CH1700 Manual de Usuario PDF

CHIEFTAIN 1700/1700S
PRODUCT USER MANUAL

STD DIESEL / DUAL POWER
OPERATION - INSTALLATION - MAINTENANCE
REVISION 14
© Copyright POWERSCREEN 2011

WARNING WARNING WARNING WARNING WARNING
DO NOT ATTEMPT TO OPERATE THIS PRODUCT UNLESS YOU
HAVE READ AND UNDERSTOOD THESE SAFETY INSTRUCTIONS.
FAILURE TO DO SO WILL INCREASE THE RISK OF INJURY OR
MAY RESULT IN DEATH!
ADVANCED TECHNOLOGY
WASHING - SCREENING
IMPORTANT
POWERSCREEN MACHINERY CAN INCLUDE
OPTIONAL EQUIPMENT AND/OR SPECIAL FEATURES
ADDITIONAL TO THE STANDARD SPECIFICATION.
THESE MAY AFFECT THE INFORMATION GIVEN IN
THIS OPERATORS MANUAL.
LOOK IN SECTION 1 ( ADDITIONAL INFORMATION)

OF THIS MANUAL FOR ANY ADDENDUM WHICH MAY
RELATE TO ADDITIONAL EQUIPMENT OR VARIATIONS
TO THE STANDARD SPECIFICATION.
TAKE NOTE OF ANY VARIATIONS TO THE

STANDARD PROCEDURES AND/OR COMPONENT
SPECIFICATIONS.
ADVANCED TECHNOLOGY
WASHING - SCREENING
IMPORTANT SAFETY NOTICE!

The environment in which the plant will operate contains inherent risks to health and
safety which the operator must take steps to guard against. Dangers from overhead conveyor
discharges, overspill material, vehicle movements, etc., as well as other site related hazards
must be anticipated. Avoid these by carrying out risk assessments before the plant is put into
operation to ensure appropriate exclusion zone measures are put in place and site personnel
safety awareness training has been undertaken.
Follow all applicable safety regulations and recommendations in this manual as appropriate to
your plant and the situation/conditions prevailing at the time.
Read this manual carefully to learn how to operate and maintain your plant correctly. Failure to
do so could result in personal injury or equipment damage.
Consider this manual a permanent part of your plant. Keep it with the plant at all times.
Federal, State, National and Local laws and safety regulations must be complied with at all times
to prevent possible danger to person(s) or property from accidents or harmful exposure.
See also the separate Operation and Maintenance Manual provided for the diesel engine fitted
to your plant and in particular read and observe the instructions within the Safety Section of the
engine manual.
INFORMATION AND ADVICE

If you need any information or advice regarding your CHIEFTAIN contact:-
Northern Ireland: America
Terex Powerscreen Terex Crushing & Screening Inc.
200 Coalisland Rd 11001 Electron Drive
Dungannon Co. Tyrone BT71 4DT Louisville,
Telephone: Kentucky 40299
Main Switchboard: United States of America
+ 44 (0) 2887 740701 Telephone:
Email: aftersales@powerscreen.com Main Switchboard: 001 (502) 736 5200

EC Conformity
This plant is in conformity with the provisions

of the EC Machinery Directive 2006/42/EC
together with appropriate EN Harmonised
Standards and National BS Standards and
Specifications.
Noise Level
HEARING HAZARD
EXCEEDS 90 dB (A)
May cause loss or degradation of hearing

over a period of time.
Wear proper hearing personal protective

equipment.
Dust Generation
INHALATION HAZARD
Death, serious injury or delayed lung

disease may result from breathing dusts
that are generated when certain hazardous
materials are crushed, screened or conveyed
with this equipment.
When dusts are generated by the operation

of this equipment, use approved respiratory
protection, as required by Federal, State and
Local safety and health regulations.
Units of Measure
Within this User Manual figures shown within brackets ( ) after the Metric unit of
measure are approximate conversions from the actual metric measurement of the item
concerned.
Copyright
The copyright of this User Manual is reserved by TEREX POWERSCREEN
This User Manual contains information and technical drawings, which may not be copied,
distributed, altered, stored on electronic media, revealed to others or used for the purpose of
competition, either partially or in its entirety.
The right is reserved to alter any details contained in this manual without notice. Copyright 2011.
Northern Ireland:
Terex Powerscreen
200 Coalisland Rd
Dungannon
Co. Tyrone
BT71 4DT
Telephone:
Main Switchboard: + 44 (0) 2887 740701
Email:aftersales@powerscreen.com
To order additional copies contact your local Dealer.

The Operator must read and understand all the
WARNING instructions in this manual before operating the
machine.
Owners, Users, and Operators:

Terex-Powerscreen appreciates your choice of our product for your application. Our
number one priority is user safety which is best achieved by our joint efforts. We feel
that you can make a major contribution to safety if you as the equipment users and
operators:
1. Comply with EC,OSHA, Federal, State, and Local Regulations.
2. Read, Understand, and Follow the instructions in this and other manuals supplied
with this product.
3. Use Good, Safe Work Practices in a common sense way.
4. Only have trained operators — directed by informed and knowledgeable supervision
— operating this product.
If there is anything in this manual that is not clear or which you believe should be added,
please send your comments to Customer Service,
Help Desk (aftersales@powerscren.com)

Main Switchboard: + 44 (0) 288740701
Fax: + 44 (0) 28874718649
Terex Powerscreen, Dungannon, Co. Tyrone BT71 4DR
Intended use
This product and its approved attachments are designed to be used in Material
Processing applications such as crushing, screening and recycling. Use of this product
in any other way is prohibited and contrary to its intended use.
The safety alert symbol is used to alert you to potential personal

injury hazards. Obey all safety messages that follow this symbol
to avoid possible injury or death.
Contents
01 Additional Information
02 Safety
03 Pictorial Decal Descriptions
04 Plant Specification & Information
05 Plant Operating System (Dual Power)
06 Plant Operating System (Diesel Power)
07 Capacity & Tonnage Calculation
08 Initial Checks
09 Daily Checks
10 Plant Components
11 Trouble Shooting
12 Unloading & Loading
13 Manoeurvring The Plant
14 Plant Setup
15 Plant Operation Controls
16 Plant Shutdown & Emergency Stop
17 Refuelling
18 Maintenance Schedules
19 Servicing Lubrication
20 Servicing The Feeder
21 Servicing Conveyors
22 Servicing Tracks
23 Servicing The Electrical System
24 Servicing The Hydraulic System
25 Changing Air & Water Filters
26 Screen Unit Maintenance

INTENTIONAL SEQUENCE BLANK PAGE
1 - Additional Information Page 1
01 - Additional Information and Features
Powerscreen Int. Dis Ltd., Dungannon, N.Ireland. WWW.POWERSCREEN.COM

1 - Additional Information Page 2

2 - Safety Page 1
02 - Safety Notices and Hazards

2 - Safety Page 2
Safety Information
Important Safety Notices
The environment in which the plant will operate contains inherent risks to health and
safety which the operator must take steps to guard against. Dangers from overhead
conveyor discharges, overspill material, vehicle movements, ecetera, as well as other
site related hazards must be anticipated. Avoid these by carrying out risk assessments
before the plant is put into operation to ensure appropriate exclusion zone measures
are put in place and site personnel safety awareness training has been undertaken.
Follow all applicable safety regulations and recommendations in this manual as
appropriate to your plant and the situation/conditions prevailing at the time.
Read this manual carefully to learn how to operate and service your plant correctly.
Failure to do so could result in personal injury or equipment damage.
Federal, State, National and Local laws and safety regulations must be complied
with at all times to prevent possible danger to persons or property from accidents or
harmful exposure.
See also the separate Operation and Maintenance Manual provided for the diesel
engine when fitted and supplied as a complete Terex Powerscreen product. In
particular read and observe the instructions within the Safety Section of the engine
manual.
This safety section covers a wide variety hazardous situations, (but not necessarily
limited to those described), which may or may not apply to any specific plant use or
installation. They are given for general guidance only to assist the operator in setting
up and maintaining an appropriate regime for the protection of health and safety.
Where the product is supplied for incorporation into plant/equipment designed,
supplied and located by others, or as a replacement product only, Terex Powerscreen
cannot be aware of particular hazards that may be present or might occur and
therefore accept no liability for addressing or resolving these issues.
For further U.K. information also refer to:

http://www.hse.gov.uk/quarries
CALIFORNIA Proposition 65 CALIFORNIA

Warning Proposition 65 Warning
Battery Posts, terminals and related WARNING: Diesel engine exhaust and
accessories contain lead and lead some of it’s constituents are known to
compounds, chemicals known to the the State of California to cause cancer,
State of California to cause cancer birth defects, and other reproductive
and reproductive harm. WASH HANDS harm.
AFTER HANDLING

2 - Safety Page 3
Organisational Measures
Ascertain from the appropriate Authority Replace unreadable or missing labels
and observe all statutory and any with new ones before operating the
other regulations that may apply to the plant. Make sure replacement parts
planned location before operating the include warning or instruction labels
plant. where necessary.
Loose or baggy clothing can get caught
in running machinery. Understand service procedure before
doing work. Keep areas clean and dry.
Where possible when working close to
Never lubricate, clean, service or adjust
engines or machinery, only do so when
machinery while it is moving. Keep
they are stopped. If this is not practical,
hands, feet and clothing clear of power
remember to keep tools, test equipment
driven parts and in running nip-points.
and all other parts of your body well
Disengage all power and operate
away from the moving parts.
controls to relieve pressure. Stop the
For reasons of safety, long hair must engine. Implement lockout procedure.
be tied back or otherwise secured, Allow the machinery to cool.
garments must be close fitting and no Keep all parts in good condition. Ensure
jewellery such as rings may be worn. that all parts are properly installed. Fix
Injury may result from being caught up damage immediately. Replace worn and
in the machinery or from rings catching broken parts. Remove any build up of
on moving parts. grease, oil and debris.
Always wear correctly fitting [EN/ Disconnect battery ground cable before
A.N.S.I. approved] protective clothing. making adjustments on electrical
systems or welding on plant.
Protective clothing includes hard hat,
For the execution of maintenance work,
safety glasses, ear protection, dust
tools and workshop equipment adapted
mask, close fitting overalls, steel toed
to the task on hand are absolutely
boots and a high visibility vest.
indispensable.
You can be injured if you do not obey Never make any modifications,
the safety instructions as indicated on additions or conversions, which might
warning signs. affect safety without the supplier’s
Observe all safety instructions and approval.
warnings attached to the plant. In the event of safety relevant
modifications or changes in the
Keep warnings and instruction labels
behaviour of the plant during operation,
clean to ensure safety instructions and
stop the plant and lock out immediately
warnings attached to the plant are
and report the malfunction to the
always complete and perfectly legible.
competent authority/person.

2 - Safety Page 4
Selection and Qualification of Personnel - Basic Responsibilities
Trained, reliable and authorised personnel only must execute any work on and/or with the
plant. Statutory minimum age limits must be observed.
Work on electrical system and equipment of the plant must be carried out only by a
skilled electrician or by instructed persons under the supervision and guidance of a skilled
electrician and in accordance with electrical engineering rules and regulations.
Only personnel with special knowledge and experience of hydraulic equipment must carry
out work on the hydraulic system.
Safety Instructions Governing Specific Operational Phases Selection
Take the necessary precautions to Special work in conjunction with

ensure that the plant is used only when utilisation of the plant.
in a safe and reliable state. Observe the adjusting, maintenance
Operate the plant only for it’s designed and intervals set out in these operating
purpose and only if all guarding, instructions, except where:
protective and safety orientated
A: Warning, horn/light/gauge or
devices, emergency shut-off equipment,
indicator calls for immediate action.
sound proofing elements and exhausts,
are in all place and fully functional. B: Adverse conditions necessitate more
Before starting the engine ensure it is frequent servicing.
safe to do so. Observe information on the replacement
In the event of material blockage, any of parts and equipment. These activities
malfunction or operational difficulty, may be executed by skilled personnel
stop the plant immediately and lockout. only.
Have any defects rectified immediately.
When the plant is completely shutdown
In-running nip points on moving
for maintenance and repair work, it must
machinery can cause serious injury or
be secured against inadvertent starting
even death.
by:
Do not reach into unguarded machinery.
Your arm could be pulled in and • Switching off the engine and remove
amputated. the ignition key.
Switch off and lockout the plant before • Implementing the lockout procedure.
removing, for adjustment purposes, any
• Attaching warning signs to the plant in
safety devices or guarding.
appropriate positions.
NEVER leave the plant unattended
whilst it is in operation.

2 - Safety Page 5
Carry out maintenance and repair work Always use any walkway/platforms
only if the plant is positioned on stable provided or a safe and secure platform
and level ground and has been secured approved by the regional safety enforcing
against inadvertent movement and authority.
buckling.
Always use an EN/A.N.S.I. approved safety
Never allow unqualified or untrained
harness when reaching any points 2m (7ft)
personnel to attempt to remove or
or more above the ground level.
replace any part of the plant, or anyone
to remove large or heavy components Keep all handles, steps, handrails,
without adequate lifting equipment. platforms, landing and ladders free from
To avoid the risk of accidents, individual dirt, oil, snow and ice.
parts and large assemblies being moved The fastening of loads and instructing of
for replacement purposes should be crane operators should be entrusted to
carefully attached to lifting equipment experienced persons only. The person
and secured. Use only suitable and marshalling and giving the instructions
technically adequate lifting equipment. must be within sight or sound of the
Never work or stand under suspended operator.
loads. After cleaning, examine all fuel, lubricant
Keep away from the feed hopper. There and hydraulic fluid lines for leaks, loose
is risk of serious injury or death due to connections, chafe marks and damage.
the loading of material. Any defects found must be rectified
Keep away from underneath the prod- without delay.
uct conveyor and the conveyor dis-
Any safety devices removed for setting
charge area. There is risk of serious
up, maintenance or repair purposes must
injury or death due to the material falling
be refitted and checked immediately upon
from the conveyor.
completion of the maintenance and repair
Falling from and/or onto a Terex
work to ensure full working order.
Powerscreen plant can cause injury or
even death. Improperly disposing of waste can
Do not climb on the plant. Never use threaten the environment and ecology.
plant parts as a climbing aid. Potentially harmful waste used with Terex
Beware of moving haulage and loading Powerscreen equipment includes such
equipment in the vicinity of the plant. items as oil, fuel, coolant, filters and
For carrying out overhead assembly batteries, etc.
work always use specially designed or Use leak proof trays and sealed containers
otherwise safety-oriented ladders and for drained fluids. Do not use food or
working platforms. beverage containers that may mislead
someone into drinking from them.

2 - Safety Page 6
Do not pour waste onto the ground,

down a drain or into any water source.
Ensure that all consumable items and
replaced parts are disposed of safely
and with minimum environmental
impact.
Always ensure that any safety fitment
such as locking wedges, securing
chains, bars or struts are utilised
as indicated in these operating
instructions.
Particularly make sure that any part
of the plant raised for any reason is
prevented from falling by securing in a
safe reliable manner.
Never work under unsupported
equipment.
Never work alone.
Diesel fuel is highly flammable.
Never remove the filler cap, or refuel,
with the engine running.
Never add gasoline or any other fuels
mixed to diesel because of increased
fire or explosion risks.
Do not smoke or carry out maintenance
on the fuel system near naked lights
or sources of sparks, such as welding
equipment.
Use of non-approved structures like
walkways or platforms etc. in the
vicinity of a Powerscreen plant is very
dangerous and could lead to serious
injury or even death through falling and/
or entanglement with the plant.
Do not use any unauthorised structures.

2 - Safety Page 7
Warning of Special Dangers

Electric Energy
Use only original fuses with the The electrical equipment of the plant
specified current rating. Switch off the is to be inspected and checked at
plant immediately if trouble occurs in regular intervals. Defects such as loose
the electrical system. connections or scorched or otherwise
damaged cables must be rectified
Plants with high voltage electrical
immediately.
equipment must be suitably earth
Necessary work on live parts and
bonded by a qualified electrician prior to
elements must be carried out only in the
activating the main isolator switch.
presence of a second person, who can
When working with the plant, maintain cut off the power supply in the case of
a safe distance from overhead electric danger by actuating the emergency shut
lines. If work is to be carried out off or main power switch. Secure the
close to overhead lines, the working working area with a red and white safety
equipment must be kept well away from chain and a warning sign. Use insulated
them. Check out the prescribed safety tools only.
distances. Before starting work on high voltage
If your plant comes into contact with a assemblies and after cutting out the
live wire: power supply, the feeder cable must
be grounded and components such
• Warn others against approaching and
as capacitors short-circuited with a
touching the plant.
grounding rod.
• Have the live wire de-energised. Tracked plants are wired with negative
Work on the electrical system or earth. Always observe correct polarity.
equipment may only be carried out by Always disconnect battery leads before
a skilled and qualified electrician or by carrying out any maintenance to the
specially instructed personnel under electrical system.
the control and supervision of such If welding is to be carried out on the
an electrician and in accordance with plant it is essential that the power pack
applicable electrical engineering rules. is isolated, refer to Servicing Safety &
Precautions.
If provided for in the regulations,
The battery contains sulphuric acid,
the power supply to parts of plants
an electrolyte which can cause severe
and plants, on which inspection,
burns and produce explosive gases.
maintenance and repair work is to be
Avoid contact with the skin, eyes or
carried out, must be cut off. Before
clothing.
starting any work, check the de-
energised parts for presence of power
and ground or short circuit them in
addition to insulating adjacent live parts
and elements.
2 - Safety Page 8
Gas, Dust, Steam, Smoke and Noise Hydraulic and Pneumatic Equipment
Always operate internal combustion Only persons having special knowledge and
engines and fuel operated heating systems experience in hydraulic systems may carry
only out of doors or in a well-ventilated out work on hydraulic equipment.
area. Check all lines, hoses and screwed
Before starting the plant in enclosed connections regularly for leaks and obvious
areas, make sure that there is sufficient damage. Repair damage immediately.
ventilation. Splashed oil may cause injury and fire.
Observe the regulations in force at the
Depressurise all system sections and
respective site.
pressure pipes (hydraulic system,
Dust found on the plant or produced
compressed air system) to be removed in
during work on the plant should be
accordance with the specific instructions for
removed by extraction, not blowing.
the unit concerned before carrying out any
Dust waste should be dampened, placed
repair work.
in a sealed container and marked, to
ensure safe disposal. Hydraulic and compressed air lines must
Carry out welding, flame cutting and be laid and fitted properly. Ensure that no
grinding work on the plant only if this has connections are interchanged. The fittings,
been expressly authorised, as there may lengths and quality of the hoses must
be a risk of explosion and fire. comply with the technical requirements.
Before carrying out welding, flame cutting Always practice extreme cleanliness
and grinding operations, clean the plant servicing hydraulic components.
and its surroundings from dust and other
Hydraulic fluid under pressure can penetrate
flammable substances and make sure
the skin causing serious injury.
the premises are adequately ventilated as
there may be a risk of explosion. Always use a piece of cardboard to check
Always ensure that operators are provided for leaks. Do not use your hand.
with ear defenders of approved pattern If fluid is injected under the skin, it must be
and that these are worn at all times when surgically removed or gangrene will result.
the plant is operating.
Get medical help immediately.
Ensure operators wear a suitable face
mask where exposed to possible harmful Always relieve pressure from the hydraulic
effects of air pollution of any kind. system before carrying out any kind of
maintenance or adjustment.

2 - Safety Page 9
Hazardous Substances When travelling on public roads, ways

and places, always observe the valid
Ensure that correct procedures are
traffic regulations and, if necessary,
formulated to safely handle hazardous
ensure beforehand that the plant is
materials by correct identification, labelling, in a condition compatible with these
storage, use and disposal. regulations.
All hazardous materials must be handled
strictly in accordance with the manufacturers
instructions and all applicable regulations
observed at all times.

Transporting, Manoeuvring and Re-commissioning
The plant is remote controlled and may start

without notice. Stay clear of the plant.
The plant must be loaded and transported
only in accordance with the operating
instructions.
For manoeuvring the plant, observe the
prescribed transport position, admissible
speed and itinerary.
Use only appropriate means of transport
and lifting equipment where applicable of
adequate capacity.
The re-commissioning procedure must be
strictly in accordance with the operating
instructions.
Before travelling with the plant, check that
the braking and any signalling and lighting
systems are fully functional.
Before setting the plant in motion always
check that the accessories have been safely
stowed away

2 - Safety Page 10
WORK AREA SAFETY
1. Keep the work area as neat and as clean as practical.
2. Keep all warning and caution signs clear and up to date
3. Make certain all electrical equipment is properly grounded.
4. Store hazardous materials in restricted access areas and mark them clearly.
5. Do not smoke or allow smoking near flammable fuels or solvents. Use non-flammable
solvents for cleaning parts and equipment.
6. Make certain enough ventilation is present to run engines safely. Do not start an engine in
an enclosed space without properly vented exhaust. Exhaust fumes from gasoline or diesel
engines can kill!
7. Avoid electrical and static sparks and any open flame while handling, storing, moving or
pouring fuels, electrolytes for batteries, hydraulic fluids or coolants.
8. Check for leaks in tanks or tubing with flashlights or other proper equipment. Never use
an open flame to check for leaks.
9. Know where fire extinguishers and other fire suppression equipment are located.
Learn how to use them.
10. Be alert and wary around any pressurized system: hydraulic or air. High pressure gases
and oils can be very dangerous. Know your equipment and operate it properly.
11. Be alert and watch for pinch points, closing mechanisms, and falling parts when working
on or around any machinery. Keep hands and tools clear.
12. Clean and properly labeled tools are safer tools. Keep your equipment and tools in order.
13. Always use hoisting equipment for heavy loads. Regularly check hooks, cables, shackles
and chains for stretch and wear. Never overload hoists, cranes or other lifting devices.
14. Keep your equipment clean and free of dirt and grease so it can be checked for loose,
cracked or broken parts. Replace defective parts as soon as they are discovered.
15. For questions concerning accumulators, which are pressure-containment vessels,

contact your Terex Powerscreen distributor. Malfunctioning valves or poor maintenance
practices can result in build-up of extremely high hydraulic and/or pneumatic pressures
inside the accumulator.

2 - Safety Page 11
HYDRAULIC SAFETY
1. Never disable or alter any hydraulic circuit or component without consulting with
Powerscreen or your local dealer.
2. Any work carried out on a hydraulic system must be performed by an engineer with
special knowledge and experience in hydraulics.
3. Relieve all pressure in hydraulic system by returning controls to the neutral position.
Turn machine off and isolate power supply before any pipes, filter caps, filters or hydraulic
fittings are disconnected or removed.
4. Ensure replacement hydraulic components are the same standard and quality as the
original parts. Ensure they are fitted correctly.
5. Beware of hydraulic oil leaks. Hydraulic fluid under pressure can penetrate the skin or
damage eyes. Fluid leaks under pressure may not be visible. Use a piece of cardboard to
find leaks but do not use bare hand.
6. Wear safety goggles for eye protection. If fluid enters skin or eye, get immediate medical
attention.
7. Replace any damaged hydraulic pipe. Leaks can cause fires. Always ensure a
replacement pipe has the same specification as the original pipe, length, fittings, orientation
and diameter. Ensure pipes are laid and fitted correctly.
8. Do not exceed safe limits. Never set a pressure relief valve to a pressure higher than that
set at the factory.

2 - Safety Page 12
ELECTRICAL AND ENGINE SAFETY
1. Never work on the electrical system of any equipment unless you are thoroughly familiar
with system details.
2. Work on the electrical system must only be carried out by a qualified electrician.
3. If machine is electric-hydraulic or direct electric drive, the ‘mains’ electrical supply to the
machine should always be isolated by unplugging/uncoupling the ‘mains’ power socket.
4. The electrical equipment of the machine should be inspected at regular intervals.

Damaged cables or loose connections must be corrected immediately. Use only original
fuses with the specified current rating.
5. It is recommended that an earth leakage safety switch be fitted in the supply line to the
power point on site. Special care should be taken to ensure that earth wires are correctly
connected.
6. Disconnect the battery ground leads whenever performing any electrical maintenance or
servicing to your engine.
7. Battery posts, terminals and related accessories contain lead and lead compounds,
chemicals known to the State of California to cause cancer and reproductive harm. Wash
hands after handling.
8. Never short across the starter terminals of a battery as this can cause a fire and could
also damage the electrical system.
9. Battery electrolyte contains acid and can cause serious injury. Avoid contact with skin
and eyes. Use gloves and protective glasses.
10. Diesel engine exhaust emissions contain products of combustion which may be harmful
to your health. Always operate the machine in a well ventilated area and if operating in an
enclosed area, vent the emissions outside.
11. Do not touch any part of the engine or exhaust system. Allow the engine and exhaust to
cool before performing any repair or maintenance.
12. Never fill the fuel tank with the engine running, while smoking or when near an open
flame.
13. Never overfill the tank or spill fuel. If fuel is spilled, clean it up immediately.

2 - Safety Page 13
SAFETY BEFORE AND DURING OPERATION
Only qualified and trained personnel should attempt to operate this machinery.
1. Read and understand the Operators Manual before you start the machine.
Study the DANGER, WARNING, CAUTION and IMPORTANT safety signs on your machine.
2. Check your machine and have all systems in good operational condition.
- Check for broken, missing or damaged parts.Replace and make necessary repairs.
- Ensure all safety guards and emergency stops are fitted and in working order.
- See ‘Daily Maintenance’ for more detailed checklist before start-up.
3. Before starting, walk completely around the machine. Make sure no one is under it, on it
or close to it. Let other workmen and bystanders know you are starting up and do not start
until everyone is clear of the machine.
4. During operation, do not climb onto, over or under moving conveyor belts and rollers.
Always use ladders, steps and walkways when mounting and dismounting.
5. Hole alignment on mechanical supports must be checked and secured with pins provided
and in accordance with safety signs.
6. Never check the tension of ‘V’ belts, drive chains and conveyors when machine is
running.
7. Never work or stand beneath machinery or attachments as it is raised or lowered.
8. Never work or stand beneath machinery as they are being loaded with and/or discharging
material.
9. Follow safe operating practices. Operate the machine controls smoothly. Avoid sudden
stops, starts or changes in direction.
10. Only use emergency stop buttons or emergency stop lines (if fitted) in emergency
situations or during safety drills.
11. After each day’s operation, always run the machine dry; never leave material in the
beltfeeder on conveyor belts or screenbox. Starting a machine with a full load will cause
strain problems in your machine.

2 - Safety Page 14
SAFETY BEFORE AND DURING MAINTENANCE
Maintenance should only be carried out by trained and qualified personnel.

1. Whenever maintenance or service is being carried out a minimum of two (2) persons
should be present at all times. NEVER WORK ALONE.
2. Prepare yourself. Wear a hard hat, safety goggles, hearing protection and other protective
equipment as required by job conditions. Do not wear loose clothing or jewellery that can
catch on controls or moving parts. Long hair must be tied back.
3. Prepare the machine. Move the machine onto a level surface and apply parking brakes
and/or wheel chocks. Shut off the engine and remove the key. Relieve all hydraulic pressure
by returning controls to neutral. Secure all hydraulically operated attachments with pins
provided.
4. Isolate all electrical supplies to the machine before starting any maintenance work.
5. Never attempt repairs or adjustments to the machine while it is running. (Exempt to this
rule: Belt tracking adjustments are only possible during working process - see Maintenance
Section Belt Tracking).
6. Remove only guards or covers that provide access. Wipe away excess grease and oil.
7. Never leave guards off or access doors open when unattended. Keep bystanders away if
access doors are open.
8. When working beneath raised equipment, always use blocks, jack-stands or other rigid
and stable supports. Never work under unsupported equipment.
9. Performing work above 6ft-6” (2m) always use an approved (EN/ANSI) safety harness.
Always use walkways and platforms provided or a safe secure platform approved by the
machine operators management. Do not use any unauthorised or unsafe platforms.
10. Never operate any type of engine without proper ventilation – EXHAUST FUMES CAN
KILL. (See Electrical and Engine Safety for more detailed checklist).
11. Checking for hydraulic leaks. Beware hydraulic fluid under pressure can penetrate
the skin or damage eyes. Fluid leaks under pressure may not be visible. Use a piece of
cardboard to find leaks but do not use bare hand.
12. Wear safety goggles for eye protection. If fluid enters skin or eye, get immediate medical
attention. (See Hydraulic Safety for more detailed checklist).
13. Clean or replace damaged, missing or painted over safety signs that cannot be read.
14. Rotating and moving parts must be inspected during maintenance and replaced if
cracked or damaged. Excessively worn or damaged parts can fail and cause injury or death.
15. After maintenance, tighten all bolts, fittings and connections.
Install all guards, covers and shields. Replace or repair any damaged ones. Refill and
recharge pressure systems with recommended fluids.
Start the engine and check for leaks. Operate all controls and make sure the machine is
functioning properly. After testing, shut down, check the work you performed (any missing
cotter pins, washers, locknuts, etc.)?
Recheck all fluid levels before releasing machine for operation.

2 - Safety Page 15
SAFETY BEFORE AND DURING TRANSPORT
1. The preparations to move equipment by articulated lorry should be supervised by a

minimum of two (2) persons.
2. Ensure persons transporting the machine adhere to all Safety Signs and procedures.
3. Before transportation on public roads, ensure the machine has been properly secured
with no loose material left in or on the machine.
On Wheeled Machine
4. Ensure wheel nuts are torqued between 500 to 550 ft.lb (69 to 76 kg.m) prior to transport.
5. Check your tyres for:- - correct pressure
- cuts or bulges
- nails or spikes
- uneven or excessive wear
- missing valve caps
6. Check your wheels for:- - damaged rims
- missing or loose wheel nuts or bolts
- obvious misalignment
7. Have cuts or punctures repaired by authorised personnel before adding air.
Beware an over-inflated tyre can explode and cause serious injury or death.
8. Extreme caution is required when transporting machinery on site. Soft or uneven ground
may cause accidents.
9. When transporting a machine on a truck or trailer, know the overall height to avoid
contacting overhead obstructions such as bridges, power lines etc. (See Plant Spec and
Info, Section 4.0)

Position of E-STOPS - DRY OTION 2 & 3 Deck
FRONT OF MACHINE
CHASSIS (LHS ONLY)
EMERGENCY STOP
2 - Safety
REAR OF
MACHINE
FRONT OF MACHINE
WALKWAY
RIGHT HAND & LEFT

HAND SIDE OF MACHINE
EMERGENCY STOP
EMERGENCY STOP
Page 16

EMERGENCY STOP
Position of E-STOPS - RINSER OPTON
FRONT OF MACHINE
CHASSIS (LHS ONLY)
EMERGENCY STOP
FRONT OF MACHINE
WALKWAY
2 - Safety
REAR OF
MACHINE
EMERGENCY STOP
RIGHT HAND SIDE +LEFT
HAND SIDE OF MACHINE
EMERGENCY STOP
Page 17

EMERGENCY STOP
2 - Safety Page 18
Machine Safety Decals
Please see Page 31 which outlines the amount and location of each safety decal on
this machine.
ANSI ISO
ELECTROCUTION
HAZARD
Death or injury will result from
contacting electric power lines.
Be aware of overhead cables

when folding machine.
KEEP CLEAR
Maintain required clearance.
Always contact the electric power
line owner.
The electric shall be disconnected
or the power lines moved or
insulated before machine opera-
tions begin.
ENTANGLEMENT HAZARD
Contact with moving belt will result
in serious injury or death.
STAY CLEAR of moving belt.

DO NOT operate this machine without
all guards and covers in place. SWITCH
OFF and LOCKOUT before adjusting or
servicing the machine.

2 - Safety Page 19
Machine Safety Decals - CONTINUED
ANSI ISO
Improper operation or maintenance can

result in serious injury or death.
Read and understand operator‘s manual and

safety signs before using or maintaining machine.
If you do not understand the information in the
manuals, consult your supervisor, the owner or the
manufacture.
INJECTION HAZARD
Escaping fluid under pressure can
penetrate skin, causing serious injury.
Relieve pressure befor disconnecting hy-

draulic lines. Keep away from leaks and pin
holes. Use a piece of caedboard to search
for leaks. Do not use hand. If fluid is injected
under skin, get medical help immediately.

2 - Safety Page 20
ANSI ISO
CRUSHING HAZARD
Serious injury can result from contact with
moving outriggers.
Keep clear of moving outriggers.
FALLING MATERIAL HAZARD

Do not walk near material discharge areas. You
are at risk of serious head injury or death.
KEEP CLEAR of hopper dring operation.

2 - Safety Page 21
ANSI ISO
FALL HAZARD
Falling from this machine can result in
serious injury or even death.
DO NOT climb on the machine. Use a

suitable lifting platform to service the
machine.
Vehicle control can be affected by impro-

per setup of vehicle.
PRIOR TO TRANSPORT
Check tyre pressures.

Check wheel nut torque.
Recheck wheel nut torque
every 150 miles (200km).
Connect and check
braking system.
Refer to operators manual to correct tyre
pressures and torque values.

2 - Safety Page 22
ANSI ISO
CRUSH HAZARD
Contact with moving components can
result in serious injury.
Keep hands clear of openings while

machine is running. SWITCH OFF and
LOCKOUT machine before maintaining or
servicing.
ELECTROCUTION HAZARD
Contact with hazardous voltage will result
in serious injury or death.
DISCONNECT, LOCKOUT power before

servicing. Only authorized personnel may
service this equipment. Read all manuals
prior to operation.

2 - Safety Page 23
ANSI ISO
HEARING HAZARD
Exposure to loud noise could result in
serious hearing loss.
Wear proper hearing personal protective

equipment.
EXPLOSION / BURN HAZARD

Death, burns, blindness or serious injury can
result from release of pressurized liquids or
due to ignition of explosive gases and corrosive
acid.
Keep all open flames and sparks away. Wear

personal protrctive equipment, including shiel,
gloves and long sleeve shirt. Consult operation
and maintneance manual for jump starting
instructions. Read all manuals prior to operation.

2 - Safety Page 24
ANSI ISO
EMERGENCY STOP
PRESS TO ENGAGE
TWIST TO RESET
FLYING MATERIAL HAZARD

May cause loss or the degradation of eye
sight.
Wear proper eye personal protective

equipment.

2 - Safety Page 25
ANSI ISO
CRUSH HAZARD
Contact with folding conveyors can result
in death or serious injury.
Keep clear of conveyors when folding for

transport or opening to working postion.
Read all manuals prior to operation.
AUTOMATIC STARTUP
Conveyors and related equipment
may start at any time without warning.
SERIOUS INJURY or DEATH could result.
Unauthorized persons prohibited.

SWITCH OFF, and LOCKOUT all energy
sources prior to performing maintenance
or servicing.

2 - Safety Page 26
FLYING MATERIAL HAZARD

SERIOUS INJURY or DEATH can result if
struck by material.
Platform is for maintenance and servicing

only. DO NOT stand on walkway while
machine is in operation. SWITCH OFF and
LOCKOUT machine before maintaining or
servicing.
INHALATION HAZARD
Death, serious injury or delayed lung
disease may result from breathing
hazardous dust.
Use dust suppresion or dust collection equipment

to minimize the dust exposure during operation of
this machine. Use approved respiratory protection to
avoid inhalation of dusts, when required by Federal,
State and local safety health regulations. Contact
your employer to establish whether these regulations
require that you use respiratory protection.

2 - Safety Page 27
ANSI ISO
CUTTING HAZARD
Contact with knives in trommel drum will
result in death or serious injury.
Stay clear of sharp knived in trommel drum.

SWITCH OFF and LOCKOUT machine
before maintaining or servicing.
CRUSH HAZARD
Machine movement can cause serious
injury or death.
Keep clear of moving machine.

2 - Safety Page 28
ANSI ISO
EXPLOSION HAZARD
May cause severe injury or death due to
ignition of explosive gasses.
Keep welding sparks away from the

battery area. Remove battery if required.
BURN HAZARD
Contact with hot surfaces can result in
serious injury or death.
KEEP CLEAR. Allow surfaces to cool

before servicing.

2 - Safety Page 29
ANSI ISO
Performing maintenance or adjustments

on powered machines can result in serious
injury or death.
SWITCH OFF and LOCKOUT all energy

sources prior to performing maintenance or
adjustments.
Safety Signs
Maintenance
Replace any missing or damaged safety

signs.
Keep operator safety in mind at all

times. Keep safety signs clean using
mild soap and water only. Do not use
solvent based cleaners because they
may damage the safety signs.

Position of warning labels (Rear view) 2 - Safety Page 30

Position of warning labels (LHS view) 2 - Safety Page 31

Position of warning labels (RHS view) 2 - Safety Page 32

Position of warning labels (Rinsre catchbox)
Note : Rinser unit has a catch box instead of tail conveyor. All other decal position are located in the
same position as the dry units
2 - Safety
1502
1502
Left & Right Side Of Machine
Page 33

2 - Safety Page 34

3 - Pictorial Decal Descriptions Page 1
03 - PICTORIAL DECAL DESCRIPTIONS

DRIVE CONTROL BANK 2-DECK
DFC2D DVMCT2D DSBTCT2D DLRSC2D
REPLACES
DRIVE DRIVE VIB. DRIVE DRIVE SIDE

FEEDER GRID & MAIN SCREENBOX & CONVEYORS
CONVEYOR TAIL
CONVEYOR
BLANK
PORT
Hold Hold Hold Hold
ENGAGE ENGAGE
TRACKS TRACKS
334 641 640 642
DRIVE
SHREDDER
REPLACES Hold
214
DSH OPTIONAL
OPTIONAL

DRIVE CONTROL BANK 3-DECK
REPLACES
DRIVE DRIVE VIB. DRIVE DRIVE SIDE

FEEDER GRID & MAIN SCREENBOX & CONVEYORS
CONVEYOR TAIL
CONVEYOR
BLANK
PORT
Hold Hold Hold Hold
ENGAGE ENGAGE
TRACKS TRACKS
334 641 640 642
DRIVE
SHREDDER
REPLACES Hold
214
OPTIONAL OPTIONAL

AUXILIARY CONTROL BANK
CHFJL CHMCSRL VGRL SRL

OPTIONAL
REPLACES
RAISE RAISE MAIN RAISE VIB. RAISE

JACKING CONVEYOR GRID RAISE SHREDDER.
LEGS
Hold Hold Hold Hold
LOWER LOWER LOWER VIB LOWER

JACKING MAIN SHREDDER.
LEGS CONVEYOR
361 320 (329) 336 325
OPTIONAL

DIRECT FEED OPTION DRIVE CONTROL BANK
DAS DMCT2D DSBTCT2D DLRSC2D

OPTIONAL
REPLACES
DRIVE DRIVE MAIN DRIVE DRIVE SIDE

AUXILIARY SCREENBOX
CONVEYOR CONVEYORS
CIRCUT & TAIL
CONVEYOR
BLANK
Hold Hold Hold
Hold PORT
ENGAGE ENGAGE
TRACKS TRACKS
566 699 640 642
OPTIONAL

DIRECT FEED OPTION AUXILIARY BANK
ASRL CHMCSRL
REPLACES
AUXILIARY RAISE MAIN

CONVEYOR
RAISE
Hold Hold
LOWER LOWER
MAIN
CONVEYOR
535 320 (329)

FLOW CONTROL MAIN POWERUNIT
CHFCPU3
REPLACES
017 379 335

AUXILIARY CIRCUIT MACHINE FLOW CONTROL POWER UNIT
ASFC CHLRSCFC
REPLACES
567 379 335

RH/S SIDE CONVEYOR OPEN CLOSE + CONVEYOR CONTROL
CHRSCOC CHTCRL CHTCHS
REPLACES
OPEN OUT RAISE TAIL RAISE TAIL

Rhs CONVEYOR CONVEYOR
CONVEYOR END SECTION
Hold Hold Hold
CLOSE IN LOWER TAIL LOWER TAIL

Rhs CONVEYOR CONVEYOR
CONVEYOR END SECTION
357 643(646) 638

RINSER OPTION RH/S SIDE CONVEYOR OPEN CLOSE + CATCHBOX RAISE
CHRSCOC CHCBRL
REPLACES
RH SIDE TAIL CONVEYOR

CONVEYOR /
CATCHBOX
OPEN OUT RAISE
BLANK
HOLD HOLD PORT
CLOSE IN LOWER
357 1199

SCREENBOX RAISE LOWER + LH/S CONVEYOR OPEN CLOSE 2-DECK
CHSBRL2D CHLSCOC2D
REPLACES
RAISE OPEN OUT Lhs

SCREENBOX CONVEYOR
Hold Hold
LOWER CLOSE IN Lhs

SCREENBOX CONVEYOR
340 356(343)

SCREENBOX RAISE LOWER + LH/S CONVEYOR OPEN CLOSE + AUXILAIRY

CONVEYOR CONTROL 3-DECK
CHA4B
REPLACES
RAISE OPEN OUT Lhs AUXILARY AUXILARY

SCREENBOX CONVEYOR CONVEYOR CONVEYOR
UPPER RAM LOWER RAM
FOLD OUT FOLD OUT
Hold Hold Hold Hold
LOWER CLOSE IN Lhs FOLD IN FOLD IN

SCREENBOX CONVEYOR
340 356 1360 1370

ROLLIN BOGIE OPTION JACKING LEGS
CH17RBJL
REPLACES
FRONT FRONT BACK JACKING BACK JACKING

JACKING LEGS JACKING LEGS LEGS LEGS
(LHS) (RHS)
EXTEND EXTEND EXTEND EXTEND
Hold Hold Hold Hold
RETRACT RETRACT RETRACT RETRACT
172 173 170 171
ROLLIN BOGIE OPTION - 4 BANK

RINSER OPTION WITH SPRAY BARS
IMPORTANT IF TOP DECK

SPRAY BARS ARE FITTED
CARE MUST BE TAKEN
WHILST MOVING THE
SCREENBOX AND MAIN
CONVEYOR
RINSER ONLY
CHTSBCMT
IMPORTANT REMOVE
TOP DECK SPRAY BARS
BEFORE LOWERING
MAIN CONVEYOR AND
SCREENBOX FOR
TRANSPORT
RINSER ONLY
CHRSBFTP

ANTI ROCK STAYS REMOVE AND REPLACE + TAIL CONVEYOR IMPACT WARNING
1 2 3
IMPORTANT
SEPERATOR ANTI-ROCK
STAYS MUST BE REMOVED
BEFORE OPERATING
1 2 3 MACHINE
ARSRAR
IMPORTANT
WHEN RAISING TAIL
CONVEYOR BE CAREFUL
NOT TO CAUSE IMPACT
WITH WALKWAY
CHTCIW

ITEMS MARKED WITH YELLOW CIRCLES + WHEEL MACHINES CHECKS

WHEN TRANSPORTING
1 2 3
ITEMS MARKED WITH A
4 YELLOW CIRCLE MUST
BE REMOVED/REPLACED
BEFORE FOLDING OUT/IN
5 6
FOR WORKING POSITION
AND TRANSPORT
POSITION
RPYCBF
WARNING
ON WHEEL MACINES
WHEN TRANSPORTING
WHEEL NUTS SHOULD
BE CHECKED EVERY 150
150
MILES
WNMC

EXTEND AND RETRACT SCREEN TENSION RAMS + BATTERY ISOLATOR SWITCH
EXTEND
SCREEN
TENSION RAMS
HOLD
RETRACT
SCREEN
TENSION RAMS
217
CHSBMT
BATTERY ISOLATOR SWITCH

ISOLATE POWER AND LOCK
MACHINE OUT BEFORE
MAINTENANCE IS CARRIED OUT
BIS

HYDRAULIC OIL, DIESEL OIL AND COLD START AID
HYDRAULIC OIL
HO
DIESEL OIL
DL
COLD START AID
CSA
BALLVALVE OPEN + CLOSED, ENGINE OIL ONLY AND HYDRAULIC OIL LEVEL
BALLVALVE OPEN + CLOSED
BV
ENGINE OIL ONLY
EO
IMPORTANT DO NOT OVER FILL

HYDRAULIC OIL TANK
HOL
CHECKAND DRAIN DIESEL WATERTRAP DAILY, SCREENBOX SPEED AND

MACHINE MUST BELEVEL AT ALL TIMES
IMPORTANT CHECK AND DRAIN

DIESEL WATERTRAP DAILY
DLWT
SCREENBOX SPEED
SBS
IMPORTANT MACHINE MUST BE

LEVEL AT ALL TIMES
ML
AIR INTAKE AREA MUST BE KEPT CLEAR AT ALL TIMES AND SCREENBOX
GREASING
AIR INTAKE AREA MUST BE

KEPT CLEAR AT ALL TIMES
AI
GREASING SCREENBOX
13 GREASE GUN
STROKES EVERY 50 IS O V G 220
WORKING HOURS
50
X
SBG1

VIBRATING GRID GREASING
VIBRATING GRID GREASING

SCHEDULE
IS O V G 220
25 X GREASE GUN PUMPS EVERY
50 WORKING HOURS
50
X
VGG1

4 - Plant Specification & Information Page 1
04 - Plant Specification and Information

04 - Specification & Plant Information
4.1 General information.........................................................................................3
4.2 Nomenclature and technical data..............................................................4
4.2.1 Feeder unit (A)....................................................................................................6
4.2.2 Main conveyor (B).............................................................................................7
4.2.3 Screen unit (C)....................................................................................................7
4.2.4 Side conveyors (D)............................................................................................8
4.2.5 Tail conveyor (E).................................................................................................8
4.2.6 Powerunit (F)......................................................................................................8
4.2.7 Hydraulics (G).....................................................................................................9
4.2.8 Chassis (H)......................................................................................................... 10
4.2.9 Shredder (I)....................................................................................................... 10
4.2.10 Auxiliary conveyor (J)................................................................................... 11
4.2.11 Catchbox (K)..................................................................................................... 10
4.2.12 Washbox (L)...................................................................................................... 10
4.3 Machine drawings......................................................................................... 11
4.4 Noise levels....................................................................................................... 17

4.1 General information
Machine..............................................................: Mobile screening machine

Type......................................................................: Chieftain 1700/1700S
Total weight (3 deck track, 12ft grid)........: 29,400 kg (32.4 US tons)
4.2 Nomenclature and technical data - DRY OPTION
D B E
J C
I
D
A H F
Id Construction unit Component
A Feeder unit Reject grid

Hopper
B Main conveyor
C Screen unit Screen box

Mesh deck
D Side conveyors
E Tail conveyor
F Power unit Engine
G Hydraulics Not shown
H Chassis Tyres/Tracks
I Shredder Not shorn
J Auxiliary conveyor 3 Deck only

4.2 Nomenclature and technical data - RINSER OPTION
D B A
C
K
J
L H D
Id Construction unit Component
A Feeder unit Reject grid

Hopper
B Main conveyor

C Screen unit Screen box
Mesh deck
D Side conveyors
F Power unit Not shown
G Hydraulics Not shown
H Chassis Tracks
I Shredder Not shown
J Auxiliary conveyor 3 Deck only
K Catchbox
L Washbox
4.2.1 Feeder unit (A)
4.2.1.1 Reject grid

Loading Width 12ft........................ 4.3m x 1.8m (14’1’’ x 5‘11“)
Loading Width 14ft........................ 4.9m x 1.8m ( 16’1’’ x 5‘11“
Grid bar aperture............................ 102mm (4’’)
Grid area 12ft................................... 3.57m x 1.8m (11’9’’ x 5’11“)
Grid area 14ft................................... 4.18m x 1.8m (13’9’’ x 5’11“)
Grid angle.......................................... 0° - 16°
Weight of grid bars........................ 700 kgs
Radio transmitter............................ 27A 12 volt battery
4.2.1.2 Vibrating grid
Loading Width................................. 3.57m x 2.14m (11’9’’ x 7“)
Grid bar aperture............................ 102 mm (4“)
Screen area....................................... 3.05m x 2.14m (10‘ x 7‘)
Grid angle.......................................... 10o - 20o (4 Positions)
Weight................................................ 4000 kgs
4.2.1.3 Feed hopper
Opening size.................................... 3.57m x 1.8m (11’9’’ x 5’11“)
Capacity (inc. grid) Track Machine 7.0 cu m (9.15 cu yds)
Capacity (inc. grid) Wheel Machine 7.0 cu m (9.15 cu yds)
4.2.1.4 Feeder conveyor
Belt width.......................................... 1050 mm (42’’)
Type..................................................... 3 ply
4.2.2 Main conveyor (B)
Belt width 1050mm (42’’)

Degree of incline:
Working Angle ....................18o - 260 Max.
4.2.3 Screen unit (C)
4.2.3.1 Screenbox
Width.................................. 1.5 m (5’)
Length..................................... 4.88 m (16’)
Weight .................................... 3500 kgs
Screen Angle .........................25o - 30o
3 Deck screenbox configuration

4.8m x 1.5 (16’ x 5’) Top & middle decks
4.3m x 1.5 (14’ x 5’) Bottom deck
2 Deck screenbox configuration

4.8m x 1.5 (16’ x 5’) Top deck
4.3m x 1.5 (14’ x 5’) Bottom deck
4.2.3.2 Screen meshes (available in a range of sizes)
Lightest mesh weight .......... 20 kgs

Heaviest mesh weight......... 150 kgs
4.2.4 Side conveyors (D)
Belt width..................................................... 650mm (26’’)

Degree of incline:
Working Angle............................................ 22o
4.2.5 Tail conveyor (E) - DRY UNIT ONLY
Belt width..................................................... 1200mm (48’’)
Degree of incline:
VariableWorking Angle . .........................25o (max.)
4.2.6 Power unit (F)
4.2.6.1 Engine
Refer to “Capacities- fluids“ Section 8, Maintenance.

Refer to engine operation manual supplied with machine.
4.2.6.2 Electric Hydraulic machine
3 phase 380 - 415 Volts (depending on normal country voltage.)

4.2.6.3 Battery
Type 12 Volt, negative earth

Cranking Power 810 amps SAE
4.2.7 Hydraulics (G)
4.2.7.1 Hoses
Type Diameter
Working Test Burst
pressure pressure pressure
2 SN-K “Semperpac 1” 3/4” 3500 psi 7395 psi 14210 psi
DIN 20022 Part 3
R1 AT
DIN 20022 Part 3 3/16” 3570 psi 8700 psi 14500 psi
1/4” 3210 psi 7830 psi 13050 psi
5/16” 3070 psi 7395 psi 12325 psi
3/8” 2570 psi 6307 psi 10440 psi
1/2” 2295 psi 5582 psi 9280 psi
5/8” 1855 psi 4567 psi 7540 psi
3/4” 1500 psi 3697 psi 6090 psi
1” 1255 psi 3045 psi 5075 psi
1 1/4” 900 psi 2175 psi 3625 psi
1 1/2” 715 psi 1740 psi 2900 psi
2” 570 psi 1392 psi 2320 psi
R2 AT
DIN 20022 Part 4 3/16” 5930 psi 14355 psi 23925 psi
1/4” 5710 psi 13920 psi 23200 psi
5/16” 5000 psi 12180 psi 20300 psi
3/8” 4710 psi 11527 psi 19140 psi
1/2” 3930 psi 9570 psi 15950 psi
5/8” 3570 psi 8700 psi 14500 psi
3/4” 3070 psi 7395 psi 12325 psi
1” 2355 psi 5655 psi 9425 psi
1 1/4” 1785 psi 4350 psi 7250 psi
1 1/2” 1285 psi 3190 psi 5220 psi
2” 1140 psi 2827 psi 4640 psi
4.2.8 Chassis (H)
4.2.8.1 Tyres
Chieftain 1700 /1700S 235/75/R17.5
4.2.8.2 Tracks
For track torques, see adjustment data, “Maintenance“ section.
Tractive effort.............................. 14,276 daN

Gradability percentage................. 77 - 75%
Gearbox ratio.............................. 1:122
Hydraulic motor........................... Rexroth 63 cc/rev.
Approximate speed...................... 0.87 Km/hr (0.54 Mph)
4.2.9 Shredder Unit (I)

Inside Width................................ 800 mm
Number of Flails.......................... 22
4.2.10 Auxiliary Conveyor (J) 3 Deck Only

Belt Width................................ 650 mm (26’’)
Stockpile.......................... 4m (13’ - 1’’)
4.2.11 Catchbox (K) - RINSER OPTION ONLY
Catchbox:
Hydraulically hinged, making mesh changing easier
50-50 Fixed division plate
Adjustable division plates
10” twin outlets
4.2.12 Washbox (L) - RINSER OPTION ONLY
Adjustable 5 nozzle spray bar.

Feed Conveyor Belt Scraper
Steel wear Plate
4.3 Machine drawings
General plan 12 & 14FT working dimensions

General plan 12 & 14FT transport dimensions

Work area required for Machine
28450mm
28250mm
14ft Transport dimensions (Wheel Machine)

Working position dimensions 14ft (Wheeled Machine)

14 ft 3 Deck extended auxiliary conveyor

4.4 Noise levels
Noise levels for the Chieftain 1700/1700S with a Cat engine running at 2200 rpm (running
empty.)

5 - Plant Operating System Page 1
DUAL POWER
05 - Plant Operating System

DUAL POWER
Contents
5.1 General Safety ......................................................................................................3
5.2 Overview ...............................................................................................................5
5.3 Operation ............................................................................................................12
5.4 Tracking................................................................................................................15
5.5 Radio Tracking with the Radio Tracking Unit...................................................33
5.6 Remote Control Tipping Grid.............................................................................35

DUAL POWER
5.1. General Safety
Safety Introduction
Before operating this machine you must be read and understand all safety instructions in the
operators manual.
Only qualified personnel should carry out any maintenance work on the electrical section of
the control systems detailed in the manual.
Operators must have received specific training in all operating and service tasks as required
for the safe operation and service of the machine.
Operators must have read and understood the Machine Operators Manual and understand
all of the safety signs located on the machine.
Operators must know the location and correct operation of all controls and safety features
such as remote stop buttons and isolator switches.
Operators must be aware of all moving parts on the machine.
Electrical Safety
The electrical mode of operation on the electric hydraulic machines operates at 380-415
Volts AC, 50/60Hz
Only fully qualified electricians should carry out any maintenance or repair work on this
section of the control system.
Before any electrical work is carried out on the machine ensure that all electrical supplies
are isolated and locked in the off position.
The electrical equipment must be inspected at regular intervals and any damaged cables,
connections or parts must be repaired immediately using only Powerscreen recommended
parts.
Always isolate the electric supply when welding on the machine.

DUAL POWER
Safety Before and During Operation
Read and understand the operation manual for the machine
Before starting, walk completely around the machine. Make sure no one is working on or
under the machine
Do not start until everyone is clear of the machine
Ensure all control levers are in the neutral position
Before moving the machine, ensure that everyone is clear from the surrounding area and
that the warning siren and beacon and the tracking umbilical Machine Stop button are
operating correctly
General Maintenance of the Powerscreen Control Systems
Ensure that only qualified and trained personnel operate and maintain this equipment
Always keep control panels closed to avoid water ingress and dust contamination and keep
keys in secure locations
Regularly check the control system and connections for any damage
Never adjust any components or settings without authorisation from Powerscreen

DUAL POWER
5.2. Overview
Control Panel Component Identification
Figure 5.2.1 below shows the Powerscreen Dual Power control panel as used on the
Powerscreen mobile plant.
Figure 5.2.1 – Dual Power Control Panel

DUAL POWER
5.2. Overview - CONTINUED
Table 5.2.1 below gives the description of the various switches and lamps on the dual power
control panel door
ID Description Function
1 MCU100 Controller Diesel Mode Control
2 Prestart Button / Lamp Electric Mode Prestart
3 Oil Cooler Start button / Run Lamp Electric Mode Oil Cooler start
4 Motor 1 Start button / Run Lamp Electric Mode Motor 1 start
5 Motor 2 Start button / Run Lamp Electric Mode Motor 2 start
6 Diesel / Electrical Mode Select Switch Select between Electric / Diesel Mode
7 EStop Reset button / Lamp Electric Mode EStop Reset
8 Oil Cooler Stop button / Trip Lamp Electric Mode Oil Cooler stop
9 Motor 1 Stop button / Trip Lamp Electric Mode Motor 1 stop
10 Motor 2 Stop button / Trip Lamp Electric Mode Motor 2 stop
11 Electric Mode On Lamp Indication of Electric Operating Mode
12 Test Mode Lamp Indication of Test Mode
13 Test / Off / Manual Selector Switch Select between Test / Manual Mode
14 Manual Mode Lamp Indication of Manual Mode
15 Ignition Switch Switch on Power in Diesel Mode
16 Emergency Stop Button EStop plant in Diesel / Electric Mode
17 Diagnostic / Maintenance Button / Lamp Achieve Flash codes
18 Speed Selection Switch Select engine speed in Diesel Mode
Table 5.2.1 – Control Panel door component identification

DUAL POWER
Control Panel Internal Component Identification
Figure 5.2.2 below shows the internal component layout in the main control panel on
Powerscreen Dual Power Machines
Figure 5.2.2 – Main Control Panel Internal Component Layout

DUAL POWER

Table 5.2.2 below gives the description of the internal components used in the Dual
Power main control panel
Table 5.2.2 – Main Panel Internal Component Identification
ID TAG Description
1 PS1 110VAC – 12VDC 25A Power Supply
2 CB1 Motor 1 MCB
3 KM1 Motor 1 Main Contactor
4 KM1.1 Motor 1 Delta Contactor
5 KM1.2 Motor 1 Star Contactor
6 T3 Motor 1 Star / Delta Timer
7 CB2 Motor 2 MCB
8 KM2 Motor 2 Main Contactor
9 KM2.1 Motor 2 Delta Contactor
10 KM2.2 Motor 2 Star Contactor
11 T4 Motor 2 Star / Delta Timer
12 ESR Emergency Stop Safety Relay
13 K1 Emergency Stop Auxiliary Relay
14 X10 Auxiliary Machine Interlock Terminals
15 CB3 415 – 110 Transformer DP Circuit Breaker
16 CB4 110VAC Control Circuit Breaker
17 CB5 110VAC – 12VDC Power Supply Circuit Breaker
18 T1 Pre-start Timer 1
19 T2 Pre-start Timer 2
20 T5 Fan Interlock Delay Timer
21 R4 Pre-start Relay 1
24 K2 Remote Interlock Relay
25 HRC Hours Run Clock (Electric Mode)
26 R1 Test Mode Relay 1
27 R2 Test Mode Relay 2
28 R3 Manual Mode Relay
29 R7 Motor 1 Trip Relay
30 R8 Motor 2 Trip Relay
31 R9 Electric Mode On Relay
32 TX1 415VAC – 110VAC 630VA Transformer
33 CB6 12VDC Power Supply Control Circuit Breaker
34 R11 Remote Tipping Grid Supply Interlock Relay
35 R12 Tracks Enabled Relay
36 IR1 EStop Healthy Signal Interface Relay
37 IR2 Keyswitch Start Signal Interface Relay
38 IR3 Radio Tracks On Relay
39 X1/X2 12VDC Power Rail Terminals (Electric Mode)
40 AR6 Engine Crank Automotive Relay 70A
41 AR11 Engine Preheat Automotive Relay 100A

DUAL POWER
42 AR1B Battery Power On Automotive Relay 100A

43 AR12 Fan 2 Delay Automotive Relay (Electric Mode) 30A
44 AR1A Mains On Interlock Automotive Relay 15A
45 AR7 ECU Ignition Relay / Fuel Solenoid Relay 15A
46 AR8 Siren / Beacon Automotive Relay 15A
47 AR9 Fan 1 Ground Interlock Automotive Relay 30A
48 AR10 Fan 2 Ground Interlock Automotive Relay 30A
49 AR2 Fan 1 Supply Interlock Automotive Relay 30A
50 AR3 Fan 2 Supply Interlock Automotive Relay 30A
51 AR4 Fan 1 On Automotive Relay 30A
52 AR5 Fan 2 On Automotive Relay 30A
53 ISO1 Main Isolator 160A 3P
54 1UVW Main Motor 1 Connection Terminals
55 2UVW Main Motor 2 Connection Terminals
56 TERM Terminals
57 X6 Automotive Fuses
58 TERM Terminals
59 KM3 Fan 1 Contactor 30A (Electric Mode)

DUAL POWER
Manual Tracking System
Figure 5.2.3 below shows the new Powerscreen Manual Tracking Umbilical Layout.
Figure 5.2.3 – Powerscreen Tracking Umbilical Layout
Table 5.2.3 below gives a description of each button on the Umbilical shown above
ID Description
1 Left Track Forward
2 Right Track Forward
3 Left Track Reverse
4 Right Track Reverse
5 Unused
6 Unused
7 Stop Tracks
8 Start Tracks

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Radio Tracking System
Figure 5.2.4 below shows the new Powerscreen Radio Tracking Transmitter Layout.
Figure 5.2.4 – Powerscreen Radio Tracking System Layout
Table 5.2.4 below gives a description of each button on the Umbilical shown above
ID Description
1 Left Track Forward
2 Right Track Forward
3 Left Track Reverse
4 Right Track Reverse
5 Stop Tracks
6 Start Tracks
7 Unused
8 Unused
9 Radio Start Button 1
0 Radio Start Button 2

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5.3. Operation
Electric Mode Operation
To operate in electric mode, first make sure that a suitably sized supply cable is
connected safely to the Dual power Control panel isolator Input side.
Ensure that this cable is suitably protected at the supply side with the appropriate
protection and isolating device in strict accordance with local and international
regulations
Supply cable should only be installed by a qualified electrician
Pre-run Check
Refer to Figure 5.2.1 and Table 5.2.1 for component locations
Before the machine can be run normally, the direction of both motors must be
checked.
First, note the required direction of the hydraulic pumps, usually indicated on the
pump housing. If unsure, contact Powerscreen for advice.
Ensure all circuit breakers are in the ON position and that the Battery Isolator switch
on the machine Powerunit is locked in the OFF position
Ensure all Emergency Stop buttons are released and that it is safe to start the
machine
Switch on the Main Panel 3P 160A Isolator switch.
Switch the Operating Mode Selector Switch to Electric Mode. The Electric Mode
lamp will illuminate
Switch Test / Manual selector switch to TEST mode.
Press the Emergency Reset Button on the main control panel. Providing the
emergency stop circuit is healthy, the green Emergency Stop Healthy Lamp will
illuminate
Next Press the Pre-Start button. This will cause the siren and beacon to activate
After 7 seconds the, Pre-Start lamp will illuminate indicating it is clear to start the
plant.

DUAL POWER
5.3. Operation - continued

Press the Oil Cooler Start Button. The Oil Cooler Run Lamp will illuminate and the
Oil Cooler Fans in the engine Powerunit will activate.
Next press Motor 1 Start button followed by Motor 1 Stop button in quick
succession. Check that Motor 1 is running in the correct direction
NOTE: Do not leave Motor running while checking the direction. Simply
‘Pulse’ the motor as described. Failure to follow these directions may
result in damage to the motors and / or pumps
Repeat the procedure for Motor 2
If the motors are running the wrong direction, swap 2 of the supply cable phases
Do not swap the motor connections in the main control panel as these are tested
before leaving the factory
Once the motors are running the correct direction the plant can be started as
follows
Normal Start Procedure

Refer to Figure 5.2.1 and Table 5.2.1 for component locations
Ensure all circuit breakers are in the ON position and that the Battery Isolator switch
on the machine Powerunit is locked in the OFF position
Ensure all Emergency Stop buttons are released and that it is safe to start the
machine
Switch on the Main Panel 3P 160A Isolator switch.
Switch the Operating Mode Selector Switch to Electric Mode. The Electric Mode
lamp will illuminate
Switch Test / Manual selector switch to MANUAL mode.
Press the Emergency Reset Button on the main control panel. Providing the
emergency stop circuit is healthy, the green Emergency Stop Healthy Lamp will
illuminate
Next Press the Pre-Start button. This will cause the siren and beacon to activate
After 7 seconds the, Pre-Start lamp will illuminate indicating it is clear to start the
plant.

DUAL POWER
5.3. Operation - continued

Normal Start Procedure
NOTE: If the Main Motors & oil cooler are not started within 30 seconds of the
Pre-Start lamp illuminating, The Pre-Start sequence will reset and will
need to be repeated in order to start the plant
Press the Oil Cooler Start Button. The Oil Cooler Run Lamp will illuminate and the Oil
Cooler Fans in the engine Powerunit will activate.
Press Motor 1 Start button. The Main contactor and Star contactors (KM1 and
KM1.1) will energise. After aprox. 5 seconds, the Star contactor will disengage and
the Delta contactor (KM1.2) will energise. This will cause the Motor 1 Run Lamp to
illuminate
Press Motor 2 Start button. The Main contactor and Star contactors (KM2 and
KM2.1) will energise. After aprox. 5 seconds, the Star contactor will disengage and
the Delta contactor (KM2.2) will energise. This will cause the Motor 1 Run Lamp to
illuminate
Once both motors and the oil cooler fans are running, the plant items can be started
via the manual levers.

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5.4. Manual Tracking Information
As the Electrical Hydraulic machine must be connected to a three phase 415VAC

50Hz electrical supply to power the electrical motors that control the hydraulic track
pumps, absolute care must be taken when tracking this machine
The operator must ensure that strict attention is paid to all relevant health and safety
regulations and guidelines when operating and tracking this machine
The electrical supply to this machine must be connected via the supplied industrial
‘spring release’ plug with safety tension cord properly attached to facilitate safe
disconnect should the cable come under strain. No other connection method to this
machine is acceptable.
When tracking the machine it must be ensured that the supply cable to the machine
is behind the direction of travel or away from the tracks and the path of travel at all
times
Notes:
1. Only a fully qualified and competent electrician must connect the electrical
supply to this machine
2. The electrical supply to this machine must be carried out in strict accordance
with all relevant local and international electrical safety regulations
3. The electrical supply to this machine must have adequate protection for safe
disconnection in the event of either over-current, short circuit or earth leakage
faults
4. The electrical supply to this machine must be fully tested and inspected
by a qualified electrician in strict accordance with all relevant local and
international electrical regulations
5. This machine must not, under any circumstances, be operated or tracked

unless it is absolutely safe to do so.

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Diesel Mode Operation
To operate in diesel mode first make sure that the mains electric supply is switched
off and disconnected if possible.
NOTE: It is not advised to run the machine in Diesel mode with the electric cable
attached due to the ability of the machine to be tracked in this mode.
Ensure the battery is connected and the battery isolator switch is in the ON position
Ensure the Main Panel Isolator is in the OFF position
Switch the Operating Mode Selector Switch to Diesel Mode.
Switch the Ignition Switch to the ON position
The Powerscreen MCU100 controller will power up and the screen will illuminate.
If there are any un-cleared or active faults, the Display will show ‘Not Ready’.
Press the Fault Reset Button on the MCU100 to clear any inactive faults.
Ensure the MCU100 is in MAN mode

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Once the MCU100 displays ‘Ready’ it is clear to begin the Start Procedure
The engine can be started by two methods:
1 – Using the Start Pushbutton
To start the engine using the Start Pushbutton simply press the Start Button when
ready to start the engine
This will cause the Siren and Beacon to operate for ten seconds
After 10 seconds, the starter solenoid will energise for five seconds and the engine
will try to start.
If the engine has not started within the five seconds the starter solenoid will
disengage and there will be a pause of three seconds.
After the three second pause, the Siren and Beacon will operate for ten seconds
After 10 seconds, the starter solenoid will energise again for five seconds and the
engine will try to start.
If the engine has not started within the five seconds the starter solenoid will
disengage and there will be a pause of three seconds.
This process will be repeated three times in total after which if the engine has not
started the MCU100 will display ‘StartFail’ alarm
Once the MCU100 reads a speed level from the engine the engine starter solenoid
will disengage and the MCU100 will display ‘Running’
The engine speed will be displayed on the MCU100 visually as an analogue gauge
and the RPM value displayed beside it as shown in Figure 5.3.1 below.
2 – Using the Ignition Switch
To start the engine using the Ignition Switch simply turn the Ignition to the ‘Crank’
position and release. The start sequence will be the same as detailed above

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Powerscreen MCU100 Controller
Overview
Figure 5.3.1 – Powerscreen MCU100 Operator Interface
Number Description
1 Mode Select - Forward Cyclic Selection of OFF-MAN-AUT
2 Mode Select - Backward Cyclic Selection of OFF-MAN-AUT
3 Unused
4 Fault Reset – Acknowledges Faults and Alarms
5 Start – Begins Start Sequence
6 Stop – Stops Engine
7 Green LED – Engine Running
8 Red LED – Fault Present
9 Page – Cyclic Selection of Display Mode
10 Up select Button – Setpoint adjust / Screen Select etc
11 Down select Button – Setpoint adjust / Screen Select etc
12 Enter – Confirm Setpoint value
Table 5.3.1 – Powerscreen MCU100 Function Key and Display LED Description

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Figure 5.3.2 – Powerscreen MCU100 Rear Connections

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Figure 5.3.3 – Basic Wiring of Powerscreen MCU100 – See appropriate

schematics for more detailed drawings

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Display
There are three Display Menus available:
1. Measurement
2. Adjustment
3. History
Scroll between the three Display Menus using the PAGE button
Mode
There are three Engine Modes available:
OFF
MAN (Manual)
AUT (Auto)
Use the MODE buttons to select between the three Modes
NOTE: You must enter minimum Level 2 Password to change modes. MCU100
must be in MAN mode to function
Viewing Measured Data
Press the PAGE button repeatedly until the Measurement Display is active. Then
use the UP and DOWN buttons to select the screen with the requested data. Press
ENTER to enter that page
View and Edit Setpoints
Press the PAGE button repeatedly until the Adjustment Display is active.
Use the UP and DOWN buttons to select the requested Setpoint Group
Press ENTER to confirm
Use the UP and DOWN buttons to select the requested Setpoint
Press ENTER to edit
Use the UP and DOWN buttons to modify the requested Setpoint
Press ENTER to confirm or PAGE to escape without saving change
NOTE: Setpoints marked with ‘*’ are password protected
HINT: Pressing and holding the UP or DOWN keys will cause the value to
ramp up or

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Changing the Display Contrast
Press ENTER and UP or DOWN at the same time to change the Display contrast
Changing Display Language
Hold ENTER and then press PAGE to go to Software Version Screen

Press PAGE to enter Language Selection Screen
Use the UP / DOWN buttons to select required language
Press ENTER to confirm language selection
Viewing Active Alarms
The Active Alarm Screen is the last screen in the Measurement Menu
Select Measurement Menu
Press UP to view Active Alarms
Alarms have four states as shown below:
Press FAULT RESET to accept all alarms

Non-active alarms will clear from the screen
NOTE: The Active Alarm List will be displayed each time a new alarm is
activated
ECU Alarm List
There is a second Alarm List that deals with only those alarms sent over CanBus via
J1939 protocol from electronic engine ECUs
This Alarm List is one screen above the Main Active Alarm List
If an ECU alarm is received an exclamation mark (!) on the Main Screen and by ECU
FAULT on the standard alarm list

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Chart Guide to Menus and Pushbutton Operation
Figure 5.3.3 below shows the navigation procedure through the various screens in
the Powerscreen MCU100

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Measurement Screens
Main Measurement Screen / Home Screen
Number Description
1 Operation Mode of Engine
2 Indication: L=Access Lock,! = Active Alarm
3 Status of Control System
4 Timer – events counting time (Prestart, Crank Pause etc)
5 Engine RPM
Analogue Inputs Screen
This screen shows the status of the analogue inputs, where used
· Oil Pressure Bargraph with Protection (Shutdown) Limits shown

· Water Temperature Bargraph with Protection (Shutdown) Limits shown
· Fuel Level Bargraph with Protection (Shutdown) Limits shown
· Battery Voltage Bargraph with Protection (Shutdown) Limits shown
Note: Depending on application, some or all of the above may be unavailable
Binary Inputs Screen
This screen shows the status of the Binary Inputs as a ‘1’ for ON or a ‘0’ for OFF
· Emergency Stop
· Pressure Setpoint 1
· Pressure Setpoint 2
· Start Feeder
· Tracks Request
· Remote Start (Ignition Crank)

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Binary Outputs Screen
This screen shows the status of the Binary Outputs as a ‘1’ for ON or a ‘0’ for OFF
· Starter Solenoid
· Fuel Solenoid / ECU On
· Cooling Fans
· Siren / Beacon
· Tracks
· ECU Ready
NOTE: All binary inputs and outputs are Negative Switching. Therefore a
0VDC input is interpreted as ON and the outputs switch 0VDC out
ECU State Screen
This screen gives the status of the ECU when used with electronic engines
· ECU Yellow Lamp

· ECU Red Lamp
· ECU Wait to Start
Statistics Screen
This screen gives an overview of the key statistics as follows:
· Run Hours Total Engine Run Hours

· Number of Starts Total Start Attempts
· E Stop Total Emergency Stop Events
· Shutdown Total Engine Shutdown Stops (excluding E-Stops)
· Next Service Time Hours remaining until Next Service is due
ECU Alarm List
Diagnostic messages are read from the ECU and displayed in this second alarm list
The J1939 standards of SPN (Suspect Parameter Number), OC (Occurrence Count)
and FMI (Failure Mode Identifier) are shown together with a text description if
available.
The following image shows typical ECU alarms being displayed on this second
alarm list. As you scroll down through the list, the additional information for
that alarm (SPN, OC and FMI) are displayed at the bottom of the page If no test
description is available, the SPN will be given in decimal and Hex.

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ECU Alarm List - CONTINUED
Figure 3.x – ECU Alarm List Screen
Standard Alarm List
This screen as detailed earlier displays active or inactive alarms. This screen will
de displayed automatically when any new alarm appears, but only from the Main
Measure (Home) screen

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Start – Stop Sequence
The order in which the Powerscreen MCU controller starts and stops the engine is
given below to enable operators to have a better understanding of the control logic
which will aid in any service issues.
Ensure System is in Ready State as indicated on the Home Page
Press Start button or turn Keyswitch to Crank position
Siren & Beacon will switch ON

Fuel Solenoid will switch ON
After 10 seconds, Siren and Beacon will switch OFF

Starter Solenoid will switch ON
Starter Solenoid will stay on for the duration of the MaxCrankTime as set in the
setpoints menu or until the engine RPM is greater than the Start RPM as set in the
setpoints menu
Once the RPM is greater than the Start RPM, the control system will enter the
Running State
If the engine RPM does not exceed the Start RPM within the MaxCrankTime, the
system will pause for three seconds then repeat the process
This Start process will repeat three times after which if the Running state is not
achieved the system will shutdown and a Start Fail fault will be displayed
To restart the sequence, press Fault Reset button and then the Start Button (or
Ignition Switch to crank position).
To stop the engine at any time, press the Stop button. If a Stop Delay time is
enabled this will begin to count down and be displayed on the Home page. Once
this time has elapsed the Fuel Solenoid will disengage and the engine will stop
If the Stop button is pressed a second time during the Stop Delay, the engine will
stop immediately.
If no Stop Delay has been enabled, pressing the Stop button once will disengage the
Fuel Solenoid and stop the engine.
NOTE: The Start-up routine can be interrupted at any time by pressing the
STOP button

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Alarm Management
There are two types of Alarm displayed:
· Warning
· Shutdown
Warning (WRN)
When a Warning Alarm is activated, the engine will not shutdown but the Alarm LED
will be Red and the fault will be displayed on the screen. This type of alarm is non-
critical
Shutdown (SD)
When a Shutdown alarm is activated, the Fuel Solenoid, Starter and Prestart outputs
are opened immediately causing the engine to shut down.

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List of Possible Alarms
Event Specification Alarm Type Description

Overspeed SD Engine RPM is greater than Overspeed setpoint

Underspeed SD Engine RPM is lower than Underspeed setpoint

EmergencyStop SD Emergency Stop Input is Open

LowCoolantLvl SD Low Coolant Level input is closed for 3 seconds or more
LowHydOilLvl SD Low Hydraulic Oil Input is closed for 3 seconds or more
AirFilterRest SD Airfilter Restriction Input is closed for 30 minutes or more
FuelContam SD Fuel Contamination Input is closed for 3 seconds or more
Sd OilPressure SD Oil Pressure Input is closed for 3 seconds or more when engine
is running

Sd EngineTemp SD Engine Temperature Input is closed for 3 seconds or more when
engine is running

PickupFault SD No RPM Reading from Magnetic Pickup or Alternator W+
terminal

StopFail SD Engine Failed to Stop

WrnServiceTime WRN Engine Run Hours reach the value in the NextServTime setpoint

ChrgAlternFail WRN Failure of Alternator to charge the battery

Wrn ECU Alarm WRN ECU Alarm List has an active fault

Low BackupBatt WRN Real time Clock internal battery is low

Ubatt WRN Battery Voltage is outside limits set in Batt Overvolt and Batt
Undervolt setpoints

Start Failed SD Engine Failed to start

Battery Flat WRN Controller shutdown due to low battery voltage


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Powerscreen MCU100 States
State Description
Init Auto Test During Power-Up

Not Ready Engine Not Ready to start

Prestart Prestart sequence in process

Cranking Engine is Cranking

Pause Pause between start attempts

Starting Starting Speed is reached

Running Engine is running at nominal speed

Stop Engine is stopped

Shutdown Shut Down alarm is activated

Ready Engine is ready to run

Cooling Engine is cooling before stop


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History File
The Powerscreen MCU100 stores a record of each important event into a history
file. The file holds 117 events. Once this count is reached, the older events are
overwritten
Historical Event Structure
Abbreviation Historical Value

Num Number of Historical Event

Reason Event Specification

Date Date of Historical Event in format DD/MM/YY

Time Time of Historical Event in format HH:MM:SS

RPM Engine Speed

Ubat Battery Voltage

OilP Oil Pressure (if used)

EngT Engine Temperature (If used)

FLvl Fuel Level (If used)

AIM1 Unused

AIM2 Unused

AIM3 Unused

AIM4 Unused

BIN State of Binary inputs (1=Closed, 0=Open)

BIM State of Additional Binary Inputs (1=Closed, 0=Open)

BOUT State of Binary Outputs (1=Closed, 0=Open)

BOM State of Additional Binary Outputs (1=Closed, 0=Open)

FC ECU Alarm Failure Code

FMI ECU Alarm Failure Mode Identifier

DUAL POWER
Viewing History
Press the PAGE button repeatedly to access the History Page

Press UP or DOWN to select required Historical Entry
Press ENTER to scroll to the Right and view various measured data at that Log Time
Use the PAGE button to get back to the Measurement Screen

DUAL POWER
5.5. Tracking
The machine can be tracked using either the Umbilical Tracking Unit as shown in
Figure 5.2.3 or the Radio Tracking Unit as shown in Figure 5.2.4 (if fitted)
Manual Tracking with the Umbilical Handset
Ensure engine is running and all conveyors, feeder etc are OFF
Press the Tracks Start button on the Umbilical – No 8 in Figure 5.2.3
The Led Indicator will illuminate RED
The Siren and Beacon will activate and continue to do so until the Tracks Stop button
is pressed
After a period of 10 seconds the LED Indicator will illuminate GREEN
At this stage pressing the various Track direction buttons will engage the respective
track solenoid
To stop the Tracking function, simply press the Tracks Stop button on the Umbilical –
No. 7 in Figure 5.2.3
Radio Tracking with the Radio Tracking Unit
Ensure engine is running and all conveyors, feeder etc are OFF
Press and hold both Radio Start buttons on the Radio Handset – No.’s 9 & 0 in Figure
5.2.4, for 3 seconds
All three LED Indicators will flash
Release the Start buttons
The Top LED Indicator will illuminate GREEN and the other two LEDs will be OFF
NOTE: At this stage the Radio Control is ENABLED and the Radio Stop button
on the Radio Handset is ACTIVE. Pressing the Radio Stop button at
this stage will shut down the machine
Press the Tracks Start button on the Radio Handset – No 6 in Figure 5.2.4

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Fast Tracking
Some machines are fitted with two-speed tracking systems.
Both the Umbilical Handset and the Radio Handset have two-step pushbuttons on
the Track Directions
The first level is the Normal Track speed
The second press level is the Fast Track Speed
You cannot slew the machine with Fast Tracks – only both forward or both reverse
tracks will engage the fast track function

DUAL POWER
5.6. Radio Controlled Tipping Grid
Some machines are fitted with a Powerscreen Radio Controlled Tipping Grid (RTG)
Figure 5.5.1 below shows an image of the new Powerscreen RTG
2 - Position Toggle Switch
Figure 5.5.1 – New Powerscreen Radio Tipping Grid Receiver

Manual Operation of the Tipping Grid
To operate the Tipping grid without using the RTG Transmitter, the two-position
toggle switch on the side of the transmitter as shown in Figure 5.5.1, can be used
Pushing and holding this switch in the UP position will energise the Grid Up solenoid
Pushing and holding this switch in the DOWN position will energise the Grid Down
solenoid.

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Radio Operation of the Tipping Grid
There are two methods of operating the Tipping Grid with the Radio Transmitter,
shown in Figure 5.5.2 below
· Using a Pre-Stored Programmed Sequence

· Using the Up/Down Sequence Override buttons
On / Off Button Status LED
Up Button Down Button
Program Start / Stop

Button Button
Figure 5.5.2 – Powerscreen RTG Transmitter

Using a Pre-Stored Programmed Sequence
Press and hold the On / Off button as shown in Figure 5.5.2 for 2 seconds to turn the
transmitter ON. Once successfully switched on the Status LED will illuminate RED.
If no button is pressed for two minutes or if the On/Off button is pressed and held
for two seconds again, the Transmitter will switch OFF to save the battery life.
To use a programmed sequence, simply press the Start / Stop button on the RTG
transmitter as shown in Figure 5.5.2. This will cause the Grid Up solenoid to energise
for a programmed time.
Once this time has elapsed, the Grid Down solenoid will energise for a programmed
time
Pressing the Start / Stop button during this sequence will Pause the sequence. To
continue the sequence, press the Start / Stop button again.

DUAL POWER
Using the Up/Down Sequence Override Buttons
The Up and Down override buttons as shown in Figure 5.5.2 can be used to
energise the Grid Up and Down solenoids respectively without any pre-programmed
time.
To do this simply press the Up and Down buttons as required
Setting a New Programmed Sequence
Ensure the Transmitter is switched ON as detailed above
Press and hold the Program (P) button on the RTG Transmitter. Continue to hold the
Program button pressed for the duration of the programming sequence.
Press and hold the UP button. This will energise the Grid UP solenoid and cause the
Grid to Rise. The Status LED will flicker.
When the Grid is at the required height, Release the UP Button, keeping the
Program button pressed
Next press and hold the Down button on the RTG Transmitter. This will energise the
Grid Down solenoid and cause the grid to Lower. The Status LED will flicker
When the Grid is almost fully down release the Down button
Finally Release the Program button
The above sequence is now stored
Pressing the Start / Stop button will activate the above programmed sequence.

DUAL POWER
Programming a New RTG Transmitter to an Existing Receiver
Ensure that the machine is safe to work on and the engine has been stopped
Open the cover of the Powerscreen RTG Receiver shown in Figure 5.5.1 by
removing the four screws in the lid
Carefully let the lid hang below the main box as the antenna is attached to the lid,
exposing the Printed Circuit Board as shown in Figure 5.5.3 below
Transmitter
Antenna Program Button
Transmitter
Grid Up Relay Program LED
Grid Down Relay Relay LED
Power Supply 2 Position

Connections Toggle Switch
Switch on the Transmitter to be programmed
Press and hold the Transmitter Program Button on the RTG Receiver Printed Circuit
Board as shown in Figure 5.5.3 above, for two seconds
The Transmitter Program LED will illuminate Red
Press any button on the Transmitter to be programmed (NOT the On/Off button)
The Transmitter Program LED will flash
Press the UP or DOWN button on the Transmitter – the respective Relay will activate
on the Receiver printed Circuit Board – this will be indicated by the respective Relay
LED illuminated RED
If there was another Transmitter already programmed to the Receiver, it will

automatically be erased once a new Transmitter is programmed
Only one Transmitter can operate the Receiver
Replace cover and process is complete

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5.6. Fault Finding
Engine Crank Failure

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5.6. Fault Finding
Engine Start Failure: Engine Cranking but will not start

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5.6. Fault Finding

Power Failure: MCU100 will not Power On
Ensure Battery Isolator is switched ON and Battery has > 12.6V Supply

DUAL POWER

Diesel
Powerscreen Int. Dis Ltd. Dungannon, N.Ireland. WWW.POWERSCREEN.COM

Diesel
Contents
6.1 General Safety ......................................................................................................3
6.2 Starting the engine ..............................................................................................5
6.3 Control Panel ........................................................................................................7
6.4 Engine PREHEAT.................................................................................................17
6.5 Radio Control.......................................................................................................18
6.6 Tipping Grid.........................................................................................................19
6.7 Tracking Handheld Remote................................................................................26
6.8 Powescreen Electronic Control Panel...............................................................27

Diesel
6.1. General Safety
Safety Introduction
Before operating this machine you must be read and understand all safety instructions in the
operators manual.
Only qualified personnel should carry out any maintenance work on the electrical section of
the control systems detailed in the manual.
Operators must have received specific training in all operating and service tasks as required
for the safe operation and service of the machine.
Operators must have read and understood the Machine Operators Manual and understand
all of the safety signs located on the machine.
Operators must know the location and correct operation of all controls and safety features
such as remote stop buttons and isolator switches.
Operators must be aware of all moving parts on the machine.
Electrical Safety
The electrical mode of operation on the electric hydraulic machines operates at 380-415
Volts AC, 50/60Hz
Only fully qualified electricians should carry out any maintenance or repair work on this
section of the control system.
Before any electrical work is carried out on the machine ensure that all electrical supplies
are isolated and locked in the off position.
The electrical equipment must be inspected at regular intervals and any damaged cables,
connections or parts must be repaired immediately using only Powerscreen recommended
parts.
Always isolate the electric supply when welding on the machine.

Diesel
Safety Before and During Operation
Read and understand the operation manual for the machine
Before starting, walk completely around the machine. Make sure no one is working on or
under the machine
Do not start until everyone is clear of the machine
Ensure all control levers are in the neutral position
Before moving the machine, ensure that everyone is clear from the surrounding area and
that the warning siren and beacon and the tracking umbilical Machine Stop button are
operating correctly
General Maintenance of the Powerscreen Control Systems
Ensure that only qualified and trained personnel operate and maintain this equipment
Always keep control panels closed to avoid water ingress and dust contamination and keep
keys in secure locations
Regularly check the control system and connections for any damage
Never adjust any components or settings without authorisation from Powerscreen

Diesel
6.2 Starting the engine
6.2.1 Diesel Standard Panel units hazards

1520 / 1513 WEAR PERSONAL PROTECTIVE
EQUIPMENT
ISO Refer this Section, safety information
All control levers must be in the 1520 / 1513 for relevant warning.
neutral (non-operational) position. ANSI
PROCEDURE
1.Observe all safety warnings.
2.Turn ignition key to position.
3.The following warning lights on the

control panel will illuminate:

(B) - Charge lamp

(D) - Control lamp
(F) - Oil pressure lamp
(O) - Emergency stop
NOTICE
Do not start engine without the

above mentioned warning lights
being illuminated.

Diesel
6.2.1 Diesel Standard Panel units
4. Fully depress and hold override

button.Fuel solenoid engages and the
control lamp (D) is extinguished.
5. Turn ignition key to position “ ”

The safety siren will start, hold in this
position until the warning siren stops
after 7 seconds.
7 seconds
6. Release ignition key immediately
after the engine starts. The key will
return to run position, “ .“
7. When oil pressure lamp (F) is

extinguished release override button
(H).
7 seconds
NOTICE
If the warning lights fail to

extinguish stop the engine and
detect the fault before using the
machine.

Diesel
6.3 Control Panel

6.3.1 cat main Electronic panel
1
2
3
4
5
6
7
8
9
10
11
12
13 14 15
G1
1. Battery Charging Warning Light
This light should illuminate when the key switch is turned to the ON position.
As soon as the engine starts it should go out. If it fails to illuminate when the key is
turned on, or if it illuminates when the engine is running, it indicates that there is a
fault in the charging circuit. Stop the engine and have the circuit checked
2. Oil Pressure Warning Light
As soon as the engine starts it should go out. If a fault occurs in the oil pressure
system the engine will shutdown after 2 seconds

Diesel
6.3 Control Panel
3. Coolant Temperature Warning Light
This light will only illuminate if a problem occurs in the coolant system, such as
low water level . The engine will shut down 5 seconds after the fault has been detected.
4. fuel contamination light
This light illuminates if a problem occurs in the fuel system, such as water
contamination. The engine will shut down 1 second after the fault has been detected
5. Engine Run Light
This light will only illuminate when the key is turned to the ON position and will
remain on at all times. If it goes out then an E-Stop has been pressed and the engine
will shut down immediately.
6 Air Breather Restriction Warning Light
This light should illuminate if a problem occurs in the air breather system. If the
AIR FILTER OVERRIDE link on the main control panel is in, then the light will remain on
continuously until the fault has been repaired. If the AIR FILTER OVERRIDE link is out
and it continues to receive a fault signal, the light will remain on for 30 minutes. After
30 minutes the engine will shut down but the light will remain on until the fault has been
repaired
7. Fuel On Light
This light should illuminate when the engine starts and will remain on at all times.
It will go out when the engine has been shut down.
8. Hydraulic Oil Level Warning Light (not shown)
This light will only illuminate if the hydraulic oil level is low. The engine will shut
down 5 seconds after the fault has been detected.
9. E-Stop Activated Light
This light will only illuminate when an E-Stop has been pressed. This will
immediately shut down the engine. If the light is flashing after shut down, this indicates
that the manual tracking doglead E-Stop has been pressed. If the light remains on
constantly then another E-Stop has been pressed.
10.Engine Pre-Heater Indicator Light
This light only illuminates when the pre-heat button is operated during start up.
11. Cat Warning Light
This light will only illuminate when the Caterpillar engine or Caterpillar component
has developed a problem. This can result in an engine shut down. In the event of a fault
causing this light to illuminate you should contact your local Caterpillar dealer for further
information.
12. Cat ecu Warning Light
This light will only illuminate when the Caterpillar engine control unit detects a
problem. This can result in an engine shut down. In the event of a fault causing this light
to illuminate you should contact your local Caterpillar dealer for further information.
Diesel
6.3 Control Panel
13. Hour Clock

This will record the number of hours that the engine has been running.
14. THROTTLE CONTROL
This is used to control the engine throttle by selecting one of the 3 speeds.
15. Key Start Switch
This is used to start the engine when required.

Diesel
6.3 Control Panel

6.2.2 DEUTZ main ELECTRONIC THROTTLE
1
2
3
4
5
6
7
8
9 11
10

3. engine fault Light
This light will only illuminate when the engine control unit detects a problem.
In the event of a fault causing this light to illuminate you should contact your local
Deutz dealer for further information.

Diesel
6.3 Control Panel

6.2.2 DEUTZ main ELECTRONIC THROTTLE
4. E Stop healthy Light

This light will illuminate when the key is turned to the ON position
and will remain on at all times. If it goes out then an E-Stop has been pressed and
the engine will shut down immediately.
5. Hydraulic Oil Level Warning Light
This light will only illuminate if the hydraulic oil level is low. The engine will
shut down 5 seconds after the fault has been detected.
6. Coolant Level Warning Light
This light will only illuminate if a problem occurs in the coolant system, such
as low water level . The engine will shut down 5 seconds after the fault has been
detected
7. engine diagnostic light
This light will illuminate when the engine is running and has no faults detected.
In the event of a fault causing this light to turn off or flash you should contact your
local Deutz dealer for further information.
immediately shut down the engine. If the light is flashing after shut down, this
indicates that the manual tracking doglead E-Stop has been pressed. If the light
remains on constasntly than another E-Stop has been pressed.
9. Hour Clock
10. Throttle control
This is used to control the engine throttle by selecting one of the 3 speeds.
This is used to start the engine when required

Diesel
6.3 Control Panel
6.2.3 cat manual THROTTLE
1
2
3
4
5
6
7
8
9
10
11
12 13 14


Diesel
6.3 Control Panel

6.2.3 cat manual THROTTLE

detected.
detected
5. Engine Run Light
This light should illuminate if a problem occurs in the air breather system.
If the AIR FILTER OVERRIDE link on the main control panel is in, then the light
will remain on continuously until the fault has been repaired. If the AIR FILTER
OVERRIDE link is out and it continues to receive a fault signal, the light will remain
on for 30 minutes. After 30 minutes the engine will shut down but the light will remain
on until the fault has been repaired
7. Fuel On Light
This light should illuminate when the engine starts and will remain on at all
times. It will go out when the engine has been shut down.
8. Hydraulic Oil Level Warning Light (not shown)
This light will only illuminate if the hydraulic oil level is low. The engine will
shut down 5 seconds after the fault has been detected.
remains on constasntly than another E-Stop has been pressed.

Diesel
6.2 Control Panel
6.2.4 DEUTZ MANUAL THROTTLE
1
2
3
4
5
6
7
8
10
11
12
13
Figure 12.3.3.1
Diesel
6.2 Control Panel

detected.
detected
5. Engine Run Light
This light should illuminate if a problem occurs in the air breather system. If the
AIR FILTER OVERRIDE link on the main control panel is in, then the light will remain
on continuously until the fault has been repaired. If the AIR FILTER OVERRIDE link
is out and it continues to receive a fault signal, the light will remain on for 30 minutes.
After 30 minutes the engine will shut down but the light will remain on until the fault
has been repaired
7. Fuel On Light
This light should illuminate when the engine starts and will remain on at all
times. It will go out when the engine has been shut down.
8. Hydraulic Oil Level Warning Light
This light will only illuminate if the hydraulic oil level is low. The engine will shut
down 5 seconds after the fault has been detected.
remains on constantly than another E-Stop has been pressed.

Diesel
6.2 Control Panel
12. Hour Clock

This is used to start the engine when required.

Diesel
6.3 Engine Pre-Heat - STD DIESEL UNIT ONLY
If an engine pre-heat sequence was installed to the control panel during

manufacture, it will be either automatic or manual.
If it is automatic then the pre-heat light (H) will illuminate when the key is turned
to the start position (C). The engine will crank automatically once the pre-heat
operation has been completed and the light will go out.
If manual pre-heat has been fitted then the light will illuminate when the key is turned
to the pre-heat position. The engine can be manually preheated by holding in the
preheat button on the side of the control panel. The light will extinguish after the pre-
heat operation has been completed and the key can be turned to the start position
(C) to crank the engine.
H. Engine
Pre-Heater
Indicator Light
C
Position of
Pre Heat
Button

Diesel
6.4 Radio Control
Hand-held radio control unit
The radio control unit consists of a receiver and a hand held, battery powered radio
control unit. It is only as an optional extra.
To operate the radio control:

1 Observe all safety warnings
2 Start the Engine
3 Ensure that all hydraulic control levers are in the correct positions.
5 Remove the doglead from the machine
6 Press any button on the transmitter. After a 7 second delay has elapsed the
directional switches become active.
NOTICE
In order to deactivate the handset press the remote off button.

Diesel
6.5 Tipping Grid Remote Control Receiver Box
The tipping grid can be operated either manually using controls on the receiver box
or via a remote control. In order to operate the tipping grid using the remote control
a cycle must be programmed using the receiver box controls. The remote control
actuates this cycle and cannot alter the cycle. The tipping grid remote control
receiver box is situated on the power unit exterior.
A
B

Diesel
6.6 Controlling the Tipping Grid
6.6.1 Setting the Grid Tipping Program
Be careful of material on the tipping grid before activation Serious

danger of falling debris.
Falling material hazard

Do not walk near material discharge areas. You are at risk of serious
head injury or death. Wear a hard hat and eye protection at all
times, when working in the vicinity of the machine.
PROCEDURE
The Tipping grid program can only be actuated using the remote control.
The angle that the grid rises to needs to be set using the remote control when the
system is installed. The receiver box can be found above the door leading to the
power unit
1 Observe all safety warnings.

2 Start the engine.
Ensure that the engine is running and that the grid is fully down
3 Press the top button (A) on the side of the receiver twice and release. Press a
third time and hold down.
4 The grid should start to rise. Once it has reached the required angle (this
should be the end of the hydraulic rams stroke) release the button and the
grid should stop.
5 Repeat this exercise for the lowering cycle by pressing the second button on
the receiver box (B).
6 This cycle will be recorded and each time the grid is operated using the
remote control the same angle and speed will be achieved.
6.6.2 Operating the Grid Manually

2 Start the engine.
3 To raise the grid manually press and hold button (C). Once the grid has
achieved the required height release the button
4 To lower the grid manually press and hold button (D). Once the grid is
completely down release the button.

Diesel
6.6.3 Operating the Grid Using the Remote Control
Before activating the tipping grid cycle using the remote control,
ensure that the grid is fully down
Be careful of material on the tipping grid before activation.
Serious danger of falling debris

2 Start the engine.
3 To activate the remote control press the on button (H) twice. The LED (F) will
flash once to indicate that the remote control is active
4 To activate the tipping cycle press button (E) once. The LED (F) will flash
rapidly each time a button is pressed
5 To stop the grid in mid-cycle press button (G) once
6 To restart the cycle press button (E) again
The tipping grid is designed to finish the cycle. If the grid is stopped in the rise
cycle, once the cycle is restarted it will continue to its highest point before
lowering again
The remote control has an automatic turn off feature. The system also has an
operating range of approximately 100m.
But longer or shorter distances will be achieved depending on the location
of the receiver box in relation to the remote control transmitter. The
surroundings will also affect the range of the device. The units are designed to
operate with internal aerials.
(E) Start
Cycle
(G) Stop Mid
Cycle
(H) On/Off
Switch
(F) LED

Diesel
6.6.4 Programming a New Tipping Grid Remote Control
Each remote control transmitter has a unique operating code. If a remote control or
receiver box is replaced then the receiver box has to be programmed to recognize
the new remote control transmitter.
If a remote control transmitter is taken from one machine or system and used to
operate another system, the original receiver box should be disabled by removing
the 2 Amp fuse on the printed circuit board (G).
Label the receiver with instructions to reprogram it before putting it back into
service into service. Otherwise the situation could arise that on remote control
could operate two different systems.
(G) 2 Amp
Fuse
The same remote control should not be used to operate more than
one system. Ensure each tipping grid has its own remote control

Diesel
6.6.5 Programming the Receiver

2 Remove the cover from the receiver box by unscrewing the 4 fixing screws (A)
3 Ensure that LED (E) on the PCB is turned on. This LED indicates that the
receiver box has a correct power supply.
4 Set the program ID switch (C) to the programming position by moving the
switch lever to the left, according to picture’s orientation.
5 Press and release the program ID push button (D). The programming LED (B)
will turn on.
6 Ensure that the remote control transmitter is turned on.
7 Press and hold any button on the remote control transmitter (except the ON
button). LED (B) will turn off and the valid signal LED (F) will turn on
Do not hold the remote control closer than 500mm from the receiver box
8 Release the button being held down on the transmitter

9 Set the program ID switch (C) to the operating position by moving the switch
lever to right position according to the pictures orientation.
10 Replace the lid on the receiver box and tighten the 4 mounting screws
(A) Mounting (A) Mounting

screws screws

Diesel
6.6.5 Programming the Receiver
(D) Program ID
(B) Program Pushbutton
LED
(C) Program
ID Switch (E) LED
(F) Valid
signal LED (G) 2 Amp
Fuse
Printed Circuit Board (PCB) of receiver box

Diesel
6.6.6 Changing the Tipping Grid Remote Control Batteries

The tipping grid remote control battery life depends on its frequency of use. Low
batteries are indicated when the LED (A) on the remote control goes dim when a
button is pressed and/or the functions do not operate.
When this happens the batteries should be replaced immediately. The batteries
consist of 2 x 1.5 volt AAA alkaline batteries located in the rear of the remote control.
NOTICE
Before replacing transmitter batteries turn off the receiver box by
disconnecting its power supply

2 Ensure machine is switched off, tagged out and locked out.
3 Undo the 3mm screw securing the battery compartment cover at the rear of
the remote control
4 To remove the cover, raise the end adjustment to the belt clip and swing the
cover and lift off.
5 Remove the exhausted batteries
6 Fit 2 new AAA size alkaline batteries taking special care to ensure the battery
polarity symbols align with the corresponding symbols embossed to the base
of the battery compartment. Incorrect polarity may damage the transmitter.
Do not mix old and new batteries
7 Refit the cover by engaging the small catches at the bottom edge of the cover
with the slots on the lower edge of the battery compartment and then fold the
cover towards the belt clip.
8 Secure the cover with the 3mm screws
(A) LED

Diesel
6.7 Tracking using the Hand-held

remote control unit
Ensure that the doglead is connected G8 Right

to the machine, and that the doglead
E-Stop is not processed. hand
Track
Start the engine as per setup Left hand Forward
procedure. Track / Track
Forward
Switch the Tracking On / Off switch / Track
on the Doglead handset to the “Track”
position. Tracking
On / Off
At this point the siren should sound for
7 seconds and the tracking beacon will Switch
flash.
The machine can now be tracked using

the controls on the doglead as shown Dog lead
opposite. Machine Stop
NOTICE
CE
When the remote control unit is not
in use, the function buttons must
remain in the neutral position.

Diesel
6.8.1 Powerscreen Electronic Control

Panel units
LCD Display
Engine Ignition Switch
For machines equiped with the Powerscreen electronic control panel the operation,
tracking* and tipping grip* controls are the same as those described in Chapter 5,
Section 5.3 Diesel Mode Operation.
* Unless fitted with JMG remote covered previously in this section.

Diesel

7 - Capacity & Tonnage Calculation Page 1
07 - Capacity and Tonnage Calculation

07 - Capacity and Tonnage Calculation
Contents
7.1 Calculating Capacity.............................................................................................3
7.1.1 Calculating Tonnage...........................................................................................3
7.1.2 Estimating Tonnage ..........................................................................................4
7.1.3 Calculating volume of stockpile . .....................................................................5

7.1 Calculating Capacity
Often it is desirable to know the weight of material being conveyed. This can be estimated
simply by using the formulae below.
7.1.1 Calculating Tonnage
Output per time unit = Belt Speed x Weight of material

Length of belt the material lies on
Example (Imperial)
Take
Belt speed 300ft/min
Weight of material on 3ft of belt 66.3 lbs
Also
60 minutes in 1 hour
2240 pounds (lbs) in 1 ton
Therefore
Tonnage per hour = 300 x 60 x 66.3 = 1,193,400 = 117.5 Tons per hour
3 x 2240 6,720
Example (metric)
Take belt speed 92 metre/min

Weight of material on 1 metre of belt 30 kg
Also
60 minutes in 1 hour
1000 kg in 1 tonne
Therefore
Tonnage per hour = 92 x 60 x 30 = 165600 = 165.6 Tonnes per hour

1000 1000

7.1 Calculating Capacity (continued)
7.1.2 Estimating Tonnage
A value for tonnage can be calculated by timing the length of time it takes a certain weight
of material to go up the conveyor belt or over the screen.
Example
A hopper containing 6 tonnes of material takes 2 1/2 minutes to empty.
Then

6 tonnes in 2 1/2 minutes

12 tonnes in 5 minutes
Therefore
Output = 144 Tonnes per hour
7.1.3 Calculating volume of stockpile
The formula for a conical stockpile of any base area is:
1 (Cross Sectional Area) x (Perpendicular Height)

3
For a stockpile with a circular base area the formula will be
1 x (π) x (R2) x (H)

3

7.1.3 Calculating volume of stockpile (continued)
For Example
For circular stockpile

Radius (R) 1.5m
Stockpile height (H) 2m
7.1.4 Calculating volume of a radial stockpile
Volume = 1 x (π) x (R2) x (H) = 1 x (π) x (1.52) x (2) = 4.71m3

3 3
θ
R
γ L
The volume of a radial conveyor can be found using the formula:
Volume of = H x H x 2 x L x ( ) + Volume of Stockpile

Radial Stockpile Tan  360

7.1.4 Calculating volume of a radial stockpile (continued)
For Example
For Circular Stockpile
Radius (R) 1.5m

Stockpile height (H) 2m
Angle of repose (è) 53o
Radial Stockpile
Radial Conveyor Radius (L) 18

Radial Conveyor Angle (ã) 140
Volume of = 2 x 2 x 2 x 18 x (140 ) + 4.71 = 137.33m3

Radial Stockpile Tan 53 (360)

8 - Initial Checks Page 1
08 - Initial Checks

08 - Initial Checks
(Running In)
Contents
8.1 Initial Start-Up ......................................................................................................3
8.2 Screen.................................................................................................................................3
8.3 Feeder.................................................................................................................................3

8.1 Initial Start-up 8.2 Screen

1. Check the oil levels. 1. Ensure that the tension of the screen
mesh(es) is satisfactory.
2. Check the hydraulic oil level in the tank. 2. Frequently check the flow of material
over the screen mesh(es) to confirm
satisfactory separation is taking place.
3. Refer to engine manual for initial start up of
3. Make sure that the screen mesh
engine. apertures are free of ‘pegged’ material
and that they remain in good condition.
4. Run the plant empty for a short period of 4. Check the vibrating unit bearing
time and check for abnormal noises, vibration temperatures using a contact
or excessive heat from the shaft bearings. thermometer on the end covers; record
for future reference and fault diagnosis.
(Maximum acceptable temperature is
80ºC [176°F] ).
Actions during this period
8.3 Feeder
5. Each day during the initial days of operation .
check the tension of the conveyor belts. 1. Ensure that the feeder unit is operating
before any material is introduced to the
6. Frequently check the overall stability of the
plant.
plant, re-position if necessary.
7. Check the plant is level, re-position if nec-

essary. NOTICE
Checks on the plant are crucial
8. Frequently check the hydraulic oil level in
during the first week of operation.
the tank.
This section should be read
and understood prior to
starting the plant. If there
are any doubts, consult your
local POWERSCREEN dealer
or POWERSCREEN Technical
Support department.


9 - Daily Checks Page 1
09 - Daily Checks

09 - Daily Checks
Contents
9.1 Checks Prior to Daily Start ..............................................................................................3
9.2 Powerunit .......................................................................................................................6
9.3 Screenunit .......................................................................................................................6
9.4 Tracks ...............................................................................................................................6
9.5 Conveyors .......................................................................................................................6

Plant
1. Observe all safety warnings.
2. Visually check and inspect all guards, covers
WARNINGS
and doors are in position and secure.
3. Check that all equipment and tools that are It is imperative that the operator
hazardous to operation are removed from the carries out regular and diligent
immediate site. checks before operating the plant,
especially with operational safety
4. Perform all actions required in the
lubricationschedule requiring a daily check or in mind.
lubrication, refer to servicing - lubrication.
Always consider what particular
5. Make sure all warning and safety signs are
safety hazards could occur at
clean and visible, see plant specification
specific sites and eliminate them
and information for their part numbers and
before commencing work.
positions.
6. Ensure that the screenunit and the feed DANGER
hopper are empty.
DO NOT allow an excavator bucket
7. Check hydraulic oil level and filter condition
feeding material into the hopper
indicators. to pass overhead or near the plant
8. Visually check the hydraulic system for operator.
damage or leaks.
9. Check belts for damage, wear and fraying. WARNING
10. Clean away dirt and grit from maintenance NEVER leave the plant unattended
platforms. whilst it is in operation.

9.1 Checks Prior to Daily Start - 9.1 Checks Prior to Daily Start -
CONTINUED CONTINUED
11. Do check regularly that the oil cooler 16. Check that all safety equipment,
fan is running correctly and that dust/ alarms and interlocks are operative.
dirt has not built up in the fan and radiator
unit (overheating can occur if dust/dirt is 17. Replace repair items as necessary to
allowed to build up). Blow out dust/dirt if avoid damage to the machine.
necessary.
18. Check setup of the screenunit and
12. DO NOT allow a build up of material at the adjust as necessary to the required
feed on points to enter. settings.
13. DO check frequently the stability of the 19. Check the wear parts to ensure
plant. The chassis SHOULD NOT bounce speed is suitable for the application
during operation. and feed rate not excessive.
14. DO NOT allow the engine RPM run at a

speed not suited for the application.
15. AVOID frequent starting and stopping of

the plant unnecessarily as it WILL cause
damage to the plant.
! danger !
DO NOT STAND ON THE
MAINTENANCE PLATFORM WHILST
THE SCREEN AND FEEDER ARE
OPERATING.

10 - Plant Components Page 1
10 - Plant Conponents
10 - Plant Components
Contents
10.1 General Information.................................................................................................................................................. 3
10.2 Construction units . ................................................................................................................................................... 4
10.2.1 Construction units - Feeder unit........................................................................................................................ 4
10.2.1.1 Reject grid.............................................................................................................................................................. 5
10.2.1.2 Remote Control Reject Tipping Grid............................................................................................................. 6
10.2.1.3 The vibrating grid................................................................................................................................................ 7
10.2.1.4 Feed Hopper.......................................................................................................................................................... 8
10.2.1.5 Feed conveyor....................................................................................................................................................... 9
10.2.2 Main conveyor........................................................................................................................................................10
10.2.3 Side conveyor.........................................................................................................................................................10
10.2.4 Screenunit................................................................................................................................................................11
10.2.5 Tail conveyor...........................................................................................................................................................14
10.2.6 Powerunit.................................................................................................................................................................15
10.1 General Information

Front
Left and Right hand
When using this handbook, at all Left

times the right and the left hand Right
references are viewed from the
hopper end of the machine.
Front and Rear
When using this handbook, at all

times the rear of the machine is
situated at the towbar end.
Rear
Front
Left
Rear
Right
10.2 Construction units
1a
10.2.1 Feeder unit (A)
The feeder unit consists of 3

main components: 1b

A1a Reject grid
A1b Vibrating grid
A2 Feed hopper
A3 Feeder conveyor
A1
A2
A3
10.2.1.1 Reject grid (A1)
The reject grid is attached to the

CHIEFTAIN`s feed hopper for the
purpose of protecting the feeder
unit and for separating big rocks
m
and heavy material. 02 m
<= 1
The standard aperture is 102mm

(4’’) but a 150mm (6’’) is also
available.
The reject grid bars are spaced
at 102mm (4’’) when leaving the
factory.
NOTICE
Do not adjust reject grid bars to

be spaced wider than 150mm
(6’’.)
THE TIPPING GRID
The tipping grid is an optional piece of equipment, which is used to remove pieces of
material too large to be effectively screened. In the case of the tipping grid material is
fed on top of the tipping grid, material smaller than 102 mm (4“), which is the standard
aperture size, will tend to fall between the bars of the tipping grid under the force of
gravity. The grid is angled to allow the oversized material to fall off the tipping grid
where it can typically be reprocessed. On occasions material will tend to sit on top
of the reject bars, to remove this material the grid can tip.
10.2.1.2 Remote Control Reject Tipping Grid
The hydraulically operated reject grid can be raised in the following way:
Operating the radio transmitter (RT), by pointing it in the direction of the radio receiver
(RR) fitted above the power unit.
The reject grid will lower automatically.


10.2.1.3 THE VIBRATING GRID
The Vibrating grid is designed for the same purpose as the tipping grid, however the
efficiency of the system increases when a vibrating grid is used. Whereas the tipping
grid uses gravity alone to seperate the oversized from the processable material. The
vibrating grid uses vibration as well. The effect of this is too ensure that little or no
material rests on top of the reject bars at any time.
Vibrating Grid
Fly wheel cover
Sub
Frame
Figure 10.2.1.3
10.2.1.4 Feedhopper (A2)
The 12 ft feed hopper capacity is 7cu.m

(9.15cu.yds,) on the track machine & 7.5
cu.m (9.8cu.yds,) on the wheel machine
with clamping arrangement for rubber
skirts.
A2
The wide belt allows steep hopper sides
to minimise material built-up.
10.2.1.5 Feeder conveyor
The feeder conveyor is attached

to the CHIEFTAIN`s feeder unit
for the purpose of feeding ma-
terial from the feed hopper and
to the main conveyor.
The feeder belt is driven by a

hydraulic motor with a variable
speed gearbox adjustment to
determine the feed rate.
Belt tension adjustments are
made outside of the guard A3
doors.
Conveyor belt assembly
The conveyor belt assemblies

on all POWERSCREEN machi-
nes consists of :
1 Drive drum and motor

2 Tail drum 9
3 Conveyor belting
8 5 45 34
4 Side rollers 3
5 Center rollers
6 Return rollers
7 Belt scrapers 2
8 Guarding
9 Viewing apertures
6 1 7
10.2.2 Main conveyor
The main conveyor is attached to

the CHIEFTAIN`s chassis for the
purpose of feeding material from
the hopper to the screen unit.The
main conveyor belt is driven by
a hydraulic motor.
It is fully skirted, belt tension
adjustments can be made outside
of the guard doors.
10.2.3 Side conveyors
The side conveyors are attached

to the CHIEFTAIN`s chassis for the
the screen unit. To stockpile
10.2.4 Auxiliary conveyors
The auxiliary conveyor is attached

to the CHIEFTAIN`s chassis for the
the screen unit. To stockpile
10.2.5 Screen unit
The screen unit is the single most important component on the CHIEFTAIN and must
be considered the heart of the machine.
The Chieftain 1700/1700S is equipped with a 16‘ x 5‘ (4.8m x 1.55m), triple deck, grease
filled 2 bearing system or a 16‘ x 5, (4.8m x 1.55m) double beck, grease filled 2 bearing
system. Both options have a 14‘ x 5“ (4.2m x 1.55m) bottom deck.
Screenbox
Bearing
Eccentric
Shaft
Flywheel
Springs
Sub-frame
10.2.5 Screen unit

(STANDARD DRY OPTION)
The screen unit is attached at
the end of the CHIEFTAINS main
conveyor where it screens raw
material into different sizes.
The screen unit is belt driven.
The screenbox angle is changed

by raising or lowering the screen-
box hydraulically.
To prepare for operation, raise

the screenbox. To prepare for
transport, lower the screenbox.

10.2.5 Screen unit
This is a two-bearing screenbox

which gives three-way separation
of raw material.
Meshes and speedharps of diffe-

ring sizes are available to cater
for all applications.
The anti rock stays (8) are remo-

ved after machine has been set
8
up in position on the site.
The screen unit consists of a

2/3 deck screenbox fitted with 2
flange mounted bearings on an
eccentric shaft.
The outer ends of the screen

shaft is fitted a flywheel com-
plete with weights and pully. The
screen shaft is driven from the
motor fitted on the subframe by
three pulley belts
The subframe in turn is rigidly

connected to the chassis of the
machine.
Screen springs are used to sup-

port the box totally on this new
system.
10.2.6 Tail conveyor
The tail conveyor is attached to

the CHIEFTAIN`s front chassis for
the purpose of feeding the fines
material from the screen. The
conveyor is hydraulically opened
to working position and retracted
to ground level facilitating quick
machine set up and shut down.
The tail conveyor belt is driven

by a hydraulic motor.
10.2.7 Power unit
The power unit is attached at the chassis of the CHIEFTAIN, under the
main conveyor.
The power unit is completely enclosed, sound suppressed and lockable.
Power unit
Electric and Dual Power below
Power unit
Diesel unit shown above

G1
10.2.7 Power unit (G) - CONTINUED G2
The CHIEFTAIN has ten control units.
The control panel (G1)

The control valve unit (G2)
Hand throttle (G3)
The control valve unit (G4)
The control valve unit (G5) G2
Walkway control valve (G6)
Track Machine Only G5

Radio control (G7)
Remote control (G8)
Jacking Leg Control (G9)
G4
Dual Power option
Electric control panel (G10) G6 G9
The control panel G1, control valve unit
G2 and hand throttle G3 are situated at
the powerunit on the right hand side of
the machine.
The control valves (G4 & G5) are

situated at the front of the machine.
They can be found to the right hand G7
and left hand sides respectively, under
the foot plates. JMG
PS unit unit
The control valve (G6) is situated at the
front of the machine on the walkway.
(OPTIONAL) PS unit
The controls (G7 & G8) are

independant control units. G8 JMG
unit
They control the movement of the
tracks.
They are described in more detail at the Electric
end of this section. Panel
shown
The Roll in Bogie has an additional may not
control bank (G9), that controls the be actual
jacking legs required for the bogie. fitted
G10
11 - Trouble Shooting Page 1
11 - Trouble Shooting

11 - Trouble Shooting
Contents
11.1 General Troubleshooting ...................................................................................3
11.2 Electrical Troubleshooting . ...............................................................................6
11.3 Hydraulic Troubleshooting ................................................................................7
11.4 Track Troubleshooting .......................................................................................8
NOTICE
TROUBLE SHOOTING GUIDE
If any problem arises that is not listed, or if a problem persists after carrying out
the recommended checks, contact Powerscreen Aftersales Service Department for
further assistance.

11.1 General Troubleshooting - CONTINUED
FAULT CAUSE CORRECT MEASURE

DRIVE DRUM TURNS Too much load on belt Reduce load on belt
BUT BELT DOES NOT Incorrectly tensioned belt Tension belt
MOVE
Worn belt Replace belt
BELT COMPLETELY Material jam Remove material jam
STOPPED Taperlock is not tight or broken Tighten or replace taperlock
BELTS ARE TRACKING Machine is not level Ensure machine is on level
OFF ground
Belts are not aligned Align belts
Belts are not being fed evenly, Ensure conveyor is fed more
material is tending to be fed to evenly
one side of conveyor
MATERIAL COLLECTS Skirting rubbers not adjusted Adjust skirting rubbers
UNDER BELT
FEEDER CONVEYOR IS Feeder kickout circuit has been Allow material in drum to be
NOT MOVING activated processed before re-engaging
control lever
RUMBLING NOISE Bearing lacking lubricant Follow greasing procedure
FROM BEARING Incorrectly aligned bearing Align bearing
Bearing is damaged Replace bearing
SCREECHING NOISE Conveyor belt wedged or rub- Clear obstruction, adjust and
WHEN CONVEYOR IS bing against fixed parts align conveyor belt
RUNNING Belt scaper too tightly placed Re-adjust belt scaper
against belt
TIPPING GRID WILL Low battery charge level Charge battery. Top up elec-
NOT OPERATE IN trolyte level
EITHER MANUAL OR Insufficient flow to hydraulic Check flow from pump and
REMOTE CONTROL ram control valve
MODE
Electrical problem Check fuses, relays and all
connections
Poor hydraulic ram condition Replace hydraulic ram
Poor connection between tip-
ping grid reeiver and solenoids
Damaged solenoid Replace solenoid


MACHINE COMPO- Obstruction (e.g stone, mate- Clear obstruction
NENTS RUNNING rial build up etc)
SLOWLY Check general condition of Correct problem if pos-
machine (e.g oil leaks, exces- sible
sive heat, hose blockages etc)
Low engine speed Correct engine speed
Low hydraulic oil level. Top up hydraulic oil level
Return line filter blockage Replace return line filter
Pre-pump filter blockage Replace suction strainer
Machine is overloaded Check mesh size cal-
culations, alter screen
angle
Incorrect control valve relief Check and correct relief
valve pressure settings pressure setting
Incorrect Pressure relief block Check and correct relief
pressure settings pressure setting
Pump cavitation, suction line Open gate valve
is collapsed Low oil level
Flow at pump is not as ex- Check flow after pump,
pected after control valve and
after motor. These val-
ues should be the same
MACHINE WILL Machine is not level Place machine on level
NOT JACK TO ground
WORKING POSI- Securing pins not removed Remove securing pins
TION Blockage along hose Remove blockage, re-
place hose if necessary
Incorrect control valve relief Correct control valve
pressure relief pressure
EXCESSIVELY Blockage at pre pump filter Replace suction strainer
NOISY PUMP Misalignment between drive Correctly align drive
source and pump source to pump
Incorrect hydraulic oil Drain hydraulic and re-
place with correct hy-
draulic oil
Obstruction at inlet pipe Remove obstruction

Screen Starts Slow Drive belt slipping Tighten belt; replace worn belt or
sheave
Spillage Stroke angle too Set it to run at a more shallow
steep angle
Screen speed too Set it to run slower
fast
Stroke is too long Reduce stroke length, if
possible
Worn screen rubbers Replace screen rubbers or
or curtain curtain
Decks overflowing; Screen is overloaded Check plug weight

Placement - Increase RPM,
but stay within stroke speed
Rock moves across Rpm too high Decrease rpm but stay within
screen too fast stroke-speed range
Stroke angle too flat Increase stroke angle
Rock moves across Rpm too low Increase rpm but stay within
screen too slowly stroke speed range
Stroke angle too Decrease stroke angle
steep
Decks blinded with clay Wire cloth wire too Use smaller-gauge wire
heavy
Excessive vibration Loose or misaligned Check counterweight bolts;
weights check number and
position of plug weights
Broken shaft Replace shaft
Impulse shafts im- Check improperly timing
properly timed

11.2 Electrical Troubleshooting - CONTINUED

TRACKS RADIO Not correctly charged Charge battery
CONTROL UNIT
DOES NOT WORK
TRACKS DO NOT Changeover switch Engage changeover
WORK not engaged switch
Control bank levers Place control bank levers
are not in correct posi- in correct position
tion
Fuse F3 blown Replace fuse and check
for short circuit between
control panel, track junc-
tion box and doglead

11.3 Hydraulic Troubleshooting

NO RESPONSE Low oil level Top up hydraulic oil level
FROM ANY HY- Return line element is Replace return line ele-
DRAULIC SYSTEM clogged (Check blockage ment
indicator)
Damaged suction line Replace suction line pipe
Pressure relief valve stuck Replace valve
in open position
MACHINE OPER- Low oil level Top up hydraulic oil level
ATING SLOWLY. Incorrect hydraulic oil Drain tank and replace
NO EXTERNAL OIL hydraulic oil
LEAKS Worn or damaged pump Replace pump
Worn or damaged drive Replace motor
motor
Loose or damaged taper- Replace taperlock
locks
Feeder kickout engaging Reset feeder kickout
at low pressure pressure
Engine performance Consult engine manual
EXCESSIVE NOISE Damaged pump Replace pump
FROM HYDRAULIC Low oil level causing cavi- top up oil level
PUMP tation
Misaligned drive source Align pump correctly
(engine or motor) to pump
Damage to suction pipe Replace pipe
Incorrect hydraulic oil Drain tank and replace
(fluid viscosity too high) hydraulic oil

11.4 TRACKS TROUBLESHOOTING
(i)One Track not operating or operating slower than the other

- Check that the same size of Motors have been fitted to both Tracks.
- Check if the brake is releasing.
Fit a pressure clock to the Brake Hose. A pressure of at least 285 PSI / 20 bar is
required to release the brakes.
If the correct pressure is not going to the Brake hose it is likely to be a problem with
the Motion Control Block possibly contamination. If a Load Control Valve should
jam due to oil-entrained debris then the likelihood is that it will not open and will not
allow the motor to turn in one direction.
This will cause the Host Machine to ‘crab’ in one direction. Swapping the valves
over from one Track to the other will usually transfer the problem to the opposite
direction.
Similarly, if the Brake Pressure Regulator Valve is jammed due to debris the motor
will stop turning on one side. Swap the Pressure Regulator from the opposite block
to see if the problem is in the Brake Valve.
Try removing the Valves and cleaning them thoroughly taking care not to damage the
external cavity seals.
Also check the ports in the Block for dirt etc. If this does not work replace the valves
with new ones. Always cross-reference the part numbers on the new valves with the
old valve, before fitting. It is critical that the correct Valves are fitted. Valves should
never be dismantled as no internal seals or parts are available.
If the valves continue to jam then the oil in the hydraulic system is not being filtered
to the required level of cleanliness.
- If the correct pressure is going to the Brake Hose then the Motor, Brake or Brake
Piston Seals may be damaged.
- To check for a Motor fault swap over the Motors on the two Tracks. If the fault is in
the Motor, replace with a new Motor.
- To check for a faulty Brake remove the Motor and look into the Gearbox for heat
discolouration and/or fragments of Brake disc. If the fault is in the Brakes the
complete Gearbox will have to be replaced.
-To check for faulty Brake Piston seals remove the Motor. If there is Hydraulic oil
in the Gearbox entrance then the seals are damaged. While it may be possible to
replace these seals on-site we strongly recommended that a replacement Gearbox
is fitted and an overhaul of the damaged Gearbox be carried out off-site.

11.4 TRACKS TROUBLESHOOTING (CONTINUED)
(ii). Excessive oil leaking around Drive Assembly
- Seals damaged between Motion Control Block and Motor.
Remove Motion Control Block and replace seals.

Note: Seal damage may be caused by excessive oil temperatures. Check oil
operating temperature and environmental conditions.
- Seal damaged between Motor and Gearbox.
Remove Motor and replace seal.

Note: Seal damage may be caused by excessive oil temperatures. Check oil
operating temperature and environmental conditions.
(iii) Track will not stay tensioned
- Grease escaping.
Check that the Track Adjuster Grease Valve is tight, has a properly fitted seal and
that there is no grease leaking past it.
Check around the Tensioning Cylinder for escaping grease. This will indicate that
the seals are damaged in the Tensioning Cylinder. Replace with a new Cylinder
immediately.
(iv) Track Group running off Sprocket and/or Idler
- Track Group too loose. Check Track tension

- Excessive misalignment. Check alignment of Sprocket, Idler and Track Rollers.
- Excessive component wear. Check wear limits,
- Twisted Track Frame. Check Track Frame.
(v) Excessive Component Wear Rate
- Included in this section
(vi) Track Roller leaking oil
- Damaged or worn seals. Replace with a new Track Roller.


12 - Unloading & Loading Page 1
12 - Unloading & Loading

12 - Unloading & Loading
Contents
12.1 Unloading ............................................................................................................3
12.2 Loading.................................................................................................................3
12.3 Removing Machine from the Prime Mover (WHEEL MACHINE).....................4
12.4 Removing Machine from the Low Loader (TRACK MACHINE’S)....................6

12.1 Unloading 12.2 Loading

1. A tracked plant will normally be 1. Before loading, the plant must be
secured to a low loader trailer. prepared for transportation, refer to
preparing to move plant.
2. Removing the fastenings securing
the plant and any loose items to a trailer 2. Check that the travelling dimensions
is the responsibility of the haulage and weight, when loaded, will be within
contractor. the regulation limits, refer to plant
specification and information.
3. If the plant has been manufactured to
connect to special rear bogie, refer to 3. Observe all safety warnings.
the special instructions to separate the
plant from its bogie.
4. Ensure all loose items are carefully
stowed and secured if these are to be
transported on the plant.
5. Make sure suitable ramps are
5. Make sure suitable ramps are
positioned at the end of the trailer to
positioned at the end of the trailer to
unload the plant.
load the plant.
6. Check that any loose items
6. Ensuring that the engine/motors are
transported with the plant will not cause
running at idle load the plant slowly on
a hazard while unloading.
the trailer, manoeuvring the plant with
the tracks, using the umbilical control
7. Depending on type of machine either
or the remote radio control, if fitted, see
start the machine in diesel or electrical
moving the plant.
mains power mode. Ensure that the
engine/motors are running at idle while
7. Stop the machine.
manouvering.
8. Securing the plant and any loose
8. Unload the plant slowly off the trailer
items to the low loader trailer is the
into a safe position or plant operating
responsibility of the haulage contractor.
position, manoeuvring the plant with
the tracks. Use the umbilical control or
the remote radio control, if fitted, see
moving the plant.
Prior to transportation always check
9. Stop the engine, see engine stop, the plant for loose or damaged
unless required further. components.

12.3 Removing Machine from the

hazards
Prime Mover (WHEEL MACHINE) EQUIPMENT
1520 / 1513 for relevant warning.
ANSI
NOTICE
All control levers must be in the neu-
tral (non-operational) position.
2. Start the machine.
3. Remove the pin and spring pin from

the hydraulic jacking leg.
NOTICE
Slightly activate the jacking leg
lever to release the tension from
the retaining pins, allowing for
easy removal of the pins.
4.Move up lever of the auxiliary control

valve to extend the jacking legs and
raise the feeder. See Plant Setup
Section.
Auxiliary control Drive control

bank bank

12.3 Removing Machine from the Prime Mover

(WHEEL MACHINE)(CONTINUED)
Auxiliary control Drive control

5. Remove prime mover. bank bank
6. Move down lever of the auxiliary control

valve to retract the jacking legs and lower
the feeder. See Setup Section.
7. Re-insert pins and spring pins.
8. Switch off machine.

12.4 Removing machine from the low

loading trailer (track machine)
12.4.1 Radio control

hazards
NOTICE 1520 / 1513 WEAR PERSONAL PROTECTIVE
EQUIPMENT
Refer to Section 5 & 6, for complete 1520 / 1513 for relevant warning.
specification on radio/remote control ANSI
units before attempting the following 1509 ISO
prior to transport HAZARD
procedures. 1509 ANSI
Refer to Safety Chapter Section -
Machine Safety Hazard Decals for
relevant warning
All control levers must be in the
neutral (non-operational) position.
PROCEDURE
2. Prepare the low loading trailer, for

removing the CHIEFTAIN on tracks.
NOTICE
The Screen and Tail conveyor
must be raised to allow adequate
ground clear for the tail conveyor
when the machine is being loaded
or unloaded.
Care must be taken not to raise

the screen too far or the conveyor
will bend the walkway.


12.4.1 Radio control - CONTINUED

4. Remove the pins, spring pin and
washers (P) from Lh & Rh sides.
5. Move up, the screenbox (G4) lever P

to raise the screenbox.
8. Move up, the tail conveyor lever (G5)

to raise the tail conveyor.
9: Machine should be in the position

with the screenbox and tail conveyor
G4
raised enough to allow removal from
low loader.
Ensure that tail conveyor does not G4

impact on screen box or walkway
when raising.
G5
G5


12.4.1 Radio control - CONTINUED
NOTICE
Ensure all personnel are clear from
the machine.
10. Using the radio control unit (G7) to G7

operate the radio control push;
JMG
PS unit unit
11. Move the track levers down, to
activate the tracks.
12. Operate the track buttons to move

the CHIEFTAIN off the low loading trai-
ler.
13.Press the forward or backward

buttons, on the corresponding hand-
set, to move the CHIEFTAIN in the
desired direction.
14. Sreenbox and tail conveyor are

raised so they clear the ground when
loading and unloading the machine
from the low loader.

15. Move the CHIEFTAIN into the re-
quired position on the work site.

12.4.2 Remote control
Refer to Section 5 & 6, for complete

specification on radio/remote control hazards
units before attempting the following 1520 / 1513 WEAR PERSONAL PROTECTIVE
EQUIPMENT
procedures. ISO Refer this Section, safety information
ANSI
prior to transport HAZARD
1509 ISO Refer to Safety Chapter Section -
All control levers must be in the neu- 1509 ANSI Machine Safety Hazard Decals for
tral (non-operational) position. relevant warning
PROCEDURE
S
2. Prepare the low loading trailer, for

removing the CHIEFTAIN on tracks.
PS unit
3. Remove the dummy plug and insert

the remote control unit (RU,) into it‘s RU JMG
unit
socket (S,) at the rear of the CHIEFTAIN
4. Start the machine and remove from

low loader using the same procedure
as that used with the radio control.



13 - Manoeuvring Plant Page 1
13 - Manoeurving Plant

13 - Manoeuvring Plant
Contents
12. 1 Safety . ................................................................................................................3
12. 2 Track operation precautions ............................................................................4
12. 3 Undercarriage.....................................................................................................5
12. 4 Maneourving in general....................................................................................5
12. 5 Manual tracking doglead...................................................................................7
12. 15 moving the Chieftain using the doglead........................................................8

12.1 safety
Bogie safety
Please ensure all safety precautions and instructions are adhered to when installing,
operating and/or performing maintenance on the axle system.
Under no circumstances are tracked machines allowed to be

transported across or on public roads. Appropriate haulage equip-
ment must be used
Explosive seperation of tyre and rim parts can cause serious injury
or death
Check wheels for low pressure, cuts, bubbles, damaged rims or

missing lug bolts and nuts
Always maintain the correct tyre pressure. Do not inflate the

tyres above the recommended pressure. Use a clip-on chuck and
extension hose long enough to allow you to stand to one side
and not in front of or over the tyre assembly. Use a safety cage if
available
Protective equipment
Always wear protective clothing and footwear as required by job
conditions when working around this product.
Wear protective glasses when in risk of slintering debris.
Unauthorised modifications
It is important not to carry out modifications to the axle system
which could compromise proper operation and safety.
Powerscreen Intl Ltd are not responsible for any injury or damage
caused by unautorised modifications.

12.2 TRACK OPERATING PRECAUTIONS
When traveling up a gradient, the tracks should be driven forward (i.e idlers first,
drive sprocket to the rear). When traveling down a gradient, tracks should be driven
sprocket first.
ALWAYS:-
Park the machine on flat, level ground. If necessary to park the machine on a
gradient, the tracks should be solidly blocked.
Ensure the terrain the machine is working on is firm enough to adequately support
the machine.
Ensure the machine is tracked at least 10m in either direction on a daily basis, to
minimize risk of track chain seizure.
Ensure the track systems are free from debris before moving the machine.
Ensure the tracks are not frozen to the ground before moving the machine.
NEVER:-
Attempt to track the machine if there is any build up of material around the tracks
and drive sprockets.
Attempt to track the machine if the tracks are frozen to the ground.
Push or tow the machine when unable to free itself.
Failure to observe the above precautions could result in danger

to persons and damage to the track systems and may also
invalidate the warranty.

12.3 Undercarriage
Chieftain machinery can be moved one of two different ways depending on the type
of machine,
1 Bogie
2 Tracks
Each type of undercarriage must be properly maintained to ensure a safe, effective

working environment. Track machines are designed for ease of movement around
the site and should not be used on public roads. Haulage equipment, such as a
low loader or a roll in bogie, should be used for this purpose. Non track machines
should be transported using the appropriate haulage equipment.
12.4 Manoeuvring - General

• Before manoeuvring the plant, ensure the feed hopper and screen are empty,
and that all materials have run off the conveyors. STOP the feeder, sreenuint and
product conveyors.
• The safety warning horn/siren sounds continuously whilst the plant is being
manoeuvred.
• Make sure that you do not manoeuvre the plant on a gradient steeper than 30
degrees (moving fore or aft), damage may occur to the engine and/or plant.
• Avoid manoeuvring the plant over extremely uneven ground or damage may
occur. Due to the limited ground clearance, avoid running over isolated objects
between the tracks.
• Initial start up in cold weather may result in a tendency to steer to the right
whilst tracking fast forward due to the hydraulic oil being cold. Run the plant for
approx. 10 minutes with the conveyor and feeder running prior to manoeuvring
the plant.

! warning !
12.4 Manoeuvring - General
Prior to attempting any manoeuvring
• Before manoeuvring the plant, ensure of the plant the tracks must be free
the feed hopper and screen are empty, of obstructions, including screened
and that all materials have run off the material and fines. Do not push or
tow the Plant. Failure to observe
conveyors. STOP the feeder, sreenuint
this warning could result in danger
and product conveyors.
to persons and damage to the plant
which may invalidate warranty.
• The safety warning horn/siren sounds
continuously whilst the plant is being
manoeuvred.
• Make sure that you do not manoeuvre

the plant on a gradient steeper than 30
degrees (moving fore or aft), damage ! danger !
may occur to the engine and/or plant. DO NOT stand on any of the
platforms or ladders of the plant
• Avoid manoeuvring the plant over whilst it is being manoeuvred using
extremely uneven ground or damage the remote control handset.
may occur. Due to the limited ground
clearance, avoid running over isolated
objects between the tracks.
! danger !
• Initial start up in cold weather may
When manoeuvring your machine to
result in a tendency to steer to the its operating position make sure you
right whilst tracking fast forward due stand well clear of the plant but are in
to the hydraulic oil being cold. Run the a position to have all-round vision to
plant for approx. 10 minutes with the see any obstacles, dangers that may
conveyor and feeder running prior to lie ahead e.g personnel, overhead
manoeuvring the plant. cables, ditches, unsafe roadways etc.

12.5 Manual Tracking Doglead
The doglead is only used to operate the tracks. It performs no other operation.
The remote control consists of a direct lead and a handset
NOTICE
To operate the machine via the Doglead, firstly retrieve the remote control unit.
Attach the remote control unit cable to the socket at the rear of the machine.
One option available on the tracked Chieftain is the radio controlled tracking,
As with all other standard track machines a doglead is also fitted, these
models are fitted with an automatic chaneover, thus no changeover switch will
be fitted.
In this case the start up procedure is the same as for a machine which is not
fitted with a radio tracking option. That is to simply connect doglead, start
engine position appropriate levers and than press the tracks on/off button on
the doglead to initiate tracking after the 7 secomd delay finishes.

12.6 Moving the chieftain Using the Manual Tracking Doglead

2 Ensure that the Doglead is connected correctly to the machine (S) and that
the doglead machine stop (B) is not pressed.
If the machine stop (B) is pressed do not reset it until tracks and surrounding
area have been checked and it is safe to move the machine. When the
machine stop button has been pressed the engine will cut out and will need to
be started after reseting the machine stop button. The doglead machine stop
(B) can be reset by twisting it clockwise one quarter turn.
3 Start the machine

4 Ensure that all levers on the control bank are set to the tracking position.
That is, the track levers are both in the down position all other levers should
be in the neutral position.
The machine will not stop if the doglead is removed.
the large red button ( machine stop button ) on the

doglead cannot be referred to as an emergency
stop.
Should an emergency arise and the doglead is not
connected to the machine, pressing the large red
button will not stop the machine.
Should an emergency arise press an emergency stop

on the machine itself.

12.6 Moving the chieftain Using the Manual Tracking Doglead
At this point the tracking safety siren should sound and the tracking beacon
should flash
6 Press the ‘tracks on/off button’ (A) on the doglead to the right, (According to
the pictures orientation) this is the track position
7 The machine can now be tracked using the control on the doglead as shown
(T1) (T2)
(A)
(B)
The remote control unit is equipped with four different function buttons: A, B,T1 and
T2
A On/Off button
B Machine stop button
T1 Move left hand tracks backwards or forwards
T2 Move right hand tracks backwards or forwards
NOTICE
When the machine has been moved to the desired location further movement
can be prevented by moving the on/off switch to the left position.


14 - Plant Setup Page 1
14 - Plant Setup

14 - Plant Setup
Contents
14.1 Plant location considerations............................................................................3
14.2 General Information............................................................................................4
14.3 Dimensions, required space and weight...........................................................4
14.4 Measures before set up......................................................................................4
14.5 Measures after long term standstill...................................................................4
14.6 Machine setup.....................................................................................................5
14.7 Starting the machine...........................................................................................5
14.8 Machine operation..............................................................................................5
14.9 Remove machine from Prime Mover / Low Loader.........................................5
14.10 Prior Installation................................................................................................5
14.11 Raising the feeder into working position (Wheel machine)...........................6
14.12 Lowering the rear support legs (Track Machine)............................................9
14.13 Opening out the side conveyors....................................................................10
14.14 Opening out the auxiliary conveyor...............................................................12
14.15 Attaching side conveyor padels.....................................................................16
14.16 Lowering the tail conveyor (Head section)...................................................17
14.17 Raising the screenbox into working position...............................................18
14.18 Raising the tail conveyor into working position..........................................19
14.19 Positioning the main conveyor.......................................................................20
14.20 Adjusting the spreader plate..........................................................................21
14.21 Removing screen anti-rock stays..................................................................22
14.22 Walkway setup instructions...........................................................................23

14.1 Plant location considerations

hazards
Prior to setting up the machine, 1520 / 1513 WEAR PERSONAL PROTECTIVE
EQUIPMENT
consideration should be given to a suitable ISO Refer this Section, safety information
layout to prevent oversize material or metal 1520 / 1513 for relevant warning.
from entering the machine. In order to ANSI
prevent damage of the sreenunit no material 1532 ISO LOCKOUT AND TAGOUT
Refer this Section, safety information
above the size recommended should be fed 1532 ANSI for relevant warning.
into the plant.
FALL HAZARD
Position the plant in a safe, level, operating 1508 ISO
position making sure both tracks are in 1508 ANSI for relevant warning.
full contact with the ground to minimise
movement of the Plant. Regularly check the
plant is level and stable.
Pay attention to access from the loading The environment in which the plant will
area and to where material is to be
operate contains inherent health and
deposited.
safety risks, which the operator must
Ensure the area under the tail drum of the take steps to avoid.
product conveyor is free of large stones etc.
Dangers from overhead conveyor
which may cause damage to the belt.
discharges, overspill material, vehicle
movements, etc., as well as other site
related hazards must be anticipated.
Avoid these by carrying out risk

assessments before the plant is put
into operation to ensure appropriate
exclusion zone measures are put
in place and site personnel safety
awareness training has been
undertaken.

14.2 General information
When setting up the CHIEF-

We recommend that the TAIN pay particular attention
assembly/ installation work to the following points:
of the CHIEFTAIN be carried
out by the POWERSCREEN 1. The CHIEFTAIN must be
customer service department. placed on solid ground capable
The manufacturer/supplier of carrying the machine‘s
will not be liable for damage weight.
caused by improper assembly/
installation. 2. Before detaching the
CHIEFTAIN from the prime
mover, it is important that the
14.3 Dimensions, required space chosen site is level.Level the
and weight work site foundation with the
loading shovel.
Dimensions
Refer to Chapter Plant 3. Level the CHIEFTAIN with a
Specification and Information precision spirit level.
Required space 4. Do not position the machine

Refer to Chapter Plant above ground level, eg. on
Specification and Information blocks etc..
Weight
Refer to Chapter Plant
Specification and Information
14.5 Measures after long term
standstill
14.4 Measures before set up
Check tracks before transpor-
1. Ensure all guards are fully ting or moving the machine.
secured in correct/closed
position.
2. Remove all loose items NOTICE

from the belt by untying the
Prior to putting into operation per-
securing ropes.
form daily
(10 hour) maintenance schedule.
3. Put control valve levers
in neutral (non-operational)
position.

14.6 Machine set up 14.7 starting the MACHINE
For dusty conditions some ac- See Chapter 5 & 6.

count should be taken of the
prevailing wind direction to
minimize the possibility of dust
entering the air intake.
14.8 mACHINE OPERATION
When setting up the
CHIEFTAIN ensure that enough See Chapter 5 & 6.
space is available around the
machine/plant to enable easy
set up, servicing and repair
14.9 Remove from prime mover /
work.
low loader
Machines arranged before and
after the CHIEFTAIN will have See Chapter 12.
to be placed accordingly.
The general arrangement 14.10 prior installation

diagram giving you the basic
information of the CHIEFTAIN 1.Observe all safety warnings.
including measurements and 2.Remove items, such as packing kit,
weight is provided in Chapter ladder etc.,
Plant Specification and
Additional Information
Before setting up the

CHIEFTAIN this Section and
all of the previous Sections
must be read, understood and
observed.
Any work on and with the

machine must be carried
out only by personnel with
specialized knowledge of and
experience with maintenance
and operation. Statutory
minimum age limits must be
observed.

14.11 Raising the feeder into working

position
(Wheel machine)
hazards
NOTICE ISO
EQUIPMENT
ANSI
Before starting the engine the anti

rock-stays must be removed.
PROCEDURE
3. Remove the pin and spring pin and

manually lower support legs from towing
position to ground level.
Stand clear of support leg when

withdrawing the main support pin.
The inner telescopic member of
the jacking leg is heavy and may
cause serious injury if allowed
to fall after pin withdrawal.


position
(Wheel machine)-CONTINUED
4. Remove the pin and spring pin from

the hydraulic jacking leg.
NOTICE
Slightly activate the jack leg lever
to release the tension from the
retaining pins, allowing for easy
removal of the pins.
5. Move up jacking leg control lever to

extend the jacking legs and raise the
feeder.
6. Move down jacking leg control lever

to retract the jacking legs and lower
the feeder.

7. When the feeder is at it‘s correct
height adjust slightly to align holes in
the 2 support legs and 2 jacking legs.


position (Wheel machine)
8. Re-insert pins and spring pins.
9. Bolt the hopper support legs, cross-

tie into position.
10. Slightly move down the feeder

control lever to retract the jacking
legs. The weight of the feeder end of
the machine is now supported by the
support leg pins.
11. Move feeder control lever and

auxiliary control lever into neutral
position.

14.12 Lowering the rear support legs

(Track Machine)
hazards
NOTICE ISO
EQUIPMENT
ANSI
All control levers must be in the neu-
tral (non-operational) position.
PROCEDURE
Stand clear of support leg when

withdrawing the main support pin.
The inner telescopic member of P
the support leg is heavy and may
cause serious injury if allowed to
fall after pin withdrawal.
3. Move jacking leg lever down, to

lower jacking legs, (track machine only.
4. Reinsert the pin and spring pin (P,)

into the support leg, 1 off Lh/Rh.

14.13 Opening out the side hazards

conveyors WEAR PERSONAL PROTECTIVE
1520 / 1513
EQUIPMENT
PROCEDURE ISO Refer this Section, safety information
1. Observe all safety warnings. ANSI
2. Remove the transport pins (P,) 1 off

Lh/Rh. from each of the side convey-
ors.
3.Remove all tying from each of the

side conveyors.
NOTICE
Take care not to nip the conveyor
belt between moving parts P
5.Move up left hand side conveyor

lever to open out the left hand side
conveyor, fully into position.

14.13 Opening out the side conveyors

- CONTINUED
6.Move up right hand side conveyor

lever to open out the right hand side
conveyor, fully into position.
7.Slide the box section (BS,) up to

the top hole and reinsert the pin,
spring pin and washer (P,) 1 off Lh/
Rh.
BS

14.14 Opening out the auxiliary conveyor
PROCEDURE hazards
EQUIPMENT
1. Observe all safety warnings 1520 / 1513 for relevant warning.
ANSI
2. Remove the transport stay (TS) from
the auxiliary conveyor
4. Activate the auxiliary conveyor (up-

per ram) lever into raised position.
TS


- CONTINUED
5. Rotate the conveyor until rotated A

into the position shown in Figure A.
Stop when the conveyor starts to lift
away from the lower transport bracket.
6. Fold out the conveyor to approxi-

mately 30 degrees by activating the
auxiliary conveyor (lower ram) lever into
the raised position as shown in figure
B1. Stop when the conveyor reaches
the position shown in figure B2.
Lower Transport
Bracket
B1
B2


- CONTINUED
7. Take care not to rotate the conveyor

too much or it will hit the support post
causing possible machine damage.
8. Rotate the conveyor to the position

shown in figure C by activating the
auxiliary conveyor (upper ram) lever
into the raised position.


- CONTINUED
9. Rotate the conveyor into working
position by activating the auxiliary
conveyor (lower ram) into the raised
position
10. When auxiliary conveyor is in the

required position fit safety pin to tel-
escopic support leg and fit support
chain..
Safety Pin
Support Chain

14.15 Attaching the side conveyor

padels.
hazards
1502 ISO entanglement manual
1502 ANSI for relevant warning.

PROCEDURE ISO
EQUIPMENT
ANSI
SP
2. Retrieve the padels (SP,) 2 off Lh/Rh.
3. Attach the padels (SP,) 2 off Lh/Rh.
4. Tighten into place using the suplied

bolts and clamp.(BC)
BC

14.16 Lowering the tail conveyor

(Head section)
hazards
EQUIPMENT
ANSI
PROCEDURE
NOTICE
T
belt between moving parts.
2: Remove transport stays from the

tail conveyor (T)
3.Move down the tail conveyor lever

(G4) to lower the tail conveyor head
section.
G4
4.Position tail conveyor head section
(H) as shown.

hazards
EQUIPMENT
14.17 Raising the screenbox into 1520 / 1513 for relevant warning.
working position ANSI
1506 ISO CRUSHING HAZARD


read operator‘s manual
neutral (non-operational) position. 1503 ISO
PROCEDURE
1. Observe all safety warnings. P

NOTICE
Slightly activate the screenbox lever
to release the tension from the retai-
ning pins, allowing for easy removal
of the pins.
2. Remove pins and spring pins (P),

1off Lh/Rh, from the screen box sup-
port legs.
3. Move screenbox lever to raise the

screen box.
4. Raise the screenbox to the required

working position.
5. Reinsert the screen box support leg

pins and spring pins (P), 1 off Lh/Rh.
6. Stop the machine.

14.18 Raising the tail conveyor into

working position
PROCEDURE
hazards
EQUIPMENT
1.Observe all safety warnings. 1520 / 1513 for relevant warning.
ANSI
2. Remove retaining pin (P) from the tail

conveyor struts.
3.Move up the tail conveyor lever to

raise the tail conveyor.
4. Place retaining pin (P) into the tail

conveyor struts.

G4

NOTICE


14.19 Positioning the main conveyor

hazards
EQUIPMENT
ANSI
PROCEDURE
1508 ISO FALL HAZARD
SWITCH OFF AND LOCKOUT
1532 ISO
NOTICE 1532 ANSI
for relevant warning.
Position the main conveyor so the

screening material will deflect off the
deflector plate and use the full scree-
ning area of the screenbox.
2. Raise lever in auxiliary bank to extended

main conveyor

3. Lower lever in auxiliary bank to retract

main conveyor


14.20 Adjusting the spreader plate
hazards
NOTICE 1520 / 1513 WEAR PERSONAL PROTECTIVE
EQUIPMENT
All control levers must be in the ANSI
PROCEDURE
1532 ISO
1.Observe all safety warnings. 1532 ANSI for relevant warning.
2.Remove bolt (B,) 1 off Lh/Rh.
B N
3.Adjust the spreader plate, forward or
back, one hole (N,) at a time, Lh/Rh.
4.Replace and tighten bolt (B,) 1 off Lh

Rh.


14.21 Removing screen anti-rock

stays
hazards
EQUIPMENT
PROCEDURE 1520 / 1513 for relevant warning.
ANSI

1.Observe all safety warnings. Refer this Section, safety information

2.Remove bolts (A) and anti-rock stays 1532 ISO
(8,) 1 off Rhs and 1 off Lhs. 1532 ANSI for relevant warning.
3. Place bolt (A) and anti-rock stays in

the toolbox, to have them available for
re-use when the machine is towed on
the highway.

14.22 Walkway setup instructions hazards

EQUIPMENT
1520 / 1513
NOTICE ANSI

1508 ANSI
Machine must be on level ground for relevant warning.
prior mounting.
1532 ISO
All control levers must be in the 1532 ANSI
PROCEDURE
2. Unbolt the four retaining bolts (A)

from each corner of the screenbox.
3. While standing on the step at the

end of the main chassis, pull each side B
of the walkway out to full extension.
A
Replace the retaining bolts.
4. Release quick release hitch (B) and

fold down walkway section.
5. Attach the ladder (C) to the walkway

with the supplied bolts, one per side.
C
5. Fold down each of the end sections
(D) and bolt into position.
6. Attach chains (E) into position on

each side of the walkway.
E


15 - Plant Operation Controls Page 1
15 - Plant Operation Contols

15 - Plant Operation Controls
Contents
15.1 Safe operation of the plant............................................................................. 3
15.2 Normal operation............................................................................................. 7
15.3 Direct feed opertaion.................................................................................... 10
15.4 Operating reject grid..................................................................................... 12
15.15.1 Operating shredder.................................................................................. 13

15.1 Safe Operation of the plant
! notice !
The prouduct may only be operated if the
KEEP AWAY FROM THE CON-
safety instructions provided have been
observed and the described procedures VEYOR BELTS, where there is risk
have been performed. of serious injury or death due to
rejected processed material and
danger from other heavy machi-
nery working in the area, unless
Operate the machine only if all protective and you are a fully-trained operator
safety devices, such as removable safety de- engaged in collecting processed
vices, emergency shut-off equipment, sound-
material.
proofing elements and exhausts are in place,
fully functional and properly maintained.
In the event the machine malfunctions for any

reason, stop the machine and lock out immedi-
ately. Report the malfunction to the competent
authority in charge. ALWAYS WEAR A EN/ANSI appro-
ved HARD HAT AND FOOTWEAR
DO NOT continue to operate the machine UN- WITH ADEQUATE TOE PROTEC-
TIL the malfuncton is corrected! TION when working in the vicinity
of the machine and on the work
site.

15.1 Safe Operation of the plant - CONTINUED

15.1.2 SAFETY BEFORE AND DURING OPERATION
Only qualified and trained personnel should attempt to operate this machinery.
1. Read and understand the Operators Manual before you start the machine.
Study the DANGER, WARNING, CAUTION and IMPORTANT safety signs on your machine.
2. Check your machine and have all systems in good operational condition.
- Check for broken, missing or damaged parts. Replace and make necessary repairs.
- Ensure all safety guards and emergency stops are fitted and in working order.
- See ‘Daily Maintenance’ for more detailed checklist before start-up.
3. Before starting, walk completely around the machine. Make sure no one is under it, on it
or close to it. Let other workmen and bystanders know you are starting up and do not start
until everyone is clear of the machine.
4. During operation, do not climb onto, over or under moving conveyor belts and rollers.
Always use ladders, steps and walkways when mounting and dismounting.
5. Hole alignment on mechanical supports must be checked and secured with pins provided
and in accordance with safety signs.
6. Never check the tension of ‘V’ belts, drive chains and conveyors when machine is
running.
7. Never work or stand beneath machinery or attachments as it is raised or lowered.
8. Never work or stand beneath machinery as they are being loaded with and/or discharging
material.
9. Follow safe operating practices. Operate the machine controls smoothly. Avoid sudden
stops, starts or changes in direction.
10. Only use emergency stop buttons or emergency stop lines (if fitted) in emergency
situations or during safety drills.
11. After each day’s operation, always run the machine dry; never leave material in the
beltfeeder on conveyor belts or screenbox. Starting a machine with a full load will cause
strain problems in your machine.

15.1 Safe Operation of the plant -
hazards
CONTINUED
15.1.3 PRE-OPERATION CHECK WEAR PERSONAL PROTECTIVE
1520 / 1513
EQUIPMENT
(i) Prior to operation ensure the machine is ISO Refer this Section, safety information
positioned on a level firm foundation with 1520 / 1513 for relevant warning.
adequate space around the machine for ANSI
operation, material stockpiles, maintenance 1508 ISO FALL HAZARD
and vehicular movement. Refer this Section, safety information
(ii) Ensure the material being feed into

the feeder / screenunit is below the 1532 ISO SWITCH OFF AND LOCKOUT
size limitations recommended by the 1532 ANSI for relevant warning.
manufacturer.
(iii) Ensure all safety guards are in position.
(iv) Observe all safety instructions and

ensure the correct protective clothing and
equipment are used by operators.
(v) Check the oil level and hydraulic oil

level.
(vi) Chech the oil cooler fan and radiator for

any build up of dust/dirt. Blow out dust/dirt
if necessary.

15.2 Normal operation

G2
15.2.1 Putting into operation
PROCEDURE
(2 Deck Machines)
3. Move up side conveyor lever to start
the conveyors. The side conveyors are
equiped with a 10 second start delay
and warning siren.
(3 Deck Machines)
4. Move up side and auxiliary conveyor
levers to start the conveyors. The
LH side and auxiliary conveyors are
equiped with a 10 second start delay
and warning siren.
5. Move up screenbox and tail conveyor

lever to start the screenbox and tail
conveyor.
6. Move up main conveyor lever to start

the main conveyor and vibrating grid (if
NOTICE
The main conveyor will only operate
when the screenbox control valve is
engaged.



- CONTINUED
6. Move up Shredder lever to start the

Shredder. (LEVER OPTIONAL)
NOTE Lever will not be present on non
shredder machine.
7. Move up feeder conveyor lever to

start the feeder
8. To obtain maximum feeder speed,

turn the control knob of the variable
speed flow control valve counter clock-
wise.
9. Set the side conveyor speeds on the

variable speed control relative to mate-
rial.
10. Check that all conveyor belts are

running in alignment.

11. Turn the control knob of the variable

speed flow control valve to level 2.
12. Fill up the feed hopper.




- CONTINUED
G2
13. To obtain optimal feeder speed,
speed flow control valve:

counter clockwise:
To increase the feeder speed.

clockwise:
To decrease the feeder speed.
c de
14. Re-check that all conveyor belts are
running in alignment. If an adjustment
is necessary refer to Section, “Mainte-
nance.” Check that screenbox is run-
ning and is capable of screening.
15. Re-fill feed hopper.
16. To obtain optimal feeder speed,

speed flow control valve:

counter clockwise:
To increase the feeder speed.

clockwise:
To decrease the feeder speed.
17. The machine is now adjusted for

continuous operation.

15.4 Operating reject grid
15.4.1 Raising reject grid

hazards
NOTICE EQUIPMENT
The Feeder conveyor, control lever ANSI
must be moved up (working position)
before the hydraulic grid will
operate.
The hydraulically operated reject grid

can be raised in the following way:
Operating the radio transmitter,by

pointing it in the direction of the radio
receiver fitted above the power unit.
15.4.2 Lowering reject grid
The reject grid will lower automatically.

15.5 Operating Shredder
15.5.1 Raising shredder

hazards
PROCEDURE 1520 / 1513 WEAR PERSONAL PROTECTIVE
EQUIPMENT
All control levers must be in the ANSI
neutral (non-operational) position. FALL HAZARD
1508 ISO
1.Move up the shredder raise/lower con- 1532 ISO SWITCH OFF AND LOCKOUT
trol lever to raise the shredder. 1532 ANSI for relevant warning.
A shredder or any other raised part

of the machine can fall, causing
serious injuries or death.
Always fit a safety support stay if

any part of the machine (such as
the shredder chamber) must not
be raised for any reason whilst in
operation.
Never work under unsupported
equipment.
Never work alone.
2.When the shredder is fully raised, fit

and pin the support stays in place to se-
cure the raised position and return lever
to neutral position.

15.5 Operating Shredder

15.5.2 Lowering shredder
hazards
All control levers must be in 1502 ANSI for relevant warning.
the neutral (non-operational)
position. EQUIPMENT
ANSI
1. Remove the shredder support stay.
2. Move down the shredder raise/lower

control lever to lower the shredder and
return lever to neutral position.


16 - Plant Shutdown & Emergeny Stop Page 1
16 - Plant Shutdown & Emergency Stop

16 - Plant Shutdown & Emergency Stop
Contents
16.1 Switch off, tagout & lockout procedure.................................................................3
16.2 Putting the machine in the transport position.......................................................4
16.3 Retracting the main conveyor...............................................................................5
16.4 Lowering the tail conveyor ...................................................................................6
16.5 Lowering the screenbox........................................................................................7
16.6 Walkway retraction instructions............................................................................8
16.7 Folding in the auxiliary conveyor...........................................................................9
16.8 Closing in the side conveyors.............................................................................13
16.8.1 Closing the RH side conveyor..........................................................................13
16.8.2 Closing in the LH side conveyor......................................................................14
16.9 Retracting the tail conveyor................................................................................15
16.10 Diesel machine shutdown.................................................................................16
16.11 Dual power machine shutdown.........................................................................17
16.12 Electric hydraulic machine shutdown...............................................................19
16.13 Emergency stopping the plant..........................................................................20
16.14 Re-setting emergency stops.............................................................................21
16.15 Testing emergency stops..................................................................................21

16.1 SWITCH OFF, tagout and lockout PROCEDURE
When carrying out maintenance or adjustment the following

procedure must be followed
1 Disengage each machine component (e.g conveyors etc) using the control levers as
described in the following pages.
Turning all machine components at once causes a pressure spike in the hydraulic
circuit and a voltage spike in the electrical circuit both of which are detrimental to the
machine. A slight pause between disengaging each component can prevent this spike
taking place.
Turn components off in the order

A Feeder
B Shredder
C Main Conveyor + Grid
D Tail + Screen
E 2 Deck: LH & RH side Conveyors.
3 Deck: LHS & Auxiliary Conveyors
F 3 Deck RH side conveyor
2 Switch off engine and remove ignition key. Carry the key with you
3 Engage emergency stop
4 Place appropriate maintenance warning sign
5 Use padlock to secure isolater and prevent restart

16.2 Putting the machine in the

transport position
hazards

PROCEDURE ISO
EQUIPMENT
2. Start the engine / machine.

RINSER UNIT ONLY
3. Remove top deck spray bars hoses. IMPORTANT
Do not move screenbox or main conveyor If top deck spay bars are
into transport position without removal of fitted care must be taken
top deck spray bars hoses. (Rinser option while moving the screen-
ONLY). box and main conveyor!
4. Retract the main conveyor
5. Prepare tail conveyor before lowering RINSER UNIT ONLY

the screenbox. IMPORTANT
Remove top deck spray
6. Lower the screenbox bars before moving main
conveyor and screenbox
7. Prepare the walkway for transport. for transport.
8.Retract the tail conveyor. Ensure tail

conveyor does not impact screen box.
9. Close in the auxiliary conveyor
10.Close in the side conveyors

hazards
16.3 Retracting the main conveyor 1520 / 1513 WEAR PERSONAL PROTECTIVE
EQUIPMENT
ANSI
PROCEDURE 1508 ISO FALL HAZARD
RINSER UNIT ONLY 1532 ISO SWITCH OFF AND LOCKOUT

IMPORTANT 1532 ANSI for relevant warning.
bar hosess before moving
main conveyor and screen-
box for transport.
2. Lower lever in auxiliary valve to re-

tract main conveyor fully.

16.4 Putting the machine in the

transport position hazards
16.4.1 Lowering the tail conveyor 1520 / 1513 WEAR PERSONAL PROTECTIVE
EQUIPMENT
ANSI
PROCEDURE
NOTICE
2: Remove retaining pins from the tail P

conveyor struts. (P)
3. Move down the tail conveyor lever

to lower the tail conveyor feedboot
section.
4. Position tail conveyor for lowering

the screen box.
G4

16.5 Lowering the screenbox

hazards
EQUIPMENT
PROCEDURE ANSI

RINSER UNIT ONLY Refer this Section, safety information
1508 ANSI
IMPORTANT for relevant warning.

bar hoses before moving
main conveyor and screen-
box for transport.
2. Remove pins and spring pins (B),

1off Lh/Rh, from the screen box sup-
port legs.
3. Slide the box section, down into

transport position.
4. Move screenbox lever, to lower the B

screen box.
5. Reinsert the screen box support leg

pins and spring pins (B), 1 off Lh/Rh.

16.6 Walkway retraction instructions hazards

EQUIPMENT
1520 / 1513
NOTICE ANSI

1508 ANSI
Machine must be on level ground for relevant warning.
prior mounting.
1532 ISO
All control levers must be in the 1532 ANSI
PROCEDURE
1. Observe all safety warnings. A

2. Remove chains from (A) position on
each side of the walkway.
3. Fold up each of the end sections (B)

and secure into transport position with B
cable tie.
4. Remove the bolts from the ladder

(C) and store, remove ladder from the
walkway and store for transport.
5. Fold up walkway section and cable

tie into position.
C
5. Take out four retaining bolts at each
corner of screenbox (E). Push walkway
inwards on both sides.
6. Rebolt the four retaining bolts at

each corner of the screenbox (E) into
transport position.
D
E

16.7 Folding in the auxiliary conveyor

hazards
PROCEDURE ISO
EQUIPMENT
ANSI
2. Remove support chain.
3. Remove telescopic support leg

safety pin.
4. Rotate conveyor into position shown

in figure A1 & A2 by lowering the auxil-
iary conveyor (lower ram) lever.
Support Chain
Safety Pin
A1 LH side view A2 Plan view


- Continued
5. Rotate the conveyor into the posi-
tion shown in figure B by lowering the
auxiliary conveyor (upper ram) lever.


- Continued
6. Bring the conveyor towards the
machine by lowering the auxiliary con-
veyor (lower ram) lever . Stop moving
once conveyor rest on lower transport
bracket.
Review diagrams to ensure that you

have achieved the correct angle.
Too High
If conveyor is closing to high adjust
angle by lowering lever 3.
Correct Angle
To Low
If conveyor is closing to low adjust
angle by raising lever 3 .
1 2 3 4
Angle to low
Angle to high


- Continued
7 Once the conveyor is located cor-
rectly on the lower transport bracket 1 2 3 4
rotate into final transport position by
lowering lever 3.
8. When in position attach top trans-

port bracket (TB).
TB

16.8 Close in the side conveyors
16.8.1 Close in the RH side

hazards
conveyor EQUIPMENT
ANSI
PROCEDURE

2. Move down, right hand side

conveyor lever to close in the right
hand side conveyor, in fully.
3. Pin the right hand side conveyor into

position, using the pin, washer bolts
and spring pin (P).

16.8 Close in the side conveyors
16.8.2 Close in the LH side conveyor

hazards
EQUIPMENT
ANSI
PROCEDURE
NOTICE
2. Move down, left hand side conveyor

lever, to close in the right hand side
conveyor in fully.
3. Pin the left hand side conveyor into

position, using the pin, washer bolts
and spring pin (P).

16.9 Retracting the tail conveyor

hazards
PROCEDURE ISO
EQUIPMENT
ANSI
NOTICE
Ensure that tail conveyor does not
make contact with walkway whilst
folding up.
2. Move down the tail conveyor lever

to lower the tail conveyor feedboot
section.
3. Move up tail conveyor lever to raise

the tail conveyor end section.
4. Bolt transport stays (T) to secure tail T

conveyor.

16.9 Diesel machine shutdown
1. Observe all safety warnings. NOTICE
For normal closing down the

2. Stop all hydraulics. plant, DO NOT use the emergency
stop buttons [or, if fitted, radio
3. Set the engine at its slowest speed.
remote control stop buttons] or by
switching off the engine ignition
4. Let the engine idle with no load for 3 to 5 to close down the plant. Always
minutes. follow the correct preparation
sequence.
5. Turn the ignition key to the off position to

NOTICE
stop the engine and remove the key.
The feeder, screenbox and
conveyors must be stopped in
6. If the radio remote control, if fitted, has
sequence and emptied before the
been in use switch off by depressing the
next section is stopped.
stop button.

16.10 Dual Power machine shutdown
Diesel mode:
The diesel mode dual power hydraulics operate as any other diesel machine.
1. Firstly stop all all hydraulics.
2. Set the engine to its lowest speed.
2. Then stop the engine which is carried out by the large electrial panel, the small
panel within the power unit is not present on dual power machinery.
3. On dual power units stop the machine / diesel engine via the key switch on the
large electrical panel also needs to be switched from Diesel to off.
Fig. Dual Power Electrical Panel

Panels can vary!

16.10 Dual Power machine shutdown
Electrical mains power mode:
To shutdown the machine from three phase supply electrics the sequence of the
electrical mode as follows:
2. Stop motor 2 by pressing motor 2 stop button on the panel front.
3. Stop motor 1 by pressing motor 1 stop button on the panel front.
4. Stop the oil cooler by pressing oil cooler stop button on the panel front.
5. Main isolator must be switched to the off position.
6. Set the key switch on the large electrical panel from electric selection to the off
selection.
Fig. Dual Power Electrical Panel

Panels can vary!

16.11 Electric Hydraulic machine shutdown
Electrical mains power mode:
To shutdown the machine from three phase supply electrics the sequence of the
electrical mode as follows:

2. Stop Motor 2 by pressing Motor 2 stop button on the panel front.
3. Stop Motor 1 by pressing Motor 1 stop button on the panel front.
4. Stop the oil cooler by pressing oil cooler stop button on the panel front.
5. Main isolator must be switched to the off position.
6. Set the key switch on the large electrical panel from electric selection to the off
selection
Fig. Electric Hydraulic Electrical panel

Panels can vary!

16.12 Emergency Stopping the Plant
IN AN EMERGENCY ONLY, STOP THE WARNING

ENGINE AND PRODUCT OPERATION BY
The stop button on the remote
USING AN EMERGENCY STOP BUTTON
radio control, if fitted, is NOT an
emergency stop as it may not be
1. Pressing any of the emergency stops on
operative at all times.
theplant or umbilical control will stop the
engine and plant. See Safety section for
emergency stop locations.
WARNING
2. When the plant has been stopped using an
emergency stop button the ignition switch When an emergency stop has been
stays on. initiated, DO NOT attempt to restart
the engine until it is safe to do so.
3. The safety alarm will sound until it is

acknowledged and cancelled.
NOTICE
4. Turn the key to off position as soon as
The plant should not be re-started if
possible and remove the key.
the crusher is full of material
5. Set the battery disconnect switch off to the

position.
6. The button will remain engaged until physi-

cally released by pulling or twisting, depend-
ing upon the type fitted.
7. The engine cannot be started if any of the

emergency stops remain depressed.

16.13 Re-setting Emergency stops
6. The button will remain engaged until physically released by pulling or twisting, depending
upon the type fitted.
7. The engine cannot be started if any of the emergency stops remain depressed.
16.14 Testing Emergency stops

2. Start the engine, see engine starting.
3. Push in an emergency stop and the engine will stop.
4. Alarm messages are shown on plants with a display.
5. The safety alarm will sound.
6. Acknowledge the alarm.
7. Re-set the emergency stop by pulling or twisting, depending on the type fitted.
8. Turn the key off the 0 position.
9. Turn ignition key to the first position again.
10. Wait for the pre-start warning to complete.
11. Turn ignition key to start the engine again.
12. Repeat the process for all other emergency stops.


17 - Refuelling Page 1
17 - Refuelling

17 - Re-fuelling
Contents
17.1 Check Fuel Level and Top-up............................................................................ 3
!NOTICE!
Do Not fill the tank to overflow or full capacity.
Allow room for expansion and wipe up spilt fuel immediately.

17.1 Check Fuel Level and Top-up
Diesel fuel is highly flammable and

is an explosion/burns hazard.
NEVER leave your product
unattended whilst it is in operation.
NEVER remove the filler cap or
refuel, with the engine running.
PROCEDURE NEVER add gasoline, petrol or any

other fuel mixes to diesel because
1. Observe all safety warnings. of increased fire or explosion risks.
2. Check the fuel level gauge / indicator. DO NOT smoke while refilling or
carrying out maintenance on the
3. Clean the area around the filler cap. fuel system.
4. Remove the filler cap and top up DO NOT carry out maintenance on
fuel level as required with specified the fuel system near naked lights or
diesel fuel. Refer to the engine sources of sparks, such as welding
manufacturer’s operation manual. equipment.
5. Preferably re-fuel at the end of

each day where possible, to reduce
overnight water condensation within
the tank.
6. Replace the filler cap and close the

door if applicable.
7. If required, switch on the ignition

briefly to check the fuel gauge.
A
Diesel tank dual power machine


18 - Maintenance Schedules Page 1
18 - Maintenance Schedules

18 - Maintenance Schedules
Contents
18.1 Practice Safe Maintenance ...............................................................................3
18.2 Air Cleaner Elements..........................................................................................5
18.3 Maintenance Schedules.........................................................................................6

18.1 Practice Safe Maintenance
Understand service procedure

ALWAYS REPLACE SAFETY GUARDS
before doing any work. Keep area
AFTER MAINTENANCE.
clean and dry.
NEVER START THE MACHINE WITH
FAULTY OR MISSING GUARDS.
Never lubricate, clean, service or
adjust machine whilst it is moving.
Keep hands, feet and clothing

clear of power driven parts and in-
running nip points.
Disengage all the power and

operate controls to relieve
pressure. Stop the engine.
Implement lockout procedure.
Allow machinery to cool.
Securely support any machine

elements that must be raised for
service work.
Keep all parts in good condition

and properly installed. Attend to
damage immediately. Replace worn
or broken parts.
Remove any build up of grease, oil

or debris.
Disconnect battery ground cable

(-) before making adjustments
on electrical systems or welding
on machine.

18.1 Practice Safe Maintenance - CONTINUED

General Information
Regular Servicing
Guide to Maintenance Particular attention should be paid to
When performing maintenance, always institute a regime of strict adherence
observe rules provided in the safety from the start of operations for all
Section. aspects of routine maintenance.
Breakdown caused by insufficient or Keep a detailed Maintenance Log of

improper maintenance will cause high all work carried out, recording faults
repair costs and long term standstill. experienced and actions taken, details
Therefore, regular maintenance is of routine maintenance, personnel
imperative. name(s), method statements, parts
fitted, consumables used, dates, hours
In addition to several other factors, the run, etc. etc. Also note any extended
reliability and life of the product depends periods when the plant is inactive and
on regular and proper maintenance. steps taken for protection whilst the
plant is laid up.
The following Section contains
maintenance instructions as well as Check daily on the condition of the wear
maintenance schedules for normal parts and replace as required so that
operating conditions. the machinery is kept in prime operating
condition.
The plant has been designed to facilitate
easy routine maintenance, but where
Lubricants
necessary to remove any guards make
sure that they are replaced before the
Use only unadulterated mineral
machine is restarted.
lubricants. On no account should the
lubricant contain uncombined mineral
Engine Servicing
acids, free-alkaline or metal-corroding
additives.
Ensure that you read and understand
the engine manufacturer’s hand
book supplied with this machine ! notice !
and that all engine maintenance is DO NOT MIX GREASES.
carried out in accordance and within The blend can have a
the time periods recommended lower specification than an
by the engine manufacturer. The individual grease and can
following maintenance tables in this lead to premature bearing failure
section contain engine servicing
recommendations which should be
carried out in combination with those in
the engine handbook.

18.1 Practice Safe Maintenance - CONTINUED
Servicing Safety Precautions
hazards
Make sure that only suitably competent
personnel with the necessary training/
experience for the task(s) in hand are WEAR PERSONAL PROTECTIVE
1520 / 1513
employed. ISO
EQUIPMENT
A person should never work alone. Refer this Section, safety information
Observe the advice in the Safety Sections ANSI
as appropriate to any task(s) undertaken.
1532 ISO
Read the appropriate manual relevant to 1532 ANSI for relevant warning.
the operation in hand. Carry out a Risk
Assessment for all servicing operations.
Have suitable lifting equipment available 18.2 Air Cleaner Elements.
for the components involved together with
all necessary and suitable tools/equipment The life span on air cleaner elements is
ready for the task(s) in hand and always dependant on the environment the plant
secure parts liable to movement before is used in and as such a maintenance
starting work. schedule can not be implemented for their
replacement. Powerscreen machines are
Powerscreen Technical Support equipped with an air filter restriction sensor
department is available for advice when which will highlight the need for mainte-
required. nance. We recommend that air cleaner
The plant should be completely emptied of elements are replaced and not washed or
all material. reused.
Implement the Lockout Procedure.
Display a prominent ‘tag’ at the control
station or other appropriate place to warn
of work being carried out.
Keep clear of moving parts when trying to
identify or isolate any unusual noises.
Fit dismantled parts in the same location
from which they were removed.
Ensure that the area surrounding the
servicing site is clear of any obstructions.

18.3 Maintenance schedules
Daily (10 hour) maintenance schedule
Construction unit/ Job Remarks Sign

object
VIEW CONTROL
Guards check/ replace
Pipelines/Hoses/Leaks check/ replace Check hoses and wear
areas for leaks
Valves check/ replace
Bolts and pins check/ fasten/
replace
POWER UNIT
Refer to engine operation check/ top up/ Complete checks /
manual Replace work as specified in
engine manufactures
manual
Coolant level check/ top up
Engine oil level check/ top up
Hydraulic oil level check/ top up
Hydraulic return line filter Check Replace filters when
indicator indicated
Fuel water trap Check/drain
Fuel tank level check/ top up
MOVING PARTS
Material build up remove
Moving free check/ ensure
SCREEN UNIT
Material build up remove
Screen meshes, wear check/ replace
Screen meshes, tension check/ tune
Rubber cushions check/ replace
Screen bearings oil level check/top up Oil bath bearings only

Weekly (50 hour) maintenance schedule (machine stopped)

object
FIRST
Carry out daily (10 hour)
maintenance schedule
FEEDER HOPPER
Skirting rubbers check / ad-
just / replace
Feeder gearbox oil change After first 50 hours then
after every 2000 hours.
Or annually.
Belt cleaners check / ad-
just
ALL CONVEYORS
Belt cleaners check / ad-
just / replace
Skirting rubbers check / ad-
just / replace
SCREEN UNIT
Grease filled Bearings grease
Labriynth seals grease
POWER UNIT
Refer to engine operation check/ top Complete checks / work
manual up/Replace as specified in engine
manufactures manual
Engine air filter pre clean- clean out
er
Battery electrolyte level check / top
up

100 hour maintenance schedule (machine stopped)

object
FIRST
Carry out daily (10 hour)
Carry out weekly (50
hour) maintenance
schedule
ALL CONVEYORS
Tail drum bearings grease
Drive drum bearings grease


object
FIRST
Carry out daily (10 hour) main-
tenance schedule
Carry out weekly (50 hour)
Carry out 100 hour mainte-
nance schedule
POWERUNIT
Engine Check/adjust/re- Complete checks / work as
place specified in engine manu-
factures handbook
Engine Speed Check/adjust

object
FIRST
tenance schedule
nance schedule
nance schedule
POWERUNIT See engine operation

manual
Refer to engine operation check/top up /replace Complete checks / work as
manual specified in engine manu-
factures manual



object
FIRST
tenance schedule
nance schedule
nance schedule
nance schedule
POWER UNIT See engine opera-

tion manual /Engine
Maintenance Table
Refer to engine operation Check/top up/re- Complete checks / work as
manual place specified in engine manual
MACHINE OILS Oils should be replaced every 2000 Hrs or annualy, whichever
comes first. For engine oil refer to manufactures handbook.
Hydraulic oil Replace
Feeder gearbox oil Replace

19 - Servicing Lubrication Page 1
19 - Servicing Lubrication

19 - Servicing Lubrication
Contents
19.1 Regular Servicing ...........................................................................................3
19.2 Lubrication and Routine Servicing ...............................................................4
19.3 Lubrication and Fluids ...................................................................................5
19.4 Lubrication - Capacities ................................................................................6
19.5 Greasing Schedule ..........................................................................................7
19.6 Recommended Grease ...................................................................................8

19.1 Regular Servicing
It is important that a strict routine of

regular servicing is undertaken from the
start of operation of the plant. To deliver the specified quantity of
Regular checks on fluids and the
lubrication of the plant, in accordance grease to shaft bearings, ascertain
with the schedule, is essential. the amount the grease gun will
In addition to the lubrication points, the deliver with each ‘pump’. Do not
lubrication schedule lists the regular
guess or assume an amount !
attention required to the plant hydraulic
system. Check the greasing equipment used
The engine oil and coolant also requires regularly.
checking regularly.
To prevent contamination of the
grease, wipe the grease nipples clean
before applying the grease gun.
!NOTICE!
It is bad practice to mix greases. The
blend can have a lower specification
than the individual greases and can
lead to premature bearing failure.
USE ONE BRAND ONLY.
It is the operators responsibility to
ensure that all bearings are greased
with the correct quantity and type
of grease at the correct intervals
specified.

19.2 Lubrication and Routine

Servicing HAZARDS
19.2.1 Plant Lubrication Points ISO
EQUIPMENT
Regular lubrication of the plant 1520 / 1513 for relevant warning.
ANSI
machinery in accordance with the
Lubrication and Servicing Schedule is 1508 ISO FALL HAZARD
essential. 1508 ANSI for relevant warning.
The locations of the lubrication points

are as follows:- 1532 ISO
• Screen
• Feeder tail drum bearings ! NOTICE !
• Collection conveyor drive and tail DO NOT MIX GREASES.
bearing grease nipples. The blend can have a
lower specification than an individual
• Track unit gearbox oil levels. grease and can
• Side conveyors drive and tail bearing lead to premature bearing failure.
grease nipples.
• Tail conveyor drive and tail bearing
grease nipples.
19.2.2 Lubricants
• Periodically lubricate hinges, pivot
pins, adjusting screws and similar Use only unadulterated mineral
points with oil or grease to prevent lubricants. On no account should the
seizure during lengthy spells of lubricant contain uncombined mineral
inactivity. acids, free-alkaline or metal-corroding
additives.
The correct lubricants are listed in the

table on following pages.

19.3 Lubricants and Fluids
NOTICE
Always use lubricants and fluid that meet the above international specificati-
ons-
DO NOT MIX OILS OR GREASES
NOTICE
The feeder unit gearbox does NOT use the same type of gear oil as the track
gearbox
NOTICE
A Different type of grease is used for lubricating the screen bearings than that
used on the rest of the machine.
ALWAYS USE THE CORRECT GREASE AS SPECIFIED ABOVE.
NOTICE
The coolant used in all Powerscreen machines is a 50 - 50 mix of coolant to
water. Always check if coolant supplied is premixed or in concentrate form

19.4 Capacities - Fluid

Capacities - Fluid

Engine coolant (Cat) 11.4ltr (2.5 gal)
Engine coolant (Deutz) 13.6ltr (3 gal)
Engine oil including filter (Cat) 7.3ltr (1.6 gal)
Engine oil including filter (Deutz) 14ltr 3.1 gal)
Hydraulic tank 564ltr (124 gal)
Fuel tank 346ltr (74 gal)
Adjustment Data
Engine speed 2200rpm

Screen shaft speed 920rpm ±20 rpm
Pressures
Hydraulic system 210bar (3000psi)

19.5 Greasing schedule

AREA FREQUENCY GUN STROKES*

All Conveyor Tail Drum Bearings Lh/Rh 100 HRS 2
All Conveyor Drive Drum Bearings Lh/Rh 100 HRS 2
Screen Bearings Lh/Rh 50 HRS 13
Vibrating Grid 50 HRS 25

Drum Bearing = 180 L-XDGHB 2

Vibrating Grid Grease / Screen Bearing Grease Grade = 220 L-XDGFB 2
*Grease gun delivering 1cc per stroke.
19.6 Recommended Hydraulic Oil

Standard ambient temperature range of 4 to 30 degrees celcius use
Maxol hydramax 46.
For temperatures adove 30 degrees celcius use Renolin CL100


20 - Servicing The Feedeer Unit Page 1
20 - Servicing The Feeder Unit

20- Servicing Feeder Unit
Contents
20.1 Feeder - Servicing ........................................................................................3
20.1.1 Clean & check the conveyor belt .............................................................3
20.1.2 Tensioning the feeder conveyor belt .......................................................4
20.1.3 Feeder conveyor alignment . ....................................................................5

20.1 Feeder Conveyor - Servicing
20.1.1 Clean & check the conveyor hazards

belt 1520 / 1513 WEAR PERSONAL PROTECTIVE
EQUIPMENT
PROCEDURE ANSI

1.Observe all safety warnings. Refer this Section, safety information
2.Stop the engine.
1532 ISO
3.Clean the conveyor belt using a high 1532 ANSI
pressure hose. Ensure that eyes are
protected by wearing safety glasses.
4.Check the belt for cuts, tears, rips or

any other physical damage. Do not unfasten or remove any
guard while the machine is run-
5.Close and secure the guard doors in ning or start the machine while a
the correct position. guard is unfastened or removed.
If any damage to the belt is found,

do not operate the machine until it
is repaired or replaced entirely by
your local POWERSCREEN dealer.

hazards
20.1.2 Tensioning the feeder EQUIPMENT
conveyor belt ISO Refer this Section, safety information
ANSI
PROCEDURE 1508 ISO FALL HAZARD
1508 ANSI
1.Observe all safety warnings. for relevant warning.

1532 ISO
2.Start the feeder conveyor. 1532 ANSI
(Refer to Section 10).
3.Run the feeder conveyor at desired

speed.
4.Tighten the belt by adjusting both Do not overtension the belt as this
belt adjusters evenly. will damage the drum bearings.


hazards
EQUIPMENT
20.1.3 Feeder conveyor alignment ISO Refer this Section, safety information
ANSI

PROCEDURE Refer this Section, safety information
1.Observe all safety warnings. SWITCH OFF AND LOCKOUT

1532 ISO
2.Start the feeder conveyor.
3.Turn control knob of the variable

speed control valve COUNTER
CLOCKWISE to run the feeder
conveyor at maximum speed.

20.1.3 Feeder conveyor alignment

- CONTINUED
Do not unfasten or remove any
4. Observe the conveyor through the ning or start the machine while a
viewing apertures and determine to guard is unfastened or removed.
which side the conveyor is “tracking
off. ”
5. The conveyor is tracking off to the

right side.
Solution
Operate the right side adjuster - one
turn at a time until the belt tracks cor-
rectly.
The conveyor is tracking off to the left

side.
Solution
Operate the left side adjuster - one
rectly.

21 - Servicing Conveyors Page 1
21 - Servicing Conveyors

21 - Servicing - Auxiliary Conveyor
Contents
21.1 Conveyor - Servicing . ..................................................................................3
21.1.1 Clean & check the conveyor belt .............................................................3
23.1.2 Tensioning the conveyor belt ...................................................................4
23.1.3 Conveyor alignment ..................................................................................5

21.1 Conveyor - Servicing
hazards
21.1.1 Clean & check the conveyor 1520 / 1513 WEAR PERSONAL PROTECTIVE
EQUIPMENT
belts ISO Refer this Section, safety information
PROCEDURE ANSI

1532 ISO
2. Stop the engine / machine.
3. Open the guard doors where

necessary.
Do not unfasten or remove any
4.Clean the conveyor belts using a high ning or start the machine while a
pressure hose. Ensure that eyes are guard is unfastened or removed.
protected by wearing safety glasses.
5.Check the belts for cuts, tears, rips or

If any damage to the belt is found,
any other physical damage.
do not operate the machine until it
is repaired or replaced entirely by
your local POWERSCREEN dealer.


hazards
21.1.2 Tensioning the conveyor 1520 / 1513 WEAR PERSONAL PROTECTIVE
belts ISO
EQUIPMENT
PROCEDURE ANSI

2. For main conveyor open hopper 1532 ISO
access doors if necessary. 1532 ANSI for relevant warning.
3.Start the conveyor.
4.Tighten the belt by adjusting both

belt adjusters evenly, 2 turns at a time Do not overtension the belt as this
until slippage stops. will damage the drum bearings.

hazards
21.1.3 Conveyor alignment 1520 / 1513 WEAR PERSONAL PROTECTIVE

EQUIPMENT
PROCEDURE ANSI

1.Observe all safety warnings. 1508 ANSI for relevant warning.
2. For main conveyor open hopper

access doors if necessary. 1532 ISO
3.Start the conveyor.
4. Observe the conveyor and determine

to which side the conveyor is „tracking
off.“
5.The conveyor is tracking off to the

right side.
Solution
Operate the right side adjuster - one
rectly.
6. The conveyor is tracking off to the

left side.
Solution
Operate the left side adjuster - one turn
at a time until the belt tracks correctly.


22 - Servicing The Tracks Page 1
22 - Servicing The Tracks

22 - Servicing Tracks
Contents
22.1 Plant Tracks ..............................................................................................................3
22.2 Measuring Track Tension . .......................................................................................4
22.3 Adjusting Track Tension ..........................................................................................5
22.4 Gearbox Oil Level .....................................................................................................7
22.5 Draining Gearbox Oil . .............................................................................................8
22.6 Cleaning the tracks.........................................................................................................8

22.1 Plant Tracks
PROCEDURE hazards
EQUIPMENT
Keeping the track correctly adjusted will 1520 / 1513 for relevant warning.
increase the service life of the track and ANSI
drive components. 1508 ISO FALL HAZARD
Frequently check for loose bolts, oil 1508 ANSI for relevant warning.
leaks, master pins are correctly located
and tight, general wear and damage, SWITCH OFF AND LOCKOUT
1532 ISO
correct track tension, etc. to ensure safe 1532 ANSI for relevant warning.
working and long life
!NOTICE!
To maximise the life of the track,
keep it movable and avoid damage,
the plant should be moved at least
every week, by a distance exceeding
four times the track length. It should
also be parked on level ground
overnight and during periods to
of non-usage. This is particularly
important when working in adverse
conditions.
It is essential that the tracks are
correctly tensioned at all times.
Check track tension regularly.
Moving the plant with incorrectly
tensioned tracks can cause severe
damage to the undercarriage
components and may invalidate the
warranty.

22.2 Measuring Track Tension WARNING

1. Observe all Safety Warnings. Prior to attempting any manoeuvring
2. Position the plant on solid and level of the plant the tracks must be free
ground and drive 2 metres (2 yards) of obstructions, including crushed
minimum in a forward direction, track material and fines. Do not push or
idler roller leading. tow the plant. Failure to observe
3. Close down the plant and implement this warning could result in injury
the Lockout Procedure. to persons and damage to the plant
4. One track at a time, measure the which may invalidate warranty.
sag on the top part of the track on the
longest section of unsupported track by
placing a ‘straight edge’ long enough It is important that the track is not
to reach from the drive sprocket to the tensioned too tightly as this places
nearest skid plate. excessive loads on the gearbox
5. Measure the maximum amount of grease cylinder and idler bearings. It
track sag from the high point of the will also lead to accelerated wear and
track to the bottom of the ‘straight premature failure.
edge’. Correctly adjusted, the sag
should be within the limits set for each
supplier as shown in the table below.
SAG VALUE
6. Depending upon the need to either
slacken or tension the track, proceed as
follows.
IDENTIFICATION SAG VALUE

TRACKLINE 5MM - 15MM
STRICKLINE 5MM - 15MM
TEREX 20MM - 40MM

22.3 Adjusting Track Tension
1. Observe all Safety Warnings. hazards

EQUIPMENT
2. Close down the plant and implement ISO Refer this Section, safety information
the Lockout Procedure. ANSI

3. Locate the access aperture on the 1508 ANSI
side of the track frame and remove the
cover, where fitted, to reveal the relief
valve inside. 1532 ISO
To Release Track Tension [After

DANGER
measurement]:-
Grease coming out of the relief valve
4. Loosen the relief valve by turning
counter clockwise using gradual under pressure can penetrate the
increments until the grease begins to body causing injury or death; DO NOT
be expelled. Care must be taken not to watch the relief valve to see if grease
loosen the relief valve too quickly because is escaping but instead watch the
the grease inside is under high pressure. track adjustment cylinder to verify
5. When the correct track tension has that the track is being loosened.
been measured, turn the relief valve clock-
wise to tighten and then clean away all
trace of expelled grease.
6. If the track fails to slacken after the
grease fitting has been loosened, do not
attempt to remove the tracks or disas-
semble the track tensioner, or remove the
grease fitting. It is possible that running
the tracks with the grease fitting loosened
may help to expel the grease

22.3 Adjusting Track Tension - CONTINUED
To Increase Track Tension [After

measurement]:-
7. Connect the grease gun to the
grease fitting and add grease until the
track tension is within the specified
dimension, see ‘Measuring Track
Tension’ and refer to lubricant and fluid
specifications.
Re-check Tension
8. Operate the plant in track mode and
drive the plant 50 metres (50 yards)
forwards and 50 metres (50 yards)
backwards, check track tension and
repeat the above steps if it is within the
specified dimension, see ‘Measuring
Track Tension’.
9. If room for manoeuvring the plant is
restricted, drive the plant forwards and
backwards several times over a shorter
distance.
DO NOT SET TRACK TENSION TOO

TIGHT.

22.4 Gearbox Oil Level

NOTICE
Checking and Filling Gearbox
Oil Cleanliness is essential when
checking, filling or replacing oil in
1. Ensure machine is switched off, the gearbox. Gearbox operating life
locked out and tagged out. Remove will be dramatically shortened if the
ignition key, carry it with you. oil becomes contaminated. Only use
new clean oil in clean containers and
2. Move the machine to a level surface fillers.
and bring the oil drain holes to the
position shown in fig 22.4.
3. Thoroughly clean around both plugs NOTICE

removing all potential contaminants. The Gearbox should hold
approximately 5 litres of oil,
4. Remove both plugs.
which should be filtered through
5. Fill the oil through the upper hole until a 10 micron filter before entering
it runs out through the lower hole. the gearbox.
6. Wait a few moments until any trapped

air has escaped and then re-check the
level. Add more oil if necessary.
Oil Fill Hole
Oil Drain
Hole
Fig 22.4

22.5 Draining Gearbox Oil
1. Ensure machine is switched off,

locked out and tagged out. Remove
ignition key, carry it with you
2. Move the machine to a level surface

and bring the oil fill and oil drain holes Oil Fill
to the position shown in fig 22.5 Hole
3. Thoroughly clean around both plugs
removing all potential contaminants. Oil Drain
Hole
4. Remove both plugs and allow the oil
to drain. The oil will drain quickly if it is
hot, however care should be taken to
avoid burns to the operator. Figure 22.5
5. Move the machine to bring the plugs

to the fill position shown in fig 28.5
Do not move the machine any

further until the gearbox oil has been
replaced
6. Re fill the oil as per the procedure in

22.4
Dispose of oil safely and in a

environmentally friendly manner
22.6 Cleaning the tracks
2. On a daily basis the tracks should be

hosed down to dislodge any build up of
material on the tracks.

23 - Servicing The Electrical System Page 1
23 - Servicing The Electrical System

23 - Servicing Electrical System
Contents
23.1 General ..........................................................................................................................3
23.2 Electrical safety instructions ....................................................................................4
23.3 General electrical safety ...........................................................................................6
23.4 Modifications ...............................................................................................................6
23.5 Check Battery .............................................................................................................7
23.6 Battery removal ..............................................................................................................8
23.7 Battery installing . ............................................................................................................8
23.8 Changing Fuses..............................................................................................................9

23.1 - General
hazards
Depending upon the model of plant ISO
EQUIPMENT
and the equipment fitted, various types 1520 / 1513 for relevant warning.
of control, monitoring, sequencing, ANSI
electrical safeguards and fault detection SWITCH OFF AND LOCKOUT
devices are built into the system 1532 ISO
including a multi station emergency 1532 ANSI for relevant warning.
stop circuit.
Any work on the plant electrical system

shall only be undertaken by a qualified DANGER
electrician, familiar with this type of Emergency stop equipment and
system.
all other safety systems, including
Circuit protection fuses or circuit the audible warning siren, must be
breakers fitted depend upon the plant operative at all times whilst the plant
model. The replacement of a protection is running or being manoeuvred.
device after failure must not exceed
the rating of the original otherwise The safety devices must be checked
damage to components may occur as fully operational at each daily start
and any warranty invalidated. A repeat
and must not have been tampered
of the failure must be investigated and
the problem rectified by a competent with or disabled in any way.
person.
Always keep the electrical cabinets and

control boxes shut during the screening
operation to prevent the ingress of dust
and damp.
At regular intervals check the tightness

of the electrical components on the
plant and look for any damage to the
electrical wiring.

23.2 - Electrical safety instructions
Switch off the machine immediately if trouble occurs in the electrical system.
Use only genuine fuses with the specified current rating.
When working with the machine/plant, maintain a safe distance from overhead electric lines.
If work is to be carried out close to overhead lines the working equipment must be kept well
away from them.
Unless otherwise stated the power supply to parts of machines and plants on which inspec-
tion, maintenance or repair work is to be carried out must be cut off.
Before starting any work around electrical components (after having cut off the power
supply), check the de-energized parts for the presence of power and any ground or short-
circuits. This is in addition to insulating live parts and elements.
If your machine comes into contact with a livewire:
- Warn others against approaching and touching the machine
- Ensure the live wire is de-energized
The electrical equipment of the machine is to be inspected and checked at regular intervals.
Defects such as loose connections or scorched or otherwise damaged cables must be
rectified immediately
Necessary work on live parts and elements must be carried out in the presence of a
second person, who can cut off the power supply in case of danger by actuating one of the
emergency stops or the main power switch on the control panel
Secure the area with a red and white chain and a warning sign.
Use insulated tools only

23.2 - Electrical safety instructions
Before starting work on high-voltage

assemblies and after cutting out the power
supply, the cable to the assembly must
be grounded and components such as
capacitors should be short-circuited with a
connecting rod.
All Powerscreen machines are wired on

negative earth
Always observe correct polarity.
Always disconnect battery leads before

carrying out any maintenance to the
electrical system.
Before undertaking maintenance, repairs

or retooling work on the machine, switch
off the machine and secure against unau-
thorised restarting. A sign “Do not restart“
should be hung on the control panel when
undertaking repair work. Remove the key
from the control panel switch, carry the key
with you.
NOTICE
The battery contains sulphuric acid, an

electrolyte which can cause severe burns
and produce explosive gases
clothing.

23.3 GENERAL ELECTRICAL SAFETY
While the equipment detailed in this manual is rated at 12 & 24 Volts DC, safety procedures
must be strictly adhered to. Serious injury can result from equipment that has been
incorrectly installed or tampered with.
As general safe working practice, the following procedures should be observed at all times
when carrying out electrical work on the machine.
1 Electrical work must only be carried out by a qualified electrician

2 Work on the electrical system must only be carried out by individuals with a full
understanding of the electrical system.
3 Special care should be taken when disconnecting, replacing and/or charging
batteries.
4 Ensure batteries are disconnected and reconnected correctly. Contact across the
battery terminals can cause the battery to explode.
5 Regular inspection of the electrical equipment should be carried out. Any damaged
cables or loose connections should be repaired before operation of the machine.
Use only the manufacturers replacement parts with the specified current rating.
6 Always disconnect the batteries when welding on the machine.
7 Switch off the machine immediately if malfunctions occur in the electrical system.
8 Battery posts, terminals and related accessories contain lead and lead compounds
known to the State of California to cause cancer and reproductive harm. Wash
hands after handling
23.4 MODIFICATIONS
Modification to any part of the electrical system on this machine can cause the machine to
operate in an unsafe manner.
No such modifications should be carried out unless agreed by Powerscreen engineers.

23.5 Check Battery hazards

Always disconnect battery leads before ISO
EQUIPMENT
carrying out any maintenance to the 1520 / 1513 for relevant warning.
electrical system. ANSI
The battery contains sulphuric acid, 1532 ISO
electrolyte which can cause severe 1532 ANSI for relevant warning.
burns and produce explosive gasses.
clothing.
PROCEDURE
2. Ensure that all electrical connections

are clean and tight and coat the terminals
with petroleum jelly to protect them from
corrosion.
3. Remove the battery filler plugs and

check that the electrolyte level is between
6 and 9 mm (0.25 - 0.37 ins) above the
tops of the separators.
4. If necessary, fill up with distilled water.
5. Where batteries have trough fillers, add

distilled water to the filling trough until the
trough just begins to fill with water.
NOTICE
In cold weather, distilled water should
only be added immediately before star-
ting the engine, to prevent it freezing.

23.6 Battery removal hazards

EQUIPMENT
PROCEDURE ISO Refer this Section, safety information
1.Observe all safety warnings. ANSI
1532 ISO
2.Ensure all electrical circuits are switched 1532 ANSI
off.
3.Disconnect the ground (-) lead from the

battery.
4.Disconnect the positive (+) lead from the

battery. Always disconnect battery leads
before carrying out any maintenance
5.Unlock battery bottom cover. to the electrical system.
The battery contains sulphuric acid,
6.Remove battery box cover. electrolyte which can cause severe
burns and produce explosive gasses.
7.Lift the battery from the machine. Avoid contact with the skin, eyes or
clothing.
23.7 Battery installing
PROCEDURE
1. Observe all safety warnings
2. Ensure all electrical circuits are

switched off
3. Lift the battery onto the machine
4. Replace battery box cover.
5. Lock battery box cover.
6. Connect the positive (+) lead
7. Connect the ground (-) lead

23.8 Changing Fuses
1 Observe all safety warnings. Ensure machine is switched off, locked out and tagged
out. Remove ignition key, carry it with you
2 For additional protection, disconnect both battery terminals
3 Unlock fuse box at lock on front of control panel, turning one quarter revolution
clockwise
4 Identify which fuse is to be changed, using fuse relay diagram (appendix)
5 Grip fuse carefully using needle nose pliers or preferably with plastic fuse removal
tweezers (figure 30.11 A)
6 Check fuse to see if it is blown, a blown fuse should have a gap in the ampoule (see
figure 30.11 B)
7 Insert new fuse into fusebox
8 Close fuse box , start machine and test if new fuse corrects original problem.
Figure 23.8 A Figure 23.8 B


24 - Servicing The Hydraulic System Page 1
24 - Servicing The Hydraulic System

24 - Servicing Hydraulic System
Contents
24.1 General .............................................................................................................3
24.2 - Hydraulic fluid ...............................................................................................4
24.2.1 Checking hydraulic fluid..................................................................................5
24.2.2 Adding hydraulic fluid......................................................................................6
24.2.3 Changing hydraulic oil.....................................................................................7
24.3 Checking the return line filter .......................................................................9
24.4 Changing the return Line filter .....................................................................10

24.1 - General
All hydraulic functions are powered by

pumps driven by the engine / electric
hazards
motors. EQUIPMENT
Note:- All relief valve pressures are ANSI
factory set and should not be adjusted
on site. SWITCH OFF AND LOCKOUT
1532 ISO
The hydraulic fluid reservoir together
with associated equipment must be INJECTION HAZARD
maintained in accordance with the 1504 ISO
set level and in the schedules and
types, see General Routine checks,
Specific checks, Lubrication and
Fluid Specifications. ONLY USE A
RECOMMENDED FLUID.
DANGER
THIS IS A HIGH PRESSURE SYSTEM.

Never carry out any maintenance
work without ensuring the
hydraulic system is locked out and
depressurised. Check the pressure
gauges and control screen, if fitted,
to view the current system pressure.
Open the bleed valve, if fitted, until
all pressure is relieved then close the
valve. Do not amend the hydraulic
system. In the event of any problems
these should only be dealt with by
suitably experienced and qualified
engineers.

24.2 - Hydraulic Fluid
1. Check the fluid level on the gauge hazards

and top up as necessary. 1520 / 1513 WEAR PERSONAL PROTECTIVE
EQUIPMENT
2. It is essential when replenishing
ANSI
hydraulic fluid, attending to filters, etc.
to apply the greatest degree of cleanli- 1532 ISO
ness as it is most important that con-
taminants are not allowed to enter the
INJECTION HAZARD
1504 ISO
system. Refer this Section, safety information
3. If hydraulic fluid needs to be added

to maintain the correct level, this should
be pumped in through the fill port on the
large return filter.
The air vents in the cap must be
kept open to allow the hydraulic
system to “breathe.”
Always use the correct grade

of oil, otherwise overheating
will occur. (Refer this Section,
“lubricants and fluids.”)
If the hydraulic system requires
filling up on a regular basis, all
hydraulic parts and hoses should
Filler be inspected for leaks. Any repairs
Cap should be made prior to continued
operation of the machine.
ALWAYS practice extreme

cleanliness when servicing.


hazards
24.2.1 Check hydraulic oil level 1520 / 1513 WEAR PERSONAL PROTECTIVE
EQUIPMENT
1532 ISO
2. Machine must be on level ground. Refer this Section, safety information
3. Always have the hydraulic oil at nor- INJECTION HAZARD

1504 ISO
mal operating temperature. 1504 ANSI
4. Always have all cylinders retracted

(where possible).
5. Check the level indicator (A.) The

oil level must be between the red and
black marks on the gauge.
A Hydraulic Oil Level Indicator

24.2.2 Adding hydraulic fluid

hazards
EQUIPMENT
ISO
1. Observe all safety warnings. Refer this Section, safety information
ANSI
2. Machine must be on level ground.
1532 ISO
1532 ANSI
3. Always have all cylinders retracted for relevant warning.
(where possible).
INJECTION HAZARD
1504 ISO
4. Implement lock-out procedure. 1504 ANSI for relevant warning.
5. Clean the area around the filler cap

(C.)
6. Open the filler cap (C.)
7. Fill the tank to midway between red

and black marks on the level indicator.
(Correct grade of hydraulic oil see this
Section, “lubricants and fluids.”)
C Filler Cap
Never overfill the hydraulic tank

as this will cause leakage from the
filler cap.

24.2.3 Change hydraulic oil

hazards
EQUIPMENT
1. Observe all safety warnings. ISO Refer this Section, safety information
ANSI
2. Always have the hydraulic oil at nor-
mal operating temperature. 1532 ISO
3. Always have all cylinders retracted
(where possible.) 1504 ISO INJECTION HAZARD
4. Drain the tank by removing the drain
plug (D.)
5. Remove the cover plate under the

filler cap (C.)
Discard the gasket.
ALWAYS practice extreme

cleanliness when servicing.
Before removing the drain plug

D Drain Plug (D.)
C Filler Cap
a) Release any pressure in
the hydraulic tank by slowly
C unscrewing the filler cap (C.)
b) Ensure a suitable container is

placed on the ground to catch the
full capacity of oil in the tank.
c) Remember to stand on one

side to avoid oil which will spill
from the drain hole.

24.2.4 Change hydraulic oil - hazards

CONTINUED 1520 / 1513 WEAR PERSONAL PROTECTIVE
EQUIPMENT
6. Remove the suction filters (E) by un- ANSI
screwing them from the suction pipes. SWITCH OFF AND LOCKOUT
1532 ISO
7. Flush out the tank with clean
hydraulic oil taking extreme care to
INJECTION HAZARD
remove all dirt and foreign matter. 1504 ISO
8. Fit new suction filters (E) to the suc-

tion pipes.
9. Re-fit cover plate to the tank using a

new gasket and refit drain plug (D.)
10. Change the return line filter element

(refer this Section.) Change the suction elements
when an oil change is being
11. Refill the tank with clean hydrau- carried out.
lic oil to midway between the red and
black marks on level indicator. (Correct
grade of hydraulic oil see this Section,
“lubricants and fluids.”)
12. Run the engine to circulate the oil. C

Operate the hydraulic controls to purge
any air from the system.
F
13. Stop the engine and fill up the sy-

stem as required.
E
D A

24.3 - Checking the return line filter
1. Observe all safety warnings. hazards

2. Always have the engine running at ISO
EQUIPMENT
maximum speed. 1520 / 1513 for relevant warning.
ANSI
3. Always have all hydraulic equipment 1532 ISO SWITCH OFF AND LOCKOUT
working. Refer this Section, safety information
4. Always have the hydraulic oil at INJECTION HAZARD

1504 ISO
normal operating temperature. 1504 ANSI
5. Check the return line filter blockage

indicator.
6.Change the filter element immediately

when the green sector of the blockage
indicator goes to red.
Return
Line Filter
Blockage
Indicator
Figure 24.3

24.4 Changing the Return Line Filter
1 Observe all safety warnings. Ensure machine is switched off, locked out and
tagged out. Remove ignition key, carry it with you
2 Ensure all cylinders are closed (where possible)
3 Release any pressure in the hydraulic tanks by slowly unscrewing the filler cap.
4 Clean the outside of the filter housing
5 Remove the filter by unscrewing the 4 securing nuts and removing cover.
As shown in figure 24.4
6 Lift out the old element and discard it safely and responsibly.
7 Wash out the filter cap and dry with an air hose. DO NOT USE A RAG.
8 Re-fit new filter ensuring seal ring is in good condition and correctly positioned.
9 Fit cover and fasten 4 securing nuts
Hydraulic fluid under pressure can penetrate the skin causing

serious injury.
Always use a piece of cardboard to check for leaks. Do not use
your hand. If fluid is injected under the skin, it must be surgically
removed or gangarene will result.
Return Securing
Line Filter Nuts
Blockage
Indicator
Figure 24.4

25 - Changing Air & Water Filters Page 1
25 - Changing Air & Water Filters

25 - Changing Air & Water Filters
Contents
25.1 Air Filtration ....................................................................................................3
25.2 Check both air cleaner elements ...................................................................4
25.3 Changing the outer air cleaner element .........................................................5
25.4 Changing the inner air cleaner element ..........................................................6
25.5 Draining the water fuel trap ...............................................................................7

25.1 - Air Filtration
The air required to run the engine is inducted into the engine after passing through a
filtration system. As air passes into the breather system it is initially met by the first
filter known as the precleaner. This removes the heaviest of the dust,some of which
escapes through a vent at the bottom or at the back of the precleaner.
The air than passes through the outer filter which removes more dust and than final-
ly the air passes through the inner air filter. This filtration system removes virtually
all the dust being inducted into engine.

25.2 - Check both air cleaner elements
It is recommended that air cleaner elements are not cleaned or reused but
replaced with new items.
tagged out, Remove the ignition key and carry it with you
2 Release the 3 tension clips (A) at side of cover (B) As shown in figure 25.2B
3 Remove cover
4 Carefully remove outer filter (C) and inner filter (D) As shown in figure 25.2A
5 Discard the elements if they are distorted
6 Hold each element up to the light to check for damage to the paper. The
elements should be discarded if pin pricks of light can be seen or if there are
areas of paper that appear thin.
7 Refit new or existing elements as required
Do not run the engine with the cover (B) removed
Figure 25.2 A
B
A
Figure 25.2 B

25.3 - Changing the outer air cleaner element
2 Release the 3 tension clips (A) side of cover (B). As shown in figure 25.2A
3 Remove cover (B)
4 Carefully remove outer filter (C), minimising the amount of dust spilled
5 Clean outer filter using air hose, if damage is apparent replace air filter
6 Reattach outer filter
7 Place outer cover and fasten clips
Figure 25.2 A

25.4 - Changing the inner air cleaner element
1. Observe all safety warnings. Ensure machine is switched off, locked out and
2. Release the 3 tension clips (A) at side of cover (B). As shown in figure 25.4 A
3. Remove cover
4. Carefully remove outer filter (C)
6. Remove inner element (D)

7. Clean the inside of the air cleaner casing using damp, lint free cloth
8. Replace the existing inner element (D) and fit a new outer filter (C)
9. Re-fit cover (B). Fasten tension clips (A).
Figure 25.4 A

25.5 - Draining the water fuel trap
2 Identify the water fuel trap on the left hand side of the power unit as shown in
figure 25.5
3 Unscrew drain bung at the bottom of the water trap and allow water to drain
out into a suitable container
4 Tighten the drain plug when pure diesel fuel starts to come out
5 Clean up any spilt diesel
Fuel water trap
Drain Bung
Fuel
Contamination
Sensor
Figure 25.5


26 - Screen Unit Maintenance Page 1
26 - Screen Unit Maintenance

26 - Screen Unit Maintenance
Contents
26.1 Practice Safe Screen unit Maintenance............................................................3
26.2 Changing the screen mesh.................................................................................4
26.3 Re-tuning the screen unit...................................................................................8

26.1 Practice Safe Screen unit Maintenance
See Section 2 - ‘SAFETY ’ for relevant warning information before

attempting to maintain unit.
Before undertaking maintenance, repairs or retooling work on the

machine, switch off the machine and secure against unauthorised
restarting. A sign “Do not start” should be hung on the control panel
when undertaking repair work. Remove the key from the main control
panel switch
Carry the key with you.
Never lubricate, clean, service or adjust machine while it is moving
Keep hands, feet and clothing clear of power driven parts and in-
running nip points
Keep hands, feet and clothing clear of power driven parts and in-
running nip points
Keep all parts in good condition and properly installed.

Fix damage immediately
Replace worn and broken parts
Do not unfasten or remove any guard while the machine is running or

start the machine while a guard is unfastened or removed
Do not screen material if there is any vibration present in the sub frame
or walkway. Except to set screen shaft speed or add/remove flywheel
weights.
26.2 Changing the screen mesh
Only lifting equipment capable of lifting 500kg or more may be

used for this operation
Tail conveyor must not be used as a platform unless:

1 Tail conveyor has been pinned in position
2 Screenbox has been pinned in position
3 Engine lockout procedure has been implemented
The following instructions should be carried out on both the right

and left hand side. THE SCREEN TENSIONING RAM CONTROL
LEVER CONTROLS BOTH SCREEN TENSIONING RAMS.

2 Start machine.
3 Lower the tail conveyor and pin in position. The purpose of this is to allow
easier access to the lower meshes.
4 Retract the main conveyor to its lowest point.
5 Lower the screenbox to its lowest point and pin in position.
6 Move the screen tensioning ram from the mounts on walkway to the appropriate
position on the screenbox and secure in place using correct pins.
7 Move lever on screen tensioning cylinder control valve to up position.
The screen tension rams should extend.
CB
9 Remove the retaining pins A

10 Move lever of screen tensioning cylinder control valve to the down position.
This should cause the screen tension bar to move clear of the retaining pin holes.
The screen tension bar will retract from the screen hooks
11 Switch off, lockout and tagout .
Once machine has been locked out tail conveyor may be used as a platform
to facilitate changing meshes.
12 Remove retaining pins (CB)
13 Remove screen tension bar
14 Push screen mesh back until it is free to lift up
15 Lift up using a prise bar and slide the old mesh out
16 Check the rubber cushions and replace if necessary
17 Remove any material build up from inside the screenbox
18 Insert new screen meshes ensuring the hooked end of the mesh is in the correct
position around the tension bar
Screen Tensioning
Ram Control
CB
20 Insert screen tension bar (B) ensuring it is fitted correctly in screen box and
around tension bar
21 Restart machine.
NOTICE
Tail conveyor cannot be used as platform when engine is running
22 Insert pin (CB) through screen tension bar and end of screen tensioning ram .
Move the screen tensioning cylinder control valve lever to the up position to
extend the cylinder and hence tension the mesh.
23 Insert retaining pins (A) through appropriate holes
24 Remove bolts (CB) from the end of the screen tensioning cylinders. Retract
screen tensioning cylinders using screen tensioning cylinder control valve.
Disconnect ram hoses from ports, remove both rams from screen box, and
secure them to sub-frame using the pins provided.
25 Tension screen tension bolts (C). If required.
NOTICE
The centre of the mesh tensions first and the appropriate tension is reached when
the outside edges of the mesh are taut
NOTICE
Absolute maximum tension is obtained when the screen tension bar is parallel
with the hook on the screen mesh as shown below
C CB
NOTICE
This amount of tension is not always required
26 T
o release the side tensioned impact mesh, slacken the nuts or remove the
quick release pins enough to allow the mesh to be removed from under the
clamps.
27 Replace mesh.
28 Retighten clamps and refit quick release pins or bolts.
27 Return screen unit, tail conveyor and main conveyor to original positions.
slacken nuts
Washer
Quick Release
Pin
Split Pin
26.3 Re-tuning the screen unit
Re-tuning should only be performed

by personnel trained in accordance
with instructions provided in this
HAZARDS
manual or by trained POWERSCREEN EQUIPMENT
ISO
personnel. 1520 / 1513
ANSI
When altering the flywheel counter
weights, always act on both sides of 1508 ANSI Refer this Section, safety information
the screen shaft.
1502 ISO ENTANGLEMENT HAZARD

PROCEDURE

2. Set up the machine to it‘s working/
operating position.
3. Fit meshes and speed harps as

required.

4. Move up side conveyor levers, to start
side conveyors.
26.3 Re-tuning the screen unit
5. Move up screen and tail conveyor lever,

to start screenbox and tail conveyor.
6. Move up main conveyor lever to start

the main conveyor and vibrating grid. (If
fitted)
7. Let the machine run for 45 minutes

to allow the hydraulics to warm up pro-
perly.
8. Set screen speed at 930 ±10 rpm for

3 deck machine and 905 ±10 for 2 deck
machine . Engine speed should be about
2200 rpm.
9. Stop the machine and implement

“Lockout ” procedure.

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CHIEFTAIN 1700/1700S

PRODUCT USER MANUAL

© Copyright POWERSCREEN 2011

LOOK IN SECTION 1 ( ADDITIONAL INFORMATION)

TAKE NOTE OF ANY VARIATIONS TO THE

IMPORTANT SAFETY NOTICE!

INFORMATION AND ADVICE

Northern Ireland: America

Terex Powerscreen Terex Crushing & Screening Inc.

200 Coalisland Rd 11001 Electron Drive

Dungannon Co. Tyrone BT71 4DT Louisville,

Telephone: Kentucky 40299

Main Switchboard: United States of America

+ 44 (0) 2887 740701 Telephone:

Email: aftersales@powerscreen.com Main Switchboard: 001 (502) 736 5200

This plant is in conformity with the provisions

May cause loss or degradation of hearing

Wear proper hearing personal protective

Death, serious injury or delayed lung

When dusts are generated by the operation

The copyright of this User Manual is reserved by TEREX POWERSCREEN

Main Switchboard: + 44 (0) 2887 740701

To order additional copies contact your local Dealer.

Owners, Users, and Operators:

Help Desk (aftersales@powerscren.com)

The safety alert symbol is used to alert you to potential personal

01 - Additional Information and Features

Powerscreen Int. Dis Ltd., Dungannon, N.Ireland. WWW.POWERSCREEN.COM

INTENTIONAL SEQUENCE BLANK PAGE

Powerscreen Int. Dis Ltd., Dungannon, N.Ireland. WWW.POWERSCREEN.COM

02 - Safety Notices and Hazards

Powerscreen Int. Dis Ltd., Dungannon, N.Ireland. WWW.POWERSCREEN.COM

Important Safety Notices

For further U.K. information also refer to:

CALIFORNIA Proposition 65 CALIFORNIA

Powerscreen Int. Dis Ltd., Dungannon, N.Ireland. WWW.POWERSCREEN.COM

Powerscreen Int. Dis Ltd., Dungannon, N.Ireland. WWW.POWERSCREEN.COM

Selection and Qualification of Personnel - Basic Responsibilities

Take the necessary precautions to Special work in conjunction with

Powerscreen Int. Dis Ltd., Dungannon, N.Ireland. WWW.POWERSCREEN.COM

Powerscreen Int. Dis Ltd., Dungannon, N.Ireland. WWW.POWERSCREEN.COM

Do not pour waste onto the ground,

Powerscreen Int. Dis Ltd., Dungannon, N.Ireland. WWW.POWERSCREEN.COM

Warning of Special Dangers

Powerscreen Int. Dis Ltd., Dungannon, N.Ireland. WWW.POWERSCREEN.COM

Hazardous Substances When travelling on public roads, ways

The plant is remote controlled and may start

Powerscreen Int. Dis Ltd., Dungannon, N.Ireland. WWW.POWERSCREEN.COM

WORK AREA SAFETY

1. Keep the work area as neat and as clean as practical.

2. Keep all warning and caution signs clear and up to date

3. Make certain all electrical equipment is properly grounded.

15. For questions concerning accumulators, which are pressure-containment vessels,

Powerscreen Int. Dis Ltd., Dungannon, N.Ireland. WWW.POWERSCREEN.COM

Powerscreen Int. Dis Ltd., Dungannon, N.Ireland. WWW.POWERSCREEN.COM

ELECTRICAL AND ENGINE SAFETY

4. The electrical equipment of the machine should be inspected at regular intervals.

Powerscreen Int. Dis Ltd., Dungannon, N.Ireland. WWW.POWERSCREEN.COM

SAFETY BEFORE AND DURING OPERATION

7. Never work or stand beneath machinery or attachments as it is raised or lowered.

Powerscreen Int. Dis Ltd., Dungannon, N.Ireland. WWW.POWERSCREEN.COM

SAFETY BEFORE AND DURING MAINTENANCE

Maintenance should only be carried out by trained and qualified personnel.