER
1 1 450712 PINION SHAFT
2 1 450156 KEY PINION GEAR
3 1 450058 GEAR PINION SPIRAL
4 1 450119 BRG PINION CUP INNER
5 1 450120 BRG PINION CONE INNER
6 1 450710 PINION HOUSING MACHINED
343
Crusher Parts Book

NUMBER
7 1 450117 BRG PINION CUP OUTER
8 1 450118 BRG PINION CONE OUTER
9 1 450111 NUT LOCK PINION BRG
10 1 450067 LOCKNUT SHAFT PINION
11 1 450028 FLINGER INNER
12 1 450027 PL CVR
13 1 450029 FLINGER OUTER
14 1 406275 KEY LOCK RING
15 1 084055 O-RING 6227-74
16 8 078024 WASHER LOCK 3/8
18 1 070142 SETSCREW SOC 3/8 16NC X 3/8
19 1 070626 SETSCREW SOC 1/4-20NC X 7/8
344
Crusher Parts Book
UPPER ASSEMBLY
345
Crusher Parts Book
346
Crusher Parts Book

NUMBER
1 1 450662 BONNET
2 1 450661 BONNET SUPPORT
347
Crusher Parts Book

NUMBER
3 4 450130 WEDGE BOWL CASTING
4 4 076011 NUT JAM ADJUSTING JACK
5 8 450006 CONNECTOR FLUID
6 32 080007 O-RING 2-012
7 8 450109 ASSY CLAMP CYL
8 3 450116 ASSY ADJUSTING JACK
9 1 450714 ASSY ADJUSTING JACK
11 1 450680 TIR ASSEMBLY
12 4 450689 ROTATION STOP BUSHING
13 4 450668 ROTATION STOP BLOCK
14 4 450669 ROTATION STOP PIN
17 8 076088 NUT HEX 1-8 NC G8
18 4 083017 ELBOW - 1/4 TUBE
19 2 083019 TEE - 1/4 TUBE
20 1 083010 5502-04-04
21 180 081001 TUBE .250 X .049 HYD
22 1 083475 FS6801-08-08-NWO
23 4 079052 RING RET SMALLEY WS-250
24 4 079252 RING RETAINING SMALLEY WS-350
25 4 540507 STOP WEDGE LOWER
26 6 083055 CLIP MNTG 1/4 TUBE
27 6 070055 CAPSCREW HEX 1/4 20NC X 3/4
28 6 078022 WASHER LOCK 1/4
29 2 090063 OAKUM DARK
30 1 450717 KIT HOSE UPPER ASSEMBLY
31 1 083038 CPLR DISC QUICK 3050-2 PARKER
32 1 083039 NIPPLE QUICK DIS 3010-2 PARKER
348
Crusher Parts Book
ADJUSTING JACK ASSEMBLY

NUMBER
1 1 450114 RAM ADJUSTING JACK
2 1 450003 CYL WELDMENT ADJ JACK
3 1 450110 GUIDE OUTER ADJ JACK CYL
4 1 450113 GUIDE INNER ADJ JACK CYL
5 1 080013 SEAL ADJ JACK POLY 2500-1
6 1 079006 RING SNAP SH100STPA (5100-100)
7 1 070029 RING RETAINING WH162
349
Crusher Parts Book
ADJUSTING JACK ASSEMBLY

NUMBER
1 1 450114 RAM ADJUSTING JACK
2 1 450715 CYL WELDMENT ADJ JACK
3 1 450110 GUIDE OUTER ADJ JACK CYL
4 1 450113 GUIDE INNER ADJ JACK CYL
5 1 080013 SEAL ADJ JACK POLY 2500-1
6 1 079006 RING SNAP SH100STPA (5100-100)
7 1 070029 RING RETAINING WH162
350
Crusher Parts Book
TIR ASSEMBLY
351
Crusher Parts Book

NUMBER
1 8 450530 TIR CYLINDER ASSEMBLY
2 8 450685 SPHERICAL WASHER TIR CYL
3 32 070121 CAPSCREW SOC 1/2 13NC X 2
4 8 450666 TIR CYL ANCHOR BLOCK
5 8 450686 ROD END TIR CYLINDER
6 8 450687 CYL COLLAR TIR
9 16 076088 NUT HEX 1-8 NC G8
10 4 087090 VALVE RELIEF CARTRIDGE
11 4 087091 PLUG CAVITY T16A-2
12 24 083595 FS6400-12-16-O
13 8 083545 FS6801-12-16-NWO
14 30 083435 6408-H-16-O
15 1 450683 TIR ASSEMBLY HOSE KIT
16 2 083874 FS6400-08-16-O
352
Crusher Parts Book
TIR ASSEMBLY HOSE KIT
353
Crusher Parts Book

1 8 H12R12-12FFSL-12FFSLE45-22.25 HYD HOSE
3500 PSI
2 8 H12R12-12FFSLE45-12FFSLE45-23.25 HYD HOSE
3500 PSI
3 1 H08R16-08FFSLE90S-08FFSL-36 HYD HOSE
3500 PSI
4 1 H08R16-08FFSLE90S-08MFSL-36 HYD HOSE
3500 PSI
UPPER ASSEMBLY HOSE KIT

1 1 H04IJ100-04MNPT-04FNPT-36 HYD HOSE 10000
PSI
354
Crusher Parts Book

2 1 H04R16-08FFSLE90L-04MNPT-36 HYD HOSE 3500 PSI
355
Crusher Parts Book
DECAL LOCATION 1200LS
356
Crusher Parts Book
357
Crusher Parts Book

NUMBER
1 1 090556 PL SERIAL NUMBER LS
2 2 091024 DECAL 1200LS
3 1 090485 DECAL ISO1014/6011 CRSH/LOTO
4 2 090486 DECAL ISO6202/6115/6041 HRG/EP
5 2 090490 DECAL ISO5018 FALL HZD
6 2 090497 DECAL ISO6202 EYE PROT
7 2 090498 DECAL ISO6126 READ OPS MAN
8 2 090499 DECAL ISO1017 PINCH PT
9 1 090504 DECAL ARROW CLOCKWISE ROTATION
10 2 090506 DECAL KPI/JCI 22.00 X 5.00
11 2 090508 DECAL ISO1040 WRNG HIGHPRESS
12 2 090518 DECAL ISO3005 DGR HARD HAT
13 1 090056 DECAL BUILT IN USA SMALL
14 1 090523 DECAL ISO5066 CRSHR MVNG PARTS
15 8 090625 DECAL ISO1017 PINCHPT
16 1 090626 DECAL LUBRICANTS
17 2 090510 DECAL ISO6062 STAY CLEAR
18 1 091023 DECAL CRUSHER WEIGHTS - 200LS
19 2 090489 DECAL ISO6071/6046 LIFT PTS
20 1 091048 DECAL CSS ADJUSTMENT
358
Crusher Parts Book
CONE LIFTING EYE ASSEMBLY

NUMBER
1 1 456533 CONE LIFTING EYE BASE
3 1 070548 CAPSCREW SOC 1-1/4 7NC X 4-1/2
4 1 456534 CONE LIFTING EYE WELDMENT
6 4 070486 CAPSCREW HEX 1/2-13 X 1-3/4 G8
7 1 090647 DECAL ASME BTH-1
8 1 090648 DECAL ISO6014 IMPROP USE RTM
359
Crusher Parts Book
TIR CYLINDER

NUMBER
1 1 450537 PISTON - DUCTILE IRON
2 1 450539 ROD
3 2 070142 SET SCREW SOC 3/8 16NC X 3/8
4 1 450531 BARREL WELDMENT
5 1 450546 SEAL KIT
6 1 450538 ROD GLAND
360

Operacion Servicio y Partes GT200 Cono Movil LS1200 PDF

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GT200 Operation, Service, and Parts Manual

Track Plant Model and Serial Number

Track Plant Model and Serial Number

Factory Installed Liner Configuration

Mantle Liner: 450128SX

The Importance of Record Keeping and Your Warranty....................................................64

Section 5: Maintenance........................................................................ 119

Conveyor Weekly or Every 50 Hours of Operation Schedule..........................................163

Section 6: Plant Parts Book................................................................ 185

Section 7: Crusher Parts Book........................................................... 321

Operation, Service Manual, and Parts Book

Address For Notices

JCI Parts Ordering Information

GT200 Serial Number Plate Location

1200LS Crusher Serial Number Plate Number Location

Track Plant Components

Hazard and Advisory Statements

Hazard Warning Symbol

Arc Flash Safety

Who Must Use Lockout/Tagout?

When Must Lockout/Tagout Occur?

When Can Lockout/Tagout Devices be Removed?

Additional Lockout/Tagout Requirements

TYPE A Battery Isolation Switch

TYPE B Battery Isolation Switch

Know Your Machinery

Be Prepared for Emergencies

Wear Personal Protective Equipment (PPE)

Observe Personal Safety Precautions

Help Prevent Accidents

Avoid Alcohol and Other Drugs

Be Aware of Your Surroundings

Practice Good Housekeeping

Inspect And Maintain Machinery

WARNING: DO NOT EXCEED 55 MPH! — When towing

WARNING: HAZARDOUS VOLTAGE — The electrical

WARNING: CRUSH HAZARD — The trailer can roll

WARNING: CRUSH HAZARD — This equipment drive

WARNING: LOUD NOISE HAZARD — This equipment’s

WARNING: PINCH POINT — This equipment poses a pinch

CAUTION: SLIP HAZARD — The walkways around this

WARNING: FALLING LOAD — This equipment is extremely

WARNING: FALL HAZARD — This equipment is mounted

WARNING: AVOID INJURY — This equipment poses a

WARNING: FALLING MATERIAL HAZARD — Operation

WARNING: AVOID INJURY — Performing service on this

CAUTION: USE RESPIRATORY PROTECTION —

WARNING: AVOID INJURY — Operating this equipment

WARNING: WEAR EYE PROTECTION — This machine’s

WARNING: READ AND UNDERSTAND MANUAL

WARNING: PINCH POINT — This equipment poses a pinch

WARNING: CRUSH HAZARD — This equipment’s tailgate

CAUTION: HOT SURFACE — During normal operation this

CAUTION: EQUIPMENT DAMAGE — Do not run the

WARNING: HIGH PRESSURE FLUID HAZARD — This

WARNING: FLAMMABLE MATERIAL HAZARD — Diesel

WARNING: STAY CLEAR OF MOVING MACHINERY —

WARNING: ROTATING SHAFT HAZARD — The conveyor

WARNING: ENTANGLEMENT HAZARD — Exposed

WARNING: HAND PINCH POINT HAZARD — Conveyor

WARNING: CRUSHING FORCE FROM ABOVE —

DANGER: STAY CLEAR MACHINE STARTS/STOPS

DANGER: FALLING DEBRIS HAZARD — During operation