883mkii Operation English +090312-09

Operations Manual (ENG)
883 | 883
COPYRIGHT
No copies or reproductions may be made from this manual, parts lists or illustrations without
written prior consent of Terex® MPE. This manual complete or in part must not be loaned to a
third party.
Finlay is a registered trademark for portable screening plant manufactured by Terex® MPE.
883MKII
ENGLISH OPERATION MANUAL
ORIGINAL INSTRUCTIONS
ISSUE NO. 090312/09
OPERATION MANUAL MUST BE WITH THE MACHINE AT ALL TIMES
TEREX® MPE
DRUMQUIN ROAD, OMAGH, CO.TYRONE N.IRELAND, BT78 5PN
TEL: +44(0)2882 418700
FAX: +44(0)2882 244294 (SALES) 243487 (SPARES)
252740 (TECHNICAL) 418888 (HELPDESK)
EMAIL: sales@terex.com
WEBSITE: www.terex.com
Terex® MPE reserve the right to change specification without prior notice.
CO-1
Owners, Users, and Operators:
Terex® MPE 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, (insert business unit information).
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.
Intended use
This product and its approved attachments are designed to perform the following (state
approved function). Use of this product in any other way is prohibited and contrary to its
intended use.
CO-2
CONTENTS
SECTION 1: SAFETY
1.1 SAFETY INTRODUCTION ..................................................................... SA - 2
1.2 SAFETY SIGNS ON YOUR MACHINE ................................................. SA-19
1.3 WORK AREA SAFETY .......................................................................... SA-24
1.4 HYDRAULIC SAFETY .......................................................................... SA-25
1.5 ELECTRICAL AND ENGINE SAFETY .................................................. SA-26
1.6 SAFETY BEFORE AND DURING OPERATION ................................... SA-27
1.7 SAFETY BEFORE AND DURING MAINTENANCE ............................. SA-28
1.8 SAFETY BEFORE AND DURING TRANSPORT ................................. SA-30
1.9 INFORMATION SIGNS ......................................................................... SA-31
1.10 REMOTE STOPS ON YOUR MACHINE .............................................. SA-37
1.11 SAFETY GUARDS ON YOUR MACHINE ............................................ SA-38
1.12 NOISE LEVELS AROUND YOUR MACHINE ....................................... SA-39
CO-3
CONTENTS
SECTION 2: TECHNICAL INFORMATION
2.1 FAMILIARISATION ................................................................................. TE - 2
2.2 KEY COMPONENTS ............................................................................. TE - 3
2.3 OPTIONS ............................................................................................... TE - 6
2.4 TECHNICAL DATA................................................................................. TE - 7
2.5 TRANSPORT DIMENSIONS ................................................................. TE - 9
2.6 WORKING POSITION DIMENSIONS .................................................. TE-10
2.5 TRANSPORT DIMENSIONS (LONG CONVEYOR) .............................. TE-11
2.6 WORKING POSITION DIMENSIONS (LONG CONVEYOR) ................ TE-12
2.7 CORRECT USE OF MACHINE ............................................................ TE-13
CO-4
CONTENTS
SECTION 3: INSTALLATION
3.1 SAFETY INTRODUCTION ...................................................................... IN - 2
3.2 STARTING ENGINE (STANDARD CAT ENGINE) .................................. IN - 8
3.3 STARTING ENGINE (OPTIONAL DEUTZ ENGINE) ...............................IN-12
3.4 STARTING ENGINE (TIER 4 MCU300 ENGINE) ...................................IN-15
3.5 MACHINE SETTINGS .............................................................................IN-22
3.6 TRACKING THE MACHINE ....................................................................IN-23
3.7 TRACKING OPTIONS .............................................................................IN-25
3.8 LOWERING SUPPORT LEGS ................................................................IN-31
3.9 LEVELLING .............................................................................................IN-34
3.10 FITTING SCREEN CATWALK ................................................................IN-35
3.11 FITTING CATWALK ACCESS STEPS ....................................................IN-37
3.12 UNFOLDING THE OVERSIZE CONVEYOR ..........................................IN-38
3.13 UNFOLDING THE MIDDLE GRADE CONVEYOR .................................IN-39
3.14 UNFOLDING THE FINES CONVEYOR ..................................................IN-41
3.15 LOCATING APRON FEEDER IN WORKING POSITION ........................IN-42
3.16 RAISING SCREENBOX TO WORKING POSITION ................................IN-43
3.17 SCREENBOX SPILLAGE RUBBER .......................................................IN-44
3.18 RAISING THE HOPPER EXTENSION FLAPS .......................................IN-45
CO-5
CONTENTS
SECTION 4: OPERATION
4.1 SAFETY INTRODUCTION .................................................................... OP - 2
4.2 SAFETY BEFORE AND DURING OPERATION ................................... OP - 8
4.3 OPERATING MACHINE (STANDARD CAT ENGINE) .......................... OP - 9
OPERATING MACHINE (OPTONAL DEUTZ ENGINE) ....................... OP-10
OPERATING MACHINE (TIER 4 CAT ENGINE) ................................... OP-11
4.4 SCREENING ......................................................................................... OP-12
4.5 APRONFEEDER SPEED CONTROL ................................................... OP-13
4.6 CONVEYORS SPEED CONTROLS ..................................................... OP-13
4.7 FEEDER START/SOP & ENGINE STOP (OPTION) ............................. OP-14
4.8 REMOTE FEEDER START/STOP (OPTION) ....................................... OP-17
CO-6
CONTENTS
SECTION 5: MAINTENANCE
5.1 SAFETY INTRODUCTION .................................................................... MA - 3
5.2 SAFETY BEFORE AND DURING MAINTENANCE ............................. MA - 9
5.3 HYDRAULIC SAFETY .......................................................................... MA-11
5.4 ELECTRICAL AND ENGINE SAFETY ..................................................MA-12
5.5 HYDRAULIC SYSTEM .........................................................................MA-14
5.6 HYDRAULIC FLUIDS ...........................................................................MA-15
5.7 FILTRATION ..........................................................................................MA-16
5.8 OILTANK, PIPES & FITTINGS...............................................................MA-18
5.9 DIESEL ENGINE ...................................................................................MA-19
5.10 SCREEN ...............................................................................................MA-20
5.11 BELT TRACKING ..................................................................................MA-21
5.12 BELT TRACKING ON YOUR MACHINE ..............................................MA-22
5.13 BELT TENSIONING ON YOUR MACHINE ...........................................MA-23
5.14 TENSIONING APRON FEEDER ...........................................................MA-24
5.15 FASTENING APRON PANS ON APRON FEEDER ..............................MA-25
5.16 CHANGING TOP DECK ........................................................................MA-26
5.17 BOTTOM DECK SCREEN CLOTH ......................................................MA-29
5.18 CHANGING BELTFEEDER GEARBOX OIL .........................................MA-31
5.19 CHANGING FUEL FILTER ....................................................................MA-32
5.20 WATERTRAP ........................................................................................MA-33
5.21 CHANGING HYDRAULIC FILTERS & OIL ............................................MA-35
5.22 CHANGING ENGINE FILTERS & OIL ...................................................MA-38
5.23 CHANGING GEARBOX OIL ON TRACKS ............................................MA-44
5.24 TRACK ADJUSTMENT .........................................................................MA-45
5.25 HYDRAULIC RAM MAINTENANCE ....................................................MA-48
5.26 RECOMMENDED LUBRICANTS .........................................................MA-49
5.27 REMOTE GREASING SCHEDULE ......................................................MA-51
5.28 MAINTENANCE SCHEDULES ............................................................MA-53
5.29 TIER 4 MAINTENANCE SCHEDULES ................................................MA-62
CO-7
CONTENTS
SECTION 6: TRANSPORT
6.1 SAFETY INTRODUCTION .................................................................... TR - 2
6.2 SAFETY BEFORE AND DURING TRANSPORT ................................. TR - 5
6.3 STOPPING THE MACHINE .................................................................. TR - 7
6.4 PREPARING FOR TRANSPORT ......................................................... TR - 8
6.5 RAISING THE HOPPER EXTENSION FLAPS ..................................... TR - 9
6.6 LOWERING SCREENBOX TO TRANSPORT POSITION .................... TR-10
6.7 LOCATING APRON FEEDER IN TRANSPORT POSITION ................. TR-11
6.8 FOLDING THE FINES CONVEYOR ..................................................... TR-12
6.9 FOLDING THE MIDDLE GRADE CONVEYOR .................................... TR-13
6.10 FOLDING THE OVERSIZE CONVEYOR .............................................. TR-15
6.11 REMOVING CATWALK ACCESS STEPS ............................................ TR-16
6.12 PLACING SCREEN CATWALK IN TRANSPORT POSITION .............. TR-17
6.13 RAISING SUPPORT LEGS ................................................................... TR-18
6.14 READY FOR TRANSPORT .................................................................. TR-19
6.15 PRIOR TO HAULAGE ........................................................................... TR-20
CO-8
CONTENTS
SECTION 7: FAULT FINDING
7.1 NO RESPONSE FROM ANY HYDRAULIC SYSTEM ............................ FA-2
7.2 MACHINE OPERATING SLOWLY. NO EXTERNAL OIL LEAKS ............. FA-3
7.3 EXCESSIVE NOISE FROM HYDRAULIC PUMP ................................... FA-4
7.4 SCREEN NOT WOKING .......................................................................... FA-4
7.5 FEEDER NOT WORKING WHEN MAIN CONVEYOR RUNNING .......... FA-5
7.6 SCHREECHING NOISE WHEN CONVEYOR IS RUNNING ................... FA-5
7.7 CONVEYOR BELT NOT RUNNING ......................................................... FA-6
7.8 CONVEYOR BELT TENDS TO RUN BACK IF STOPPED
WITH A LOAD ON THE BELT .................................................................. FA-6
7.9 MESHES BREAKING PREMATURELY .................................................. FA-7
7.10 SCREEN BEARINGS FAIL PREMATURELY .......................................... FA-7
7.11 ENGINE FAILS TO START ...................................................................... FA-8
7.12 BELT STOPS UNDERLOAD.................................................................... FA-8
7.13 ENGINE STOPS....................................................................................... FA-9
7.14 CONVEYOR BELTS RUNNING OUT OF LINE ....................................... FA-9
CO-9
CONTENTS
SECTION 9: APPENDIX
9. APPENDIX ............................................................................................ WA - 1
CO-10
CONTENTS
SECTION 10: WARRANTY
10. WARRANTY.......................................................................................... WA - 1
CO-11
SECTION 1: SAFETY ENG
CONTENTS:
1.1 SAFETY INTRODUCTION ................................................................... SA - 2
1.2 SAFETY SIGNS ON YOUR MACHINE ................................................ SA - 19
1.3 WORK AREA SAFETY ......................................................................... SA - 24
1.4 HYDRAULIC SAFETY .......................................................................... SA - 25
1.5 ELECTRICAL AND ENGINE SAFETY ................................................. SA - 26
1.6 SAFETY BEFORE AND DURING OPERATION................................... SA - 27
1.7 SAFETY BEFORE AND DURING MAINTENANCE ............................. SA - 28
1.8 SAFETY BEFORE AND DURING TRANSPORT ................................. SA - 30
1.9 INFORMATION SIGNS ......................................................................... SA - 31
1.9 REMOTE STOPS ON YOUR MACHINE .............................................. SA - 37
1.10 SAFETY GUARDS ON YOUR MACHINE ............................................ SA - 38
1.11 NOISE LEVELS AROUND YOUR MACHINE....................................... SA - 39
SA - 1
SECTION 1 : SAFETY
1.1 SAFETY INTRODUCTION
1.1.1 Personal Safety
Operators should be trained in the correct and safe use of all equipment.
Before operation the operator(s) must:-
(i) Have received specific and adequate training in the task to be carried out.
(ii) Have read and understood the Operators Manual and the Safety Signs in this
manual and around the machine(s).
(iii) Knows the location and function of controls and safety features such as emergency
stop buttons and safety guards.
(iv) Be aware of all moving parts of the machine.
(v) Always wear correctly fitting (EN/ANSI approved) protective clothing.
WARNING
1. Loose or baggy clothing can get caught in
running machinery.
2. Protective clothing includes Hard Hat,

Safety Glasses, Ear Defenders, Overalls,
Gloves, Steel Toed Boots and a High
Visibilty Vest.
SA - 2
1.1.2 General Safety
Overleaf are the safety symbols used on your machine, a detailed explanation of each
symbol is outlined. Take time to familiarise yourself with the symbols and explanations.
The safety symbols in this section cover the complete Terex® MPE product range, there-
fore every symbol explained may not apply to the your machine.
Safety signs throughout this manual are identified by the safety alert symbol. When you see this
symbol be alert to the possibility of personal injury or death.
Please take time to familiarise yourself with each of these signs and what they mean.
Always follow the instructions in the Safety message.
DANGER
This indicates an imminently hazardous
situation which if not avoided, will result in
death or serious injury.
WARNING
This indicates a potentially hazardous situa-
tion which, if not avoided, could result in
CAUTION This indicates a potentially hazardous situa-

tion which, if not avoided, may result in
minor or moderate injury.
It may also be used to alert against unsafe
practices.
IMPORTANT This indicates a statement of company

policy, which if not adhered to will result in
damage to your machine and/or other peo-
ples property.
SA - 3
DANGER
1. Entanglement Hazard.
Contact with moving belt will result in
serious injury or death.
2. Stay clear of moving belt.
3. Do not operate this machine without all

guards and covers in place.
4. Switch off and lockout machine before

adjusting or servicing .
DANGER
1. Injection Hazard.
Beware of escaping Hydraulic oil. High
pressure hydraulic oil can penetrate the
skin causing serious injuries.
2. Always relieve pressure from the hydraulic

system before disconnecting hydraulic
lines, attempting maintenance or
adjustments. Use a piece of cardboard to
check for oil leaks.
3. If oil is injected under the skin, get medical

help immediately.
4. Read manual prior to operation
SA - 4
DANGER 1. Electrocution Hazard.

Risk of serious injury or death will result
from contact with electrical power lines.
2. Beware of overhead cables when folding

main conveyor
3. Maintain required clearance
Line Required
Voltage Clearance
0 - 50kW 10 ft (3.0M)
50 - 200kW 15ft (4.6M)
200 - 350kW 20ft (6.1M)
350 - 500kW 25ft (7.6M)
500 - 750kW 35ft (10.7M)
750 - 1000kW 45ft (13.7M)
4. Contact electric powerline owner, Electric

power shall be disconnected or powerline
moved or insulated before machine
operation
DANGER
1. Electrocution Hazard
Contact with hazardous voltage will result in
2. Disconnect, Lockout power before

servicing.
Only authorized personnel may service this
equipment.
3. Read all manuals prior to operation.
SA - 5
DANGER
1. Entanglement Hazard.
Do not reach into an unguarded
machine.Contact with shredder will result in
2. In-running nip points can cause serious

injury or even death. Your arm could be
pulled in and amputated.

opening or removing guard doors.
WARNING
1. Impact Hazard.
Contact with spring loaded doors can
result in serious injury.
2. Keep head and face away from door.

Keep hand firmly on door until it is
completly open.
SA - 6
DANGER
1. Magnetic Hazard.
Risk of serious injury or death.
2. Magnetic fields can disturb pacemaker

operation if within 3 metres of the magnet
and result in serious injury or death to
pacemaker wearer.
3. Keep Clear from Magnet.
DANGER
1. Flying material Hazard.
2. Platform is for Maintenance purposes only.
3. If Flying material hits the head or body it

can cause serious injury or death .
4. Keep Clear. Do not use platform when

plant is in operation.
SA - 7
DANGER
1. Flying material Hazard.

2. Flying material can cause loss or

degradation of eye sight.
3. Wear proper eye personal protective

equipment.
DANGER
1. Crush Hazard.
2. Death or serious injury can result from

contact with the Track frames.
3. Keep clear of Track frames when the unit is

in operation.
SA - 8
WARNING
1. Improper operation or maintenance can
result in serious injury or death.
2. Read and understand the operators

manual before using or maintaining
machine.
2. Read and understand safety signs before

using or maintaining machine .
3. If you do not understand the information in

the manuals, consult your supervisor, the
owner or the manufacturer.
WARNING
1. Burn Hazard.
Contact with hot surfaces can result in
serious injury or death
2. KEEP CLEAR . Allow surfaces to cool

before servicing
SA - 9
WARNING
1. Falling Material Hazard.
2. Do not walk near material discharge

areas.
You are at risk of serious injury or death.
3. Keep Clear of hopper during operation
WARNING
1. Crush Hazard.
Beware of dangerous Hand and Foot
crush points.
2. Do not use any body parts e.g. hands or

feet to check hole alignment or support
machinery.
3. Always use pins and/or mechanical

supports provided.
SA - 10
WARNING
Crushing Hazard.
Unsupported shredder can crush you.
Death or serious injury can result.
1. Raise Shredder.
2. Connect red safety bar.
3. Switch off and Lockout machine before

carrying out any maintenance work under
the shredder.
WARNING
1. Crush Hazard.
Engine inspection cover can crush..
2. death or serious injury can result.
3. Install support before working under or

around engine inspection cover.
SA - 11
WARNING
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.
WARNING
INHALATION HAZARD
Death, serious injury or delayed lung
disease may result from breathing
hazardous dust.
Use dust suppression or dust collection

equipment to minimise 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.
SA - 12
WARNING
Crushing Hazard.
Contract with folding conveyors can result
in death or serious injury.
Keep clear of conveyors when folding for

transport or opening to working position.
Read all manuals prior to operation.
WARNING
Explosion Hazard.
May cause severe injury or death due to
ignition of explosive gases.
Keep welding sparks away from the

battery area. Remove battery if required.
SA - 13
WARNING
Electrocution Hazard.
Contact with hazardous voltage will result in
Disconnect, lockout power before

servicing.
Only authorizd personnel may service this

equipment.
Read all manuals prior to operation.
WARNING
Hearing Hazard.
Exposure to loud noise could result in
serious hearing loss.
Wear proper hearing personal protective

equipment.
SA - 14
WARNING
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 protective equipment,
including shield, gloves and long sleeve
shirt. Consult operation and maintenance
manual for jump starting instructions. Read
all manuals prior to operation.
WARNING
Entanglement Hazard.
Exposed buckets can cause severe injury
or death.
Keep clear of exposed buckets.
Switch off and lockout machine before

opening, removing guards or servicing.
SA - 15
WARNING
1. Fall Hazard.
Falling from this machine can result in
serious injury or even death.
2. Do not Climb on Machine.
3. Always use a suitable lifting platform to

service the machine.
WARNING Vehicle Hazard.

Vehicle control can be affected by improper
setup of vehicle.
1. Check tyre pressures.
2. Check wheel nut torque. Recheck wheel nut

torque every 150 miles (200km).
3. Connect and check braking system.
SA - 16
California Proposition 65
The following warnings are not attached to

your machine, but in the State of California
operators must be aware of the following
health warnings.
WARNING
Battery Posts terminals and related
accessories contain lead compounds,
chemicals known in the State of California to
cause cancer and reproductive harm.
Wash Hands after Handling.
WARNING
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth defects, and
other reproductive harm.
SA - 17
Lockout procedure.
Lockout is a procedure that is designed
to prevent the unexpected or accidental
startup of equipment and to alert all
workers whenever it is unsafe to operate A
any piece of equipment. When used as
intended, Lockout also protects personnel
from energy stored in devices such as
springs, accumulators, batteries, hydraulic
systems, etc.
When the symbols below appear on a
safety sign it indicates that the machine
must be switched off and locked out
before maintenance can be carried out. Starter Panel
The Isolator Switch (ItemB) is located be-

side the battery box, the switch cuts the elec-
tric supply from the battery ensuring the ma-
chine cannot be operated. The machine
must always be isolated prior to any main-
tenance work being carried out.
Isolator Switch “ON“ Machine Operational
To Lockout:
(i) Turn off the Engine at Starter Panel

and remove key (Item A)
(i) Rotate the switch (item B) to the

“OFF” position (Item C). C
(ii) Attach a padlock (Item D) to secure

in the lockout position.
(iii) During maintenance work always D

ensure the isolator is locked so the
machine cannot be started
accidently.
Isolator Switch “OFF“ and Locked out
Machine cannot operate
SA - 18
1.2 SAFETY SIGNS ON YOUR MACHINE
Safety Signs are important features of your Terex® MPE machine. Please take time to
familiarise yourself with their meaning and locations on the machine as seen below.
7 7,2 2 19
8,14,2
17 14 31 2 2 8
3,14,1,4,26 (Control Panel side)

OPTIONS- Additional safety signs
Wheeled Machine - 9
Electric machine - 12
IMPORTANT
ANY DAMAGED, MISSING OR PAINTED
OVER SAFETY SIGNS MUST BE
REPLACED IMMEDIATELY
SA - 19
ANSI Safety Signs (used in USA, AUSTRALIA, N. ZEALAND CANADA)
1. 2. 3. 4.
5. 6. 7. 8.
9. 10. 11. 12.
13. 14. 15. 16.
17. 18. 19.
SA - 20
20. 21. 22. 23.
24. 25. 26. 27.
28. 29. 30. 31.
SA - 21
ISO Safety Signs- (Yellow Background, Black Graphics)(INTERNATIONAL)

1. 2. 3. 4.
5. 6. 7. 8.
9. 10. 11. 12.
13. 14. 15. 16.
17. 18. 19.
SA - 22
20. 21. 22. 23.
24. 25. 26. 27.
28. 29. 30. 31.
SA - 23
1.3 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-flamma-
ble 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, mov-
ing 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 prop-
erly.
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 dis-
covered.
15. For questions concerning accumulators, which are pressure-containment vessels,

contact your Terex® MPE distributor. Malfunctioning valves or poor maintenance
practices can result in build-up of extremely high hydraulic and/or pneumatic pres-
sures inside the accumulator.
SA - 24
1.4 HYDRAULIC SAFETY
1. Never disable or alter any hydraulic circuit or component without consulting with Terex®
MPE 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 hydrau
lic 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 replace-
ment 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. 175 Bar (2500 PSI).
DANGER
HIGH PRESSURE
HYDRAULIC FLUID
CAN PENETRATE THE
SKIN CAUSING SERI-
OUS INJURIES
SA - 25
1.5 ELECTRICAL AND ENGINE SAFETY
1. Never work on the electrical system of any equipment unless you are thoroughly famil-
iar 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. Dam-
aged 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 cor-
rectly 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.
DANGER
ALL ELECTRICAL
WORK MUST BE
CARRIED OUT BY A
QUALIFIED
ELECTRICIAN
SA - 26
1.6 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.
WARNING
BEFORE OPERATING
THE MACHINE YOU
MUST READ AND
UNDERSTAND THE
OPERATORS MANUAL
SA - 27
1.7 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 protec-
tive 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 Mainte-
nance 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 medi-
cal 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.
SA - 28
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 miss-
ing cotter pins, washers, locknuts, etc.)?
Recheck all fluid levels before releasing machine for operation.
16. NEVER make any modifications, additions or conversions which might affect safety without
the supplier’s approval.
WARNING
PRACTICE SAFE
MAINTENANCE READ
AND UNDERSTAND
THE OPERATORS
MANUAL BEFORE
DOING ANY WORK
SA - 29
1.8 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. (See Section 6 – Transport).
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 Technical
Section)
SA - 30
1.9 INFORMATION SIGNS
A number of information signs are located

on your machine, these signs give
information that must be followed to
prevent damage to the machine. The
information outlined in the next few pages
Tighten all whell nuts before towing,
Read Manual for details
Do not elevate with pins in position
Remove pins prior to elevation.
SA - 31
Prior to Transport
Ensure transport pins & chains are secure.
Maximum Grid Speed 1050 RPM
Change reduction gear oil every 1000 hours

or at least every 6 months.
Use oil type : DARMEX 9140 NMNND
SA - 32
Machine Lift point.
Machine should only be lifted using all lift

point locations
Recommended Hydraulic Oil ISO 46.
Oil must be between Minimum and

Maximum levels (Red).
It is preferable to have the oil level in Green

area (üarea)
.
When Transporting
Do not tow machine in elevated position.
Lower the telescopic.
SA - 33
Site drawbar must not be used on public

roads, for site use only.
Use 5th wheel coupling on public roads.
Hydraulic power connections.
1. Pressure Line
2. Return Line
3. Bleed Line
Do not Stop the Hydrasander with

material in the machine.
Ensure Hydrasander has discharged all

sand before stopping..
SA - 34
Welding can destroy the electrical

components on your machine.
1. Switch off machine.
2. Refer to Operation manual,ie

Disconnecting remote receivers,
Electronic control Modules if fitted.(see
Installation section)
3. Isolate the machine using Isolator

switch located on the powerunit.
4. Welding can now take place
Protect wiring, hoses and other exposed

components from welding debris and
splatter.
The track hooks must only be used to Tie

down the macine.
The track hooks must not be used as a lifting

hook.
Do not try to unfold the conveyors with the

Transport pins in position.
Remove the Transport securing pins before

and unfold the conveyor.
SA - 35
Do not operate the adjust control when

the crusher isoperating.
Stop the crusher and then adjust.
SA - 36
1.9 REMOTE STOPS ON YOUR MACHINE
There are 4 off Remote Stop Buttons on your machine(Plus 1 on remote Handset and
Dog lead).
Please take time to familiarise yourself with their locations on the machine as seen below.
IMPORTANT
REMOTE STOP BUTTONS ARE AN
IMPORTANT SAFETY FEATURE IF
DAMAGED OR BROKEN THEY MUST
BE REPLACED IMMEDIATELY
SA - 37
1.10 SAFETY GUARDS ON YOUR MACHINE
Safety Guards are important features of the Terex® MPE machine. Please take time to
familiarise yourself with their locations on the machine as seen below.
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16
1. Apron Feeder Side Guards(Both Sides)

2. Side Conveyor Cheese Guard (Both sides)
3. Hopper Deflector Guard
4. Beltfeeder Drive Protection Guard
5. Screenbox Deflector Guards
6.
7.
Screenbox Guard(Both Sides)
Screenbox Deflector Chute WARNING
8. Oversize Conveyor Side Guards ALWAYS REPLACE SAFETY GUARDS
9. Oversize Conveyor Cheese Guard AFTER MAINTENANCE.
10. Apron Feeder Rear Guard NEVER START THE MACHINE WITH
11. Apron Feeder Underside Guard FAULTY OR MISSING GUARDS.
12. Engine Guards
13. Hydraulic Filters Protection Guard
14. Side Conveyor Idler Drum Guard(Both Sides)
15. Oversize Idler Drum Guard
16. Return Roller Nip Guard
SA - 38
1.11 NOISE LEVELS AROUND YOUR MACHINE
Noise Levels for the Terex® MPE 883MKII -Engine CAT 4.4 (Running on Empty).
WARNING
CONSTANT HIGH
NOISE LEVELS
EAR PROTECTION
MUST BE WORN
SA - 39
SECTION 2:
ENG
TECHNICAL INFORMATION
Contents
2.1 FAMILIARISATION ................................................................................. TE - 2
2.2 KEY COMPONENTS ............................................................................. TE - 3
2.3 OPTIONS ............................................................................................... TE - 6
2.4 TECHNICAL DATA................................................................................. TE - 7
2.5 TRANSPORT DIMENSIONS ................................................................. TE - 9
2.6 WORKING POSITION DIMENSIONS .................................................. TE-10
2.7 TRANSPORT DIMENSIONS (LONG CONVEYOR) .............................. TE-11
2.8 WORKING POSITION DIMENSIONS (LONG CONVEYOR) ................. TE-12
2.9 CORRECT USE OF MACHINE ............................................................ TE-13
TE - 1
SECTION 2:
ENG
2.1 FAMILIARISATION
Left Hand Side
1 2 3 5
Rear Front
6
7 4 2
Right Hand Side
1. Apron Feeder
2. Catwalk access ladders Right and Left hand sides:
3. Screenbox Catwalk As viewed from the Rear of the machine.
4. 16 x 5 Screenbox
5. Middle Grade Conveyor Front:
6. Oversize Conveyor The Oversize conveyor end of the machine.
7. Fines Conveyor
Rear:
The Apron Feeder end of the machine.
TE - 2
SECTION 2:
ENG
2.2 KEY COMPONENTS
2.2.1 Power Unit
Tier 3
The standard CAT powered machine is
powered by a CAT 4.4 water cooled diesel
engine coupled to hydraulic pumps with an
output of 83kW (111.3hp) @ 2200 RPM.
Fitted at ground level in a purpose built
compartment it is situated next to the
hydraulic tank providing easy access to all
filters and gauges.
The optional Tier 3 machine is powered by

a Caterpillar C4.4 ATAAC ACERT - 4
cylinder diesel engine developing 97kW
(130hp) @ 2200rpm.
Tier 4
The Tier 4 machine is powered by a CAT
4.4 Tier 4i, 4 cylinder diesel engine
developing 82 kW (110 Hp) at 2200 RPM.
The Optional Tier 4 machine is powered by

a CAT 4.4 Tier 4i, 4 cylinder diesel engine
developing 98kW (131 Hp) at 2200 RPM.
Only use Low Sulphur Fuel in the Tier 4

engines.
TE - 3
SECTION 2:
ENG
2.2.2 Screen
The Twin deck Screen has a 4.80 x 1.50

metres(16’ - 0” x 5’- 0”) wide top deck and a
3.65metres x 1.5metres (12’ 0” x 5’ 0”)
bottom deck.
2.2.3 Loading Hopper
The Loading Hopper is designed with a 7

cu metre(9.16 cu yds.) capacity and
tapered sides for greater efficiency.
2.2.4 Apron Feeder
The variable speed hardox steel pan apron

feeder is mounted on heavy duty chain and
driven by a high torque gearbox. The feeder
can handle the most difficult material with
maximum efficiency.
TE - 4
SECTION 2:
ENG
2.2.5 Product Conveyors
The Fines, Middle grade and Oversize

conveyors can be hydraulically folded from
the transport to working positions from
their control panels at ground level
providing easy access and vision to each
conveyor.
This facility can leave the machine ready
for road or site within minutes.
2.2.6 Central Control Panel
The Main hydraulic control panel fitted at

ground level has all the controls centrally
located.This allows the operator to quickly
and easily optimise production preventing
unnecessary downtime.
(NOTE: The control panel will vary
depending on the type of machine.)
2.2.7 Low Level Greasing
The 883 has low level greasing to all

bearings.Grease pipes are returned from
each bearing to ground level where
maintenance can be performed with ease.
(See the maintenance schedule in
Section:5 for a detailed checklist)
TE - 5
SECTION 2:
ENG
2.3 OPTIONS
2.3.1 Radio Control Handset for

Undercarriage
2.3.2 Heavy Duty Cascades tynes
2.3.3 Remote Tipping Grid (Standard

hopper extensions removed)
2.3.4 Extended Middle Grade & Fines

Conveyors
Radio Control Handset
2.3.5 Heavy duty Bofar bars
2.3.6 Middle Grade Conveyor Skirting.
2.3.7 CAT 4.4 engine (74kw)
2.3.8 Deutz TCD 2012 LO4 (74.9kw)
2.3.9 Pan feeder Cleaner Brush

DUN00082
2.3.10 Hopper Extensions
Radio Control Handset
2.3.11 Hardox Lining
2.3.12 Ground Clearance Extension
2.3.13 Punch Plate on top deck of screen
2.3.14 Cascades on Screen
2.3.15 High Spec Pre-cleaner system

(Scavenger)
2.3.16 Hydraulic Tensioning on screen

bottom deck
Punch Plate
TE - 6
SECTION 2:
ENG
2.4 TECHNICAL DATA
2.4.1 Conveyor Speeds
METRES/MIN. FEET/MIN.
Apronfeeder(Variable Speed) 0 - 25 0 -83
Transfer Conveyor 83 (fixed) 272
Fines Conveyor* 0 - 120 0 - 394
Oversize Conveyor* 0 - 50 0 - 165
Middle Grade Conveyor 0 -120 0 - 394
* The speed of the Fines and Oversize conveyors are interlinked when the speed of one is
increased the speed of the other is reduced.
2.4.2 Engine Speed 2200 RPM
2.4.3 Maximum Screen Speed 1000 RPM
2.4.4 Hydraulic Pressures
BAR PSI
Maximum Working Pressure 172 2500 - Conveyors

245 3500 - Tracks
Pressure Rating on Hydraulic Hoses 3/8” 330 4800
1/2” 275 4000
3/4” 215 3125
TE - 7
SECTION 2:
ENG
2.4.5 Machine Weight
TONNES US TONS
32 35.3
2.4.6 Noise Levels
Sound Level at Operators Position 98 dB(A)
Performance Sound Level dB(A)
2.4.7 Tank Capacities LITRES GAL (US) GAL (UK)
Diesel Tank Capacity 327 86 71
Hydraulic Tank Capacity 500 132 110
TE - 8
SECTION 2:
ENG
2.5 TRANSPORT DIMENSIONS
European Version
TE - 9
SECTION 2:
ENG
2.6 WORKING POSITION DIMENSIONS
European Version
US Version
TE - 10
SECTION 2:
ENG
2.7 TRANSPORT DIMENSIONS (LONG CONVEYOR)
TE - 11
SECTION 2:
ENG
2.8 WORKING POSITION DIMENSIONS (EXTENDED CONVEYORS)
European Version
US Version
TE - 12
SECTION 2:
ENG
2.9 CORRECT USE OF MACHINE
1. This machine should be used, for the loading, conveying, screening and
stockpiling of Recyclable and Aggregate type materials. e.g. Sand, gravel, chalk,
ore, topsoil, greenwaste,demolition ..etc.
This does not include hot materials, which will damage your machine.
2. Machine should be run in well ventilated areas.
3. Appropriate space should be allowed for material stockpiles and loading of

machine.
4. This machine should only be loaded via its Loading hopper and beltfeeder.
Loading materials on the main belt or directly onto the screen may cause
surgeblockages and eventual damage to the machine.
5. Before operating, ensure the machine has been properly installed. (See Section 3.
Installation)
6. Before operating, the machine should be levelled across the axles or

undercarriage and along the chassis. Ensuring that the weight of the machine is
evenly distributed.(See Section 3.9 Levelling)
7. Before operation the operator(s) must:

(i) Have received specific and adequate training in the task to be carried out
(ii) Have read and understood the safety instructions in Section 1
(iii) Knows the location and function of controls and safety features
(iv) Be aware of all moving parts of the machine
8. Before operating the operator(s) must ensure that they are properly equipped with
hard hat, ear and eye defenders.
9. Before operation, all safety guards must be in place
10. Before operation, ensure the machine has been properly lubricated. Always
adhere to the lubrication schedule provided (see section 5.18 Lubrication points)
11. Before transportation on public roads, ensure the machine has been properly
secured with no loose material left in or on the machine. (See section. 6 -
Preparing for transport.)
12. After each day’s operation, always run the machine dry, never leave material in the
beltfeeder or on conveyor belts. Starting a machine with a full load will cause strain
problems in your machine.
TE - 13
SECTION 3: INSTALLATION ENG
Contents
3.1 SAFETY INTRODUCTION ................................................................... IN - 2
3.2 STARTING ENGINE (Standard CAT Engine) ........................................ IN - 8
STARTER PANEL INDICATORS.......................................................... IN- 10
CAT 4.4 MONITORING SYSTEM ......................................................... IN - 11
3.3 STARTING ENGINE (Optional DEUTZ Engine) ................................... IN - 12
STARTER PANEL INDICATORS.......................................................... IN - 14
3.4 STARTING ENGINE TIER 4 MCU300 .................................................. IN - 15
3.5 MACHINE SETTINGS .......................................................................... IN - 22
3.6 TRACKING THE MACHINE ................................................................. IN - 23
3.7 TRACKING OPTIONS .......................................................................... IN - 25
3.8 LOWERING SUPPORT LEGS .............................................................. IN - 31
3.9 LEVELLING ........................................................................................... IN - 34
3.10 FITTING SCREEN CATWALK .............................................................. IN - 35
3.11 FITTING CATWALK ACCESS STEPS ................................................. IN - 37
3.12 UNFOLDING THE OVERSIZE CONVEYOR ........................................ IN - 38
3.13 UNFOLDING THE MIDDLE GRADE CONVEYOR............................... IN - 39
3.14 UNFOLDING THE FINES CONVEYOR ............................................... IN - 41
3.15 LOCATING APRON FEEDER IN WORKING POSITION ...................... IN - 42
3.16 RAISING SCREENBOX TO WORKING POSITION .............................. IN - 43
3.17 SCREENBOX SPILLAGE RUBBER ..................................................... IN - 44
3.18 RAISING THE HOPPER EXTENSION FLAPS..................................... IN - 45
IN - 1
DANGER 1. Entanglement Hazard.

Do not reach into an unguarded machine
you can be pulled in.

injury or even death.
Your arm could be pulled in and
amputated.

DANGER 1. Beware of escaping Hydraulic oil. High


system before attempting maintenance or
adjustment. Use a piece of cardboard to
3. If oil is injected under the skin, it must be

surgically removed or gangrene will result.
Get medical help immediately.
IN - 2
DANGER 1. Electrical Hazard.

2. Never work on the electrical system of any

equipment unless you are thoroughly
familiar with system details.
3. Work on the electrical system must only be

carried out by a qualified electrician.
DANGER 1. Nip Hazard. Do not reach into an

unguarded machine.


IN - 3
WARNING
manual before you work at this machine.
2. Study the different safety signs on this

machine.
3. Only qualified and trained personnel

should attempt to work at this machine.
WARNING
running machinery.
2. Always wear correctly fitting (EN/ANSI

approved) protective clothing.

Visibilty Vest.
IN - 4
WARNING 1. Falling Rock Hazard.

Do not walk near material discharge
areas.
2. Wear a hard hat at all times when working

in the vicinity of the machine.
WARNING 1. Crush Hazard.

crush points.

machinery.

supports provided.
IN - 5
WARNING 1. When performing maintenance or

adjustment to this machine always switch
off engine and remove the ignition key, (if
electric isolate power supply at source).
2. Keep ignition key on person during

maintenance.
3. Never work alone.
WARNING 1. Fall Hazard.

Do not climb onto moving or working
machinery. You could fall and be seriously
injured.

attempting maintenance or adjustment to
this machine.
3. Always use a suitable lifting platform

before attempting any maintenance work
above 2 metres(6-6”).
IN - 6
WARNING 1. Burn or scald Hazard.

Beware of hot surfaces at engine and
exhaust areas. Be careful when draining
hot coolants there is a risk of scalds.
IN - 7
3.2 STARTING ENGINE

Standard CAT Engine
The Engine must be started to provide

hydraulic power to all functions.
Before Starting:
(i) Check the Engine oil level and the

Fuel level and replenish if necessary.
(ii) Place throttle (Item G) at Idle.

A
(iii) Turn the ignition key(Item H) to B
position (Item I), the “ON” position.
C
D
The following warning lights on the control
panel will illuminate. E
F
(1) A Red light (Item A) Alternator
G
(2) A Red light (Item B) Oil Pressure
Lamp Starter Control Panel & Throttle
(3) A Green light (Item C) should H

illuminate indicating the machine can
be run. I
(4) A Green light (Item D) should
illuminate indicating Fuel on.
J
(5) Lights (Items E & F) will light for 2
seconds, then extinguish.
Do not start engine without the above

mentioned lights being illuminated.
K
(iv) Now turn the key to position (Item K).
Hold this position until the engine will Key Positions
crank and start after the warning
beeper has sounded for
approximately 7 seconds.
IN - 8
(v) All the lights should extinguish after B

start-up(with the exception of the
C
machine run and Fuel On lamps). If
the other lights remain illuminated or D
illuminate during operation, there is a
H
fault relevant to that indicator. (See
3.2.1 Starter Panel Indicators)
Return ignition key to (item E)
immediately after the engine starts. A
(vi) When stopping the engine, ensure all
control levers are in neutral. Reduce Starter Control Panel & Throttle
engine speed gradually by adjusting
the throttle lever. Then turn the key to E
position (Item F - Dia 1) and the
engine will stop.
Dia 1 - Key Positions
IMPORTANT
PREHEATING IS NORMALLY NECESSARY
WHEN AMBIENT TEMPERATURE IS
BELOW ZERO DEGREES CELSIUS
(32 DEGREES FAHRENHEIT)
IN - 9
3.2.1 STARTER PANEL INDICATORS

Standard CAT Engne A
Each light on the starter box (Item A-K) will B
illuminate when the following occur.
C
Item A Alternator Failure D
E
Item B Low Oil Pressure
F
Item C Low Coolant Level
G
Item D Fuel Contamination H
I
Item E Machine Run Lamp
J
Item F Air Filter Element Restricted
K
Item G Fuel On Lamp L
Item H Low Hydraulic Oil Level Starter Panel Indicators
Item I Emergency Stop Engaged
Item J Preheat On DANGER

Item K Warning Lamp ALL ELECTRICAL WORK
MUST BE CARRIED OUT
BY A QUALIFIED
Item L Shutdown Lamp ELECTRICIAN
The Monitoring Lamps (Items K & L) monitor the Engine: on the following page is outlined the
varies lamp combinations and their meaning. For complete details of the Monitoring system,
refer to the Engine Operation and Maintenance manual supplied with your machine.
IN - 10
3.2.2 CAT4.4 MONITORING SYSTEM

(Tier 3)
Item A - Warning Lamp
Item B - Shutdown Lamp
A
B
Warning Shutdown
Lamp Status Description of Lamp Status Engine Status
Lamp Lamp
When the engine start switch is turned The engine has
ON ON Lamp Check to the ‘ON” position both lamps will not been started.
illuminate for 2 seconds only.
OFF OFF No Faults There are no active diagnostic faults. The engine is
running normally.
Active Diagnostic An active diagnostic fault has been The engine is
ON OFF running normally.
Fault detected.
A serious active diagnostic fault has The engine is
ON FLASHING Active Diagnostic been detected and an engine derate running but has
Fault been derated.
has been invoked.
One or more of the engine protection The engine is

FLASH- OFF Warning
values has been exceeded. running normally.
ING
Derate and One or more of the engine protection The engine is
FLASH- FLASH- running but has
warning values has been exceeded.
ING ING been derated.
One or more of the engine protection The engine is
ON ON Engine Shutdown values has been exceeded or a shutdown or
serious active diagnostic fault has shutdown is
been detected. imminent.
IN - 11
WARNING
3.3 STARTING ENGINE
Optional DEUTZ Engine
BEFORE INSTALLATION
The Engine must be started to provide hy- YOU MUST READ AND
draulic power to all functions. UNDERSTAND
THE SAFETY SECTION IN
SECTION 1 OF THIS
Before Starting: MANUAL
(i) Check the Engine oil level and the Fuel A

level and replenish if necessary.
B
(ii) Adjust throttle lever (Item A) to approxi-
mately halfway. C
(iii) Turn the ignition key to the “ON” posi- D

tion. (Item E)
The following warning lights on the control

panel will illuminate.
Starter Control Panel & Throttle
(1) A Red light (Item B) Alternator E
(2) A Red light (Item C) Oil Pressure
(3) A Green light (Item D) should

illuminate indicating power on. F
(If the light does not come on
then an Emergency stop but
ton has been engaged).
Disengage it to regain power.
Do not start engine without the above G

mentioned lights being illuminated
Key Positions
(iv) Now turn the key to position (Item G)
the engine will crank and start after the
warning beeper has sounded for ap-
proximately 7 seconds.
(v) All the lights should extinguish after

start-up(with the exception of the
machine run and Fuel On lamps ). If
the other lights remain illuminated or
illuminate during operation, there is a
fault relevant to that indicator. (See
3.3.1 Starter Panel Indicators)
IN - 12
(vi) Should preheating be necessary hold

the key at position (Item E) for up to 1
minute (depending on ambient tem- IMPORTANT
perature). PREHEATING IS NORMALLY NECESSARY
(vii) The engine should be cranked for a
maximum of 20 seconds only. If the
engine does not start wait for one
minute before following the above pro-
cedure again. If the engine does not A
start on the second attempt, refer to B
the engine operator’s manual.
C
(viii) When stopping the engine, ensure all
control levers are in neutral. Reduce
D
the throttle lever. Then turn the key to
position (Item G) and the engine will
stop.
Starter Control Panel & Throttle
DANGER
ALL ELECTRICAL
WORK MUST BE
CARRIED OUT BY A
QUALIFIED
ELECTRICIAN
IN - 13
3.3.1 STARTER PANEL INDICATORS

Optional Deutz Engine
A
Each light on the starter box (Item A-K) will
illuminate when the following occur. B
C
Item A Alternator Failure
D
Item B Low Oil Pressure E
Item C High Engine Temperature
F
G
Item D Low Coolant Level
H
Item E Machine Run Lamp I
J
Item F Air Filter Element Restricted
K
Item G Fuel On Lamp
Starter Panel Indicators
Item H Low Hydraulic Oil Level
Item I Emergency Stop Engaged
Item J Preheat On
Item K Fuel Contamination

DANGER
ALL ELECTRICAL WORK
MUST BE CARRIED OUT
BY A QUALIFIED
ELECTRICIAN
IN - 14
3.4 STARTING ENGINE

Tier 4 MCU300
1
The Engine must be started to provide
hydraulic power to all functions.
OK
Before Starting:
(i) Check the Engine oil level and the Fuel

level and replenish if necessary. 4 3 2
DUN00079
USE LOW SULPHUR FUEL ONLY
Tier 4 Control Panel
(ii) Switch the engine speed switch (Item

I
3) to low.
(iii) Turn the ignition key (Item 2) to the on J

position (Item I).
The home screen will be displayed on the control

panel display screen. The indicator lamps in the
centre of the screen will illuminate and extinguish
after two seconds if there are no faults present. If K
the indicator lamps do not extinguish, refer to
Ignition Key Positions
section 3.4.2 for more information. The e-stop
healthy and fuel on symbols only should light up
green. If any symbols are highlighted red, Refer
to Section 3.4.1.
On Tier 4 machines the wait to start lamp is

illuminated briefly on the home screen. The
engine can be started after this lamp goes out.
Do not start the engine if any other lights are Home Screen (No Faults)
illuminated red or if there are any other faults
shown on the display screen.
(iv) Now turn the key to position (Item K).

Hold this position until the engine will
crank and start after the warning
beeper has sounded for approximately
7 seconds.
Home Screen (Wait to Start)
IN - 15
IMPORTANT
PREHEATING IS NORMALLY NECESSARY
(v) Should preheating be necessary hold

the key at position (Item E) for up to 1
minute (depending on ambient tem-
perature).
Tier 4 Control Panel Display Screen
(vi) The engine should be cranked for a
maximum of 20 seconds only. If the
engine does not start wait for one
minute before following the above pro-
cedure again. If the engine does not
start on the second attempt, refer to
the engine operator’s manual.
(vii) When stopping the engine, ensure all

control levers are in neutral. Reduce
the throttle lever. Then turn the key to
Engine Information Screen
position (Item F) and the engine will
stop. Symbol Description
Engine speed
(viii) To view engine information, press the
button under the engine symbol on
the home screen (item 4). Battery voltage
Coolant temperature
The engine information screen is displayed.
Refer to the table below for a description of
Air intake temperature
each of the symbols.
Fuel rate
(ix) To return to the home screen
anytime, press the button (item 2) Engine oil pressure
under the
Engine boost (or turbo) pressure
Engine load
Engine run hours
IN - 16
3.4.1 STARTING ENGINE

Tier 4 MCU300
(ACTIVE FAULT ON THE DISPLAY SCREEN) 1
OK
Do not start the engine if any red warning lights

or fault symbols are shown on the display
screen. The fault symbol indicates that there is
a fault relevant to that indicator which must be
fixed before starting the engine.
4 3 2
(i) Check the Engine oil level and the Fuel
level and replenish if necessary. Tier 4 Control Panel
(ii) Switch the engine speed switch (Item 3)

to low.
(iii) Turn the ignition key (Item 2) the “ON”
position.
The main menu is displayed on the control panel
screen. A fault symbol around the outer edge of
the home screen is highlighted red and a yellow
safety warning symbol is displayed in the bottom
left hand corner of the screen indicating that there
is a fault. The symbols shown will depend on the
fault. Refer to the table below for decsriptions of
Main Menu (Active Fault)
the fault symbols.
Display Screen Fault Codes

Indicator Fault Code Indicates
FC001 Emergency stop engaged

Flashing Icon
FC002 Low hydraulic oil level
SPN111 Low coolant level
SPN110 High engine temperature
FC005 Air filter element restricted
SPN232 Fuel contamination
SPN100 Low oil pressure
FC008 Remote stop
FC009 Battery Voltage LOW
Communication loss between

FC010
PLC and display screen
IN - 17
(iv) Press the button under the warning

symbol (item 2) to view the alarm history.
A screen showing the alarm symbol and

corresponding fault code is displayed. The engine
run hours at which the fault occurred is also
displayed. Active alarms will have the yellow
warning symbol displayed beside the fault symbol.
If a fault symbol is shown without the yellow
warning symbol, this indicates that the alarm has
occurred but it is now inactive.
Home Screen (Active Fault)
(v) The last 12 faults are stored in the control
panel. Press the right direction button
(item 5) on the panel to scroll through the
active faults.
(vi) To return to the main menu home screen

any time, press the button under the exit
symbol (item 2).
Determine the cause of the fault(s) and ensure

that the problem(s) has been fixed before
continuing. Active Fault Screen
If the engine fault screen is shown, there is a

problem with the engine. Refer to the table in the
Appendix for a list of the engine fault codes. Refer
to the engine manufacturer’s manual or your local
dealer for more information.
(vii) Press the button (item 2) on the control

panel to return to the home screen.
The home screen will be displayed with the

fault symbol shown orange indicating that Engine Fault Screen
the fault is cleared.
Home Screen (Fault Cleared)
IN - 18
(viii) If there is a communication loss fault

(FC010), the communication loss fault
icon will be displayed in the centre of
the home screen.
(ix) Press the button (item 3) on the panel to
view the machine inputs and outputs.
The controller status screen showing the input and

output connections will be displayed. If there is a
communication fault, all of the icons will be shown
in grey.
Home Screen (Communication Fault)
(x) If any of the inputs or outputs are illuminated

green, there is healthy communication
between the PLC and the display screen.
Ensure that all connections are correct.
Refer to the tables below for descriptions of
each of the inputs and outputs shown on
the controller status screen.
(xi) Press the button (item 2) on the control
panel to return to the home screen.
(xii) Turn the ignition key to the crank position
(item 3).
Controller Status Screen
The engine will crank and start after the warning
beeper has sounded for approximately 7
seconds.
Controller Status Screen Inputs Controller Status Screen Outputs

Item Description Item Description
I0 ESTOP HEALTHY O0 ENGINE CRANK
I1 TRACK REQUEST O1 FUEL SYSTEM
I2 LOW SPEED O2 HYD OIL FAN
I3 INTERSPEED O3 SIREN/BEACON
I4 HIGH SPEED O4 TRACKS ENABLE
I5 CONV1 START REQ O5 SPARE
I6 SPARE O6 SPARE
I7 SPARE O7 SPARE
I8 AIR FILTER RESTRICTION O8 SPARE
I9 START ENGINE O9 SPARE
I10 REMOTE STOP O11 CONV1 RUN
IN11 HYD OIL LEVEL O11 SPARE
IN - 19
3.4.2 CAT FAULT INDICATOR LAMPS
All faults must be identified and resolved as

soon as possible.
The fault indicator lamps in the centre of the home
screen will flash when powering up the CAT ECU
on switch on but will switch off again if there are
no faults.
If either or both of the indicator lamps are
illuminated or flashing while the engine is running,
there is a fault with the engine system which must
Warning Lamp (Alert Lamp)
be dealt with immediately. Refer to the Table on
the following page to determine the fault indicated
by the lamps.
Warning Lamp (Action Lamp)
IN - 20
Indicator Lamps Logic

Warning Shutdown
Lamp Lamp Lamp State Description Engine State
On On Bulb Check When the ignition is turned on the Key on but engine has
EMS shall illuminate each bulb for yet to be cranked.
2 seconds and extinguish them
afterwards.
Off Off No faults present With both lamps off whilst engine Engine is running with no
is running then there are no detected faults.
currently active warnings
diagnostic’s or events.
On Off Active diagnostic Should the warning lamp Engine is running
illuminate during engine running normally but has one or
this indicates that an Active more faults with the
diagnostic (Electrical fault) is engine management
present. system.
On Flash Derate (invoked by Should the warning lamp Engine is running but
active diagnostic) illuminate and the shutdown lamp has one or more Active
flash during engine running this diagnostic events that
indicates that an Active diagnostic have initiated engine
(Electrical fault) is present. The derate.
diagnostic is sufficiently serious
to invoke engine derate.
Flash Off Warning (warning Should the warning lamp flash Engine is running
only) during engine running this normally but has one or
indicates that one or more of the more monitored engine
engine protection strategy warning parameters outside of
values have been exceeded but the acceptable range.
not to a level that will invoke
Derate or Shutdown.
Flash Flash Derate (warning and Should both the Warning lamp Engine is running but
derate) and Shutdown lamp flash during one or more of the
engine running this indicates that monitored engine
one, or more, of the engine parameters has gone
protection strategy values have beyond that of warning
been exceeded beyond the level only and has now
required to invoke engine Derate. exceeded those set for
engine derate.
On On Engine shutdown Should both the Warning lamp Engine is either
and Shutdown lamp illuminate shutdown or shutdown is
during engine running this imminent, one or more
indicates that either: monitored engine
1. One or more of the engine parameters have gone
protection strategy shutdown beyond that of warning or
values has been exceeded. derate and have now
2. A serious Active diagnostic has exceeded those set for
been detected. engine shutdown. Or a
Shortly after (time duration to be serious Active diagnostic
agreed) engine will shutdown. has been detected
IN - 21
3.5 MACHINE SETTINGS
A
There are 3 machine settings on the 883
Supertrak which are controlled by the
Control levers (Items A & B) on the Main
Control panel.
POSITION 1: Screening mode
POSITION 2: Neutral
B
DEUTZ Main Hydraulic Control Panel
POSITION 3: Tracking mode
A
(i) To put the machine to the Screening
mode operate the Control levers
(Items A & B).This will operate the B
Screenbox, Fines conveyor, Main
Conveyor and Beltfeeder.
NOTE:No Track movements can be made

in this position.
(ii) To put the machine to the Neutral mode. Tier 4 Main Hydraulic Control Panel
Return the Control levers (Items A &
B) to the mid position.
(iii) To put the machine to the tracking

mode. Operate the Control levers
(Items A & B).
The Machine can now be Tracked by 2 meth-

ods depending on which options you have
fitted to your machine.
(1) Wander Lead/ Umbilical Remote Control

Handset
(2) Radio Control Handset (Optional)
IN - 22
3.6 TRACKING THE MACHINE
Before Tracking the machine on site

ensure that all material has been A
processed through it and that no material
is left on any belts, in the hopper or the
B
conveyors.
C
To Track the machine: D

(i) If the machine is running, stop all the
machine parts by returning the control E
levers(Items A-D) to the neutral DEUTZ Tier 3 Main Hydraulic Control Panel
position.
EA
C
(ii) Next operate the control levers(Items D
B
C&D) to the Track mode position.
(iii) If the Rear support legs (Item F) are

in their working position they must be
raised to the transport position.
To Raise the Rear support legs
operate the control levers (Item E). Tier 4 Main Hydraulic Control Panel
Rear Jack Leg In working Position
IMPORTANT IMPORTANT
NEVER TRACK MACHINE WITH
NEVER STOP THE MACHINE WHEN THERE
IS MATERIAL STILL BEING PROCESSED CONVEYORS IN WORKING POSITION
THROUGH IT OVER LONG DISTANCES, WARRANTY
WILL BE AFFECTED
IN - 23
(iv) If the Middle Grade conveyor is in the

working position it is necessary to
raise the feedboot (Item G) prior to
tracking.To raise the feedboot
operate the control lever (Item H).
G
(v) The Machine can now be Tracked by
either the Wander Lead control or the
optional Radio control.
Middle Grade Feedboot
IMPORTANT
NEVER STOP THE MACHINE WHEN THERE
IS MATERIAL STILL BEING PROCESSED
THROUGH IT
Control Panel
IN - 24
3.7 Tracking Options

3.7.1 Wander Lead Control Handset
(i) To operate power to the Wander lead A

COntrol handset (Item B) turn the
toggle switch (Item G) on the Track
control unit to POSITION 1.
(ii) To operate the Wander lead Control

handset (Item B), connect the Hand-
set to the machine at the connector
(Item A) at the rear of the machine. Wander Lead Handset Connector
B
(iii) The handset has 2 settings AUX and C
TRACK controlled by the toggle
switch (Item E). AUX puts the machine D
in the neutral position ready for
screening. TRACK puts the machine
ready for tracking (this will activate a E
warning siren and flashing beacon).
F
(iv) To move the tracks, press the Left and
Right,Forward and Reverse Track but-
tons (Items C&D, see following Wander Lead Control Handset
page).
(v) An Engine stop button (Item F) is fit-

ted to the handset. Engage to shut
G
down power.
IMPORTANT
THE MACHINE TRACKS WILL
NOT OPERATE UNTIL THE
SUPPORT LEGS ARE RAISED Track Control Unit & Receiver Unit
IMPORTANT Position 1 Position 2

NEVER STOP THE ENGINE OR
MACHINE WHEN THERE IS MATERIAL
STILL BEING PROCESSED THROUGH
THE MACHINE
Machine Settings
IN - 25
RIGHT RIGHT
Track B
FORWARD REVERSE
Track A
LEFT LEFT
Forward Forward
track A track B
Reverse Reverse
track A track B
AUX Track
Button Sequences
Handset Track Controls
Layout + = M ov e
Track Track B Forward

A
+ = Turn Right
Track Track B
A
+ = Rev erse
Track Track B
A
+ = Turn Left
Track Track B
A
IN - 26
B
3.7.2 Radio Control Handset (Optional)
A
C
(i) To operate power to the Radio control
handset (Item C), turn the Toggle D F G
switch (Item H) on the Track control unit
to POSITION 2.
(ii) To power the handset, engage the

E Side
Elevation
start button (Item A).
(iii) Press the button (Item G) on the side Radio Control Handset (Optional)
of the handset. (This will activate a 7
second delay in which a siren and
flashing beacon will operate before
any movement can be made).
H
(iv) To move the tracks, press the Left and
Right,Forward and Reverse Track
buttons (Items D&F).
(v) To stop the engine, press the button

(Item E) (This will operate only when
the handset is in the range of the Track Control Unit & Receiver Unit
receiver, also note when the battery
has died in the remote, the engine will
continue running). Position 1 Position 2
(vi) To turn off the remote control press the

red button at the top of the handset
(item B). NOTE: This does not turn off
the machine.
IMPORTANT
THE MACHINE TRACKS WILL Machine Settings
NOT OPERATE UNTIL THE
SUPPORT LEGS ARE RAISED
IMPORTANT
NEVER STOP THE ENGINE OR
MACHINE WHEN THERE IS MATERIAL
STILL BEING PROCESSED THROUGH
THE MACHINE
IN - 27
RIGHT RIGHT
Track B
FORWARD REVERSE
Track A
LEFT LEFT
Track A Forward Track B

Forward
Track A Reverse Track B

Reverse
Both Tracks Both Tracks

move Forward Reverse
Button Sequences
Handset Track Controls
Layout + = M ove Forward
Track Track B
A
+ = Turn Right
Track Track B
A
+ = Rev erse
Track Track B
A
+ = Turn Left
Track Track B
A
IN - 28
3.7.3 RADIO CONTROL HANDSET (OPTIONAL)
A
When the machine is positioned and sup-
port legs fitted in the working position. The E
radio contol handset can be switched off.
(i) Press the red button on the top of the B

handset (Item A). This cuts off the
handset completely and saves the
battery.
Radio Control Handset (Optional)
(ii) To re-activate the handset press the
start button. (Item E).
IMPORTANT
ENSURE RADIO CONTROL
HANDSET IS SWITCHED OFF
WHEN NOT IN USE
3.7.3.1 Battery level in handset
The battery if in constant use needs to be

charged at regular intervals. C
When the LED (Item B) shows red the
battery capacity is nearly exhausted.
(i) It is recommended that the battery is

D
recharged every 6 hours.Use the bat-
tery charger provided (Item C). Stored
in the toolbox.
Battery Charger for Radio Handset
(ii) A spare battery (Item D) is supplied
and should be used alternately.
3.7.3.2 Changing frequency in hand-

set
A frequency changeover facility is avail-
able if your radio control handset stops or
fails to respond.
Frequency changeover is detailed in the

Hetronic ‘Service manual’ included in your
toolbox with your handset.
IN - 29
3.7.4 RADIO CONTROL RECEIVER UNIT (OPTIONAL)
The Receiver unit(Item B) on your machine

is fitted behind the access door (Item A).
Before any welding work can be carried
out at this machine the Radio control
receiver unit must be disconnected. A
To Disconnect it:
(i) Open the door panel (Item A).

Radio Control Receiver Access Door
(ii) Ensure the machine has been

switched off.
B
(iii) Follow the path of the Electrical
connecting Lead (Item C).
C
(iv) At the end of the connecting Lead
(Item C) is a connector (Item D).
Disconnect the connector.
D
Radio Control Receiver Unit (Optional)
(v) Reconnect all connections after

welding work is completed and close
door panel.
WARNING
THE RADIO CONTROL RECEIVER UNIT WILL
BE PERMANENTLY DESTROYED
IF NOT DISCONNECTED PRIOR TO
WELDING AT THIS MACHINE
IN - 30
3.7.5 Manual Tracking with the Umbilical
IMPORTANT
Handset
(i) Ensure engine is running and all
conveyors, feeder etc are OFF. When the Remote Control is connected to
(ii) Connect the umbilcal handset in the the machine and in use, the Remote Stop
socket (item A) at the rear of the machine. button on the Handset is ACTIVE, Pressing
the Remote Stop button at this stage will shut
(iii) Press the Tracks Start button on the
down the machine.
umbilical remote (item 8).
Once the remote control is DISABLED the
The Led Indicator will illuminate RED. The Siren and
Beacon will activate and continue to do so until the remote stop button on the handset is
Tracks Stop button (item 7) is pressed. INACTIVE, Pressing the remote stop button
at this stage will have no effect.
(iv) After a period of 10 seconds the LED
Indicator will illuminate GREEN.
(v) At this stage pressing the various Track
direction buttons (items 1 to 4) will engage
the respective track solenoid.
(vi) To stop the Tracking function, simply
press the Tracks Stop button on the
Umbilical (item 7)
DUN00081
Tracking Umbilical Remote Layout
1 Left Track Forward

2 Right Track Forward
3 Left Track Reverse
A
4 Right Track Reverse
5 Unused
Umbilical Handset Socket
6 Unused
7 Stop Tracks
8 Start Tracks
IN - 31
3.7.6 Radio Tracking with the Radio Tracking Unit
(i) Ensure the engine is running and all
(ii)
conveyors, feeder etc are OFF.
Press and hold both radio start buttons
IMPORTANT
on the radio handset (items 9&0) for 3 When the Radio Control is ENABLED and
seconds. the Radio Stop button on the Radio Handset
All three LED indicators on the remote will flash. is ACTIVE. Pressing the Radio Stop button
at this stage will shut down the machine.
(iii) Release the start buttons.
Once the radio control is DISABLED the
The top LED indicator on the remote will illuminate
radio stop button on the radio handset is
GREEN and the other two LEDs will be OFF.
INACTIVE. Pressing the radio stop button
(iv) Press the Tracks Start button on the at this stage will have no effect.
Radio Handset (item 6).
(v) At this stage pressing the various Track
direction buttons (items 1 to 4) will
engage the respective track solenoid.
(vi) To stop the Tracking function, simply
press the Tracks Stop button on the
Umbilical (item 5).
(vii) If you have finished with the tracking
function, the radio control unit can be
disabled by pressing the radio stop button DUN00082
at the base of the radio handset.
Radio Tracking Transmitter Layout
1 Left Track Forward

3.7.7 Fast Tracking 2 Right Track Forward
Some machines are fitted with two-speed
3 Left Track Reverse
tracking systems.
4 Right Trackk Reverse
Both the Umbilical Handset and the Radio
Handset have two-step push buttons on the 5 Stop Tracks
Track Directions. The first level is the Normal
6 Start Tracks
Track speed. The second press level is the Fast
Track Speed. 7 Unused
You cannot slew the machine with Fast Tracks 8 Unused

– only both forward or both reverse tracks will 9 Radio Start Button
engage the fast track function.
0 Radio Start Button
IN - 32
3.8 LOWERING SUPPORT LEGS
Move the machine to the operating site.

Position it on a level firm foundation with
adequate space around the machine for A
operation,material stockpiles,
maintenance and vechicular movement.
(i) Once the machine has been moved

to your desired position, lower the
Rear support legs(Item A) using the
control lever (Item B).
Rear Jack Leg In working Position
(ii) NOTE: A built in safety feature does

not allow the machine to move when
the support legs are in the working
position (Tracked Machine only).
B
DEUTZ Control Panel
CAT 4.4 Tier 4 Control Panel
IN - 33
3.9 LEVELLING
Ensure that the weight of the machine is

evenly spread over the Support legs,
Chassis base and Undercarriage.
IMPORTANT
IT IS IMPORTANT THAT THE MACHINE IS
COMPLETELY LEVEL TO ENSURE OPTIMUM
PERFORMANCE
IN - 34
3.10 FITTING SCREEN CATWALK
When you receive your Machine it will

arrive with the screen catwalk in the
transport position (Item A).
To put the Catwalk to the working position.
(i) Remove the bolts(Item D) along the A

side of each catwalk. Rotate the
Catwalk frame (Item C) to the
working position. Replace the bolts
(item D) to secure in the working Catwalk in Transport Position
position.
(ii) Untie the mesh floor sections(Item B)

from the catwalk handrail and rotate
downwards to fit into the working B
position.
WARNING Catwalk holding Bolts
SWITCH OFF AND

LOCKOUT BEFORE
WORKING AT A MACHINE
DANGEROUS NIP POINTS
EXIST
DANGER
DO NOT CLIMB INTO
WORKING OR
MOVING MACHINERY
FALL HAZARDS EXIST
IN - 35
(iii) Remove the bolt (Item F) holding the

Catwalk extension (Item E) in the
transport position. Rotate the E
caltwalk extension downwards into
the working position.
(iv) Place the catwalk end handrail (Item F

G) in position and secure in position
(Item H).
(v) Repeat for catwalk on the opposite

side of the machine. Catwalk extension
WARNING G
SWITCH OFF AND
LOCKOUT BEFORE
EXIST H
DANGER Catwalk in Working Position

DO NOT CLIMB INTO
WORKING OR
MOVING MACHINERY
FALL HAZARDS EXIST
IN - 36
3.11 FITTING CATWALK ACCESS STEPS
To fit the Access steps.
(i) Firstly retrieve the access steps(Item A

A) from the apron Feeder where they
are stored for transport.
(ii) Place the steps (Item D) into position

and secure with bolts (stored in
toolbox) at positions C.
(iii) Repeat for the catwalk at the Access steps

opposite side of the machine.
WARNING
Access step Support
SWITCH OFF AND

LOCKOUT BEFORE
WORKING AT A MACHINE C
EXIST
DANGER D
DO NOT CLIMB INTO
WORKING OR
MOVING MACHINERY
FALL HAZARDS EXIST
Access steps in Working Position
IN - 37
3.12 UNFOLDING THE OVERSIZE

CONVEYOR
When you receive your Machine it will A

arrive with the Oversize Conveyor folded
(Item A).
To put the conveyor to the working

position.
Oversize Conveyor Transport Position
(i) Remove the pins (Item B) securing
the Oversize Conveyor in the
transport position on both sides of B
the conveyor.
(ii) Operate control lever (Item D) to

unfold the Oversize conveyor into the
working position and secure at each
side using pins(Item E).
Oversize Securing Pins

D
IMPORTANT
USE THE CONTROL EVERS IN A SMOOTH
AND CONTROLLED MANNER.
DO NOT RUSH OR JERK THE CONTROLS.
THIS WILL DAMAGE THE CONVEYOR
Oversize Conveyor Controls
WARNING E
HAZARDOUS NIP AND

CRUSH POINTS IN THIS
AREA
Oversize Conveyor Securing Pin
IN - 38
3.13 UNFOLDING THE MIDDLE

GRADE CONVEYOR A
When you receive your Machine it will arrive
with the Middle Grade Conveyor folded
(Item A) in the transport position.
To place the conveyor into the working

position:
Conveyor in the Transport Position
(i) To unfold the conveyor operate the B
control lever (Item C) this will raise the
head section (Item A) vertically. Ensure
C
there is adequate space for the
conveyor to unfold. D
(ii) Operate the control lever (Item D) this
will unfold the conveyor Middle and top
sections, the three sections of the
conveyor will now be in line. E
(iii) Operate the control lever (Item E ) this

will unfold the conveyor to the working Conveyor Control Bank
position (Item F).
F
(iv) (Optional Extendable conveyor). Re-
move the securing pins from (Item G)
on both sides of the conveyor. Operate
the control lever (Item B) to extend the
conveyor and replace the holding pin.
IMPORTANT Middle Grade In Working Position

THIS WILL DAMAGE THE CONVEYOR G
WARNING
HAZARDOUS NIP AND
AREA
IN - 39
To give better ground clearance when

tracking the 883, the middle grade
feedboot (Item H) is raised. The feedboot H
must be lowered prior to running the
conveyor.
To lower:
(i) Remove the Feedboot Transport Pin

(Item G) . Middle Grade Feedboot Transport pin
(ii) Operate the control lever. (Item D).

I
IMPORTANT
USE THE CONTROL EVERS IN A SMOOTH M/G Conveyor Feedboot lowered position
AND CONTROLLED MANNER. J
WARNING
HAZARDOUS NIP AND
AREA
Control Panel
3.13.1 Fitting Feedboot Extension
To prevent spillage at the feedboot fit the

feedboot extension (Item K). The
extensions are stored in the Fines
conveyor feedboot for transport. Insert the
extensions in the sockets provided and
tighten the securing bolts K
Feedboot extensions
IN - 40
3.14 UNFOLDING THE FINES

CONVEYOR
A
When you receive your Machine it will
arrive with the Fines Conveyor folded
(Item A) in the transport position.
To place the conveyor into the working

position:
(i) To unfold the conveyor operate the

control lever (Item C), this will raise the B
head section (Item A) vertically. Ensure
there is adequate space for the C
conveyor to unfold.
D
(ii) Operate the control lever (Item D) to
unfold the conveyor Middle and top
sections, the three sections of the
conveyor will now be in line.
E
(iii) Operate the control lever (Item E ) to
unfold the conveyor to the working Conveyor Control Bank
position (Item F).
F
move the securing pins from (Item G)
on both sides of the conveyor. Oper-
ate the control lever (Item B) to extend
the conveyor and replace the holding
pin.
IMPORTANT Middle Grade In Working Position

DO NOT RUSH OR JERK THE CONTROLS. G
WARNING
HAZARDOUS NIP AND
AREA
IN - 41
3.15 LOCATING APRON FEEDER IN WORKING POSITION
To allow the fines conveyor to fold into the

transport position the apron feeder has
been moved forward for transport (Item A).
When the fines conveyor has been A
unfolded the Apron feeder can be placed
in the working position.
To place Apron Feeder in the working

position:
B
(i) Remove the pin (Item B) securing the

apron feeder in the transport Apron Feeder in the Transport Position
position. (Repeat on opposite side
of the machine).
(ii) Operate the control bank (Item C) to

move the apron feeder to the working
position. C
(iii) Place securing pin (Item E) to hold in

the working position (Item D).
Apron Feeder Control Panel
WARNING D
HAZARDOUS NIP AND

AREA
E
Apron Feeder in the Working Position
IN - 42
3.16 RAISING SCREENBOX TO

WORKING POSITION
When all the conveyors have been

unfolded the screenbox can be raised to
the working position. A
To raise:
(i) Raise the screenbox using control

lever (Item B) until the desired Screenbox in Lowered position
working angle is obtained (Item D).
B
(ii) Secure in the working position by
inserting the securing pin (Item C).
Screenbox height Control
WARNING
HAZARDOUS NIP AND
AREA C
IMPORTANT
Screenbox Raised position
0
DO NOT USE THE 12 HOLE FOR 12°
WORKING, ONLY TO BE USED FOR D
13°
TRANSPORT POSITION
14°
15°
16°
17°
18°
19°
39-877
Screenbox angles
IN - 43
3.17 SCREENBOX SPILLAGE

RUBBER
When all the conveyors have been A

unfolded and the screenbox placed in the
working position a spillage rubber (Item
B) should be pushed into the bottom deck
of the Screen (Item A). This will prevent B
material spillage at the transfer point
between the Apron Feeder an dthe
screenbox Anti-spillage Rubber
WARNING
SWITCH OFF AND
LOCKOUT BEFORE
EXIST
DANGER
DO NOT CLIMB INTO
WORKING OR
MOVING MACHINERY
FALL HAZARDS EXIST
IN - 44
3.18 RAISING THE HOPPER EXTENSION FLAPS
To meet height regulations the Hopper

A
extensions are lowered during Transport.
To raise:
(i) Lift the extensions (Item A) and place

in the working position (Item B).
Hopper Extensions in Lowered position
WARNING
B
HAZARDOUS NIP AND

AREA
Hopper Extensions in Raised position
IN - 45
IN - 46
SECTION 4: OPERATION ENG
Contents
4.1 SAFETY INTRODUCTION .................................................................... OP - 2
4.2 SAFETY BEFORE AND DURING OPERATION ................................... OP - 8
4.3 OPERATING MACHINE (STANDARD CAT ENGINE) .......................... OP - 9
OPERATING MACHINE (OPTONAL DEUTZ ENGINE) ....................... OP-10
OPERATING MACHINE (TIER 4 CAT ENGINE) ................................... OP-11
4.4 SCREENING ......................................................................................... OP-12
4.5 APRONFEEDER SPEED CONTROL ................................................... OP-13
4.6 CONVEYORS SPEED CONTROLS ..................................................... OP-13
4.7 FEEDER START/SOP & ENGINE STOP (OPTION) ............................. OP-14
4.8 REMOTE FEEDER START/STOP (OPTION) ....................................... OP-17
OP-1


amputated.




OP-2



DANGER 1. Nip Hazard.

Do not reach into an unguarded machine.


OP-3
WARNING

machine.

WARNING
running machinery.


Visibilty Vest.
OP-4
WARNING 1. Falling Rock Hazard.

Do not walk near material discharge
areas.


crush points.

machinery.

supports provided.
OP-5


maintenance.

injured.

this machine.

above 2 metres (6-6”).
OP-6

OP-7
4.2 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.
OP-8
4.3 OPERATING MACHINE

STANDARD CAT ENGINE
Before loading material into the Hopper, the
WARNING
entire machine must be running. BEFORE OPERATION YOU
The sequence to start the machine is 4.3.1 to MUST READ AND
4.3.4 below. UNDERSTAND THE SAFETY
Before starting the engine ensure that all SECTION IN SECTION 1 OF
Conveyor belts are sufficiently tensioned. THIS MANUAL
4.3.1 Start the Engine and gradually increase

speed to maximum (2200 RPM).
A
4.3.2 Start the Oversize & Middlegrade
conveyors by pushing the control lever B
(Item C) The conveyor will start after a
warning beeper has sounded for
C
Start the Fines conveyor by pulling the

control lever (Item D). The conveyor will
start after a warning beeper has D
sounded for approximately 10 seconds. CAT Main Hydraulic Control Panel
If the belts are not travelling straight or

equally on the idler and drive drums, the
belts will need “Tracking” (see E
maintenance section).
(Independent Oversize and F

Middlegrade Option)
Start the Oversize conveyor using the
control lever (Item F).
Start the Middlegrade conveyor using

the control lever (Item E). The conveyor
will start after a warning beeper has Main Hydraulic Control Panel (Independent
sounded for approximately 10 seconds. Oversize and Middlegrade Option)
4.3.3 Start the Screenbox by pulling the

control lever (Item.A).
DANGER
4.3.4 Start the Apronfeeder, by pulling the
control lever (Item B). DO NOT REACH INTO A
MOVING MACHINE
4.3.5 Following the above sequence ensures DANGEROUS NIP POINTS
no material will accumulate at transfer EXIST
points and affect the running of the
machine. Also when stopping, except in
an emergency, the above sequence DO NOT CLIMB ONTO OR
should be reversed to ensure all belts ACROSS MOVING BELTS
are cleared of material. FALL HAZARDS EXIST
OP-9

OPTIONAL DEUTZ ENGINE
WARNING
4.3.4. UNDERSTAND THE SAFETY

A
4.3.2 Start the Oversize & Middlegrade
conveyors by pushing the control lever
(Item C) The conveyor will start after a B
warning beeper has sounded for
Start the Fines conveyor by pulling the C

control lever (Item D). The conveyor will
start after a warning beeper has
sounded for approximately 10 seconds.
D
DEUTZ Main Hydraulic Control Panel

belts will need “Tracking” (see
maintenance section). E
(Independent Oversize and
Middlegrade Option) F
control lever (Item F).

the control lever (Item E). The conveyor
will start after a warning beeper has
Main Hydraulic Control Panel (Independent
Oversize and Middlegrade Option)
4.3.3 Start the Screenbox by pulling the
control lever (Item.A).
DANGER
4.3.4 Start the Apronfeeder, by pulling the
DO NOT REACH INTO A
MOVING MACHINE
4.3.5 Following the above sequence ensures EXIST
no material will accumulate at transfer
points and affect the running of the
machine. Also when stopping, except in DO NOT CLIMB ONTO OR
an emergency, the above sequence ACROSS MOVING BELTS
should be reversed to ensure all belts FALL HAZARDS EXIST
are cleared of material.
OP-10
WARNING
TIER 4 CAT ENGINE
4.3.4. UNDERSTAND THE SAFETY

E A
4.3.2 Start the Oversize & Middlegrade D
C
conveyors by operating the control B

lever (Item C) The conveyor will start F
after a warning beeper has sounded for
Start the Collection and Fines conveyor

by operating the control lever (Item A).

belts will need “Tracking” (see
maintenance section). Tier 4 Main Hydraulic Control Panel

Middlegrade Option)
control lever (Item C).

the control lever (Item F). The conveyor
will start after a warning beeper has
4.3.3 Start the Screenbox by operating the

control lever (Item.B).
4.3.4 Start the Apronfeeder, by operating the

control lever (Item D). DANGER
DO NOT REACH INTO A
4.3.5 Following the above sequence ensures
MOVING MACHINE
no material will accumulate at transfer DANGEROUS NIP POINTS
points and affect the running of the EXIST
machine. Also when stopping, except in
an emergency, the above sequence
should be reversed to ensure all belts DO NOT CLIMB ONTO OR
are cleared of material. ACROSS MOVING BELTS
FALL HAZARDS EXIST
OP-11
4.4 SCREENING
Introduce the material to the Hopper.
Some operators build a ramp at the side

of the machine to give their shovel loader a
better reach into the Hopper.
If you do build a ramp avoid contact with
the side of the machine.
IMPORTANT
AVOID ANY CONTACT WITH THE SHOVEL, Loading Hopper
EXCAVATOR OR RAMP AGAINST THE
SIDE OF THE MACHINE.
Initial feed rate should be low gradually

increasing up to normal rate over first hour
of operation.
During this period the belt pressure on

each conveyor should be checked at the
control bankto ensure they are running at
the correct pressure (Max pressure is 172
Bar-2500psi).
Checking Hydraulic Pressures
After initial period stop the machine and
visually check belts, scrapers, skirting
rubbers, rollers and nip guards for
abnormal wear and obstructions.
Conveyor belts may behave different with

material on them, retracking may be
necessary.
Check the quality of the screened material.
DANGER
SWITCH OFF AND
LOCKOUT BEFORE
EXIST
OP-12
4.5 APRONFEEDER SPEED CONTROL

The operation speed of the Feeder can
be varied to suit different applications.
To INCREASE the Feeder speed move

the flow control knob (Item A) ANTI-
CLOCKWISE.
To DECREASE the feeder speed move
the lever (Item A) CLOCKWISE.
A
Feeder Speed Control
Tier 4 Feeder Speed Control
4.6 CONVEYORS SPEED CONTROLS

4.6.1 Fines Conveyor Speed Control
To INCREASE the fines move the flow B
control knob (Item B) ANTI-CLOCKWISE.
To DECREASE the Fines conveyor
speed move the flow control knob (Item B)
CLOCKWISE.
When you have acheived your desired

speed the Adjustment knob can be locked
in position with the screw fitted to the Fines Conveyors Speed Control
adjustment knob.
This will prevent any accidental movement.
DANGER
HIGH PRESSURE
HYDRAULIC FLUID CAN
PENETRATE THE SKIN
CAUSING SERIOUS
INJURIES
OP-13
4.6.2 Middle Grade & Oversize

Conveyors Speed Control
All conveyors have their speeds set at the

factory, but these can be changed if the
product is building up on one particular
conveyor due to the split of material
through the 883 . C
If required, adjust the speed of the
Oversize and Middlegrade conveyors by
rotating the dial on the Flow Control Valve
(Item C). The two conveyor are interlinked
therefore if the speed of one conveyor is Middle Grade & Oversize Conveyors Speed
increased the speed of the other conveyor Control
will decrease.
To INCREASE the speed of Middlegrade
move the flow control knob (Item C)
CLOCKWISE.
To DECREASE the Middlegrade

conveyor speed move the flow control
knob (Item C) ANTI-CLOCKWISE.
C
Tier 4 Middle Grade & Oversize Conveyors

Speed Control
DANGER
HIGH PRESSURE
HYDRAULIC FLUID CAN
PENETRATE THE SKIN
CAUSING SERIOUS
INJURIES
OP-14

Middlegrade Option)
If required, adjust the speed of the D
Oversize conveyor by rotating the dial on
the Flow Control Valve (Item C).Adjust the
speed of the Middle grade conveyor by
rotating the dial on the Flow Control Valve
(Item D).
Main Hydraulic Control Panel (Independent

Oversize and Middlegrade Option)
Tier 4 Main Hydraulic Control Panel

(Independent Oversize and Middlegrade Option)
OP-15
4.7 FEEDER START/STOP &

ENGINE STOP (OPTION)
4.7.1 Feeder Stop/Start

It is possible to start and stop the feeder
using the button (Item D) on the remote
control. This is used to control the flow of
material through the machine from a A
remote location ie. a loading shovel. The
button (Item A) on the receiver performs
the same function as button (Item D). B
4.7.2 Engine Stop Stop/Start Receiver

It is possible to stop the Engine using the
button (Item C) on the remote control. This C
is used to stop the engine from a remote
location ie. a loading shovel. The button
(Item B) on the receiver performs the
same function as button (Item C) on the
handset.
The stop button is a useful function to stop
the machine but from a safety point of view D
cannot be classed as an emergency stop
button.
Stop/Start Handset
DANGER
THE ENGINE STOP BUTTON IS NOT AN
EMERGENCY STOP BUTTON.THE BUTTON
PROVIDES A USEFUL FUNCTION BUT
DOES NOT FULFILL THE CRITERIA FOR
AN EMERGENCY STOP. OPERATORS
MUST BE MADE AWARE OF THIS
OP-16
4.8 REMOTE FEEDER START/STOP

(OPTION)
i) Press and hold the On/Off button (Item 1)

for 2 seconds to turn the transmitter on.
Once successfully switched on the Status DANGER
LED (Item 3) on the remote will illuminate
RED. A RAISED PART OF THE MACHINE CAN
FALL CAUSING SERIOUS INJURIES OR
ii) To start the feeder press button A (Item 2) DEATH. NEVER WORK UNDER
UNSUPPORTED EQUIPMENT.
on the remote.
iii) To stop the feeder press button A (item 2)

on the remote.
iv) If no buttons are pressed for two minutes 1 3

or if the On/Off button is pressed and held I
for two seconds again, the remote will
2 A B C
switch OFF to save battery life.
P S
TIRC00002
Feeder Remote Transmitter
TIRC00001
Feeder Remote Receiver
OP-17
4.8.1 PROGRAMMING A
NOTICE
TRANSMITTER TO AN EXISTING
RECEIVER
i) Ensure that the machine is safe to work ONLY ONE TRANSMITTER CAN OPERATE
on and the engine has been stopped. THE RECEIVER. IF THERE WAS ANOTHER
TRANSMAITTER AREADY PROGRAMMED
ii) Open the cover of the receiver by TO THE RECEIVER, IT WILL
removing the four screws in the lid. AUTOMATICALY BE ERASED ONCE A NEW
TRANSMITTER IS PROGRAMMED.
iii) Carefully let the lid hang below the main
box as the antenna is attached to the lid,
exposing the printed circuit board.
iv) Switch on the transmitter to be
programmed, by pressing the ON/OFF
button. 1 3
v) Press and hold the transmitter program

button on the receiver printed circuit board
for two seconds.
The transmitter program LED will illuminate 2 4
red.
vi) Press any button on the transmitter to be

programmed (NOT the On/Off Button) TIRC00001
Feeder Remote Receiver Lid Screws

The transmitter program LED will flash.
vii)Press the UP and DOWN buttons 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.
viii)Replace the receiver cover and secure
the four screws in the lid. The transmitter
should now be programmed to the receiver.
Feeder Remote Receiver Printed Circuit

Board
1 Antenna
2 Feeder On/Off relay
3 Power supply connections
4 Transmitter program button
5 Transmitter program LED
6 Relay LED
OP-18
SECTION 5: MAINTENANCE ENG
Contents
5.1 SAFETY INTRODUCTION .................................................................... MA - 3
5.2 SAFETY BEFORE AND DURING MAINTENANCE ............................. MA - 9
5.3 HYDRAULIC SAFETY .......................................................................... MA-11
5.4 ELECTRICAL AND ENGINE SAFETY ..................................................MA-12
5.5 HYDRAULIC SYSTEM .........................................................................MA-14
5.6 HYDRAULIC FLUIDS ...........................................................................MA-15
5.7 FILTRATION ..........................................................................................MA-16
5.8 OILTANK, PIPES & FITTINGS...............................................................MA-18
5.9 DIESEL ENGINE ...................................................................................MA-19
5.10 SCREEN ...............................................................................................MA-20
5.11 BELT TRACKING ..................................................................................MA-21
5.12 BELT TRACKING ON YOUR MACHINE ..............................................MA-22
5.13 BELT TENSIONING ON YOUR MACHINE ...........................................MA-23
5.14 TENSIONING APRON FEEDER ...........................................................MA-24
5.15 FASTENING APRON PANS ON APRON FEEDER ..............................MA-25
5.16 CHANGING TOP DECK ........................................................................MA-26
5.17 BOTTOM DECK SCREEN CLOTH.......................................................MA-29
5.18 CHANGING BELTFEEDER GEARBOX OIL .........................................MA-31
5.19 CHANGING FUEL FILTER ....................................................................MA-32
STANDARD CAT ENGINE ....................................................................MA-32
OPTIONAL DEUTZ ENGINE.................................................................MA-32
5.20 WATERTRAP ........................................................................................MA-33
STANDARD CAT ENGINE ....................................................................MA-33
OPTIONAL DEUTZ ENGINE.................................................................MA-34
MA-1
5.21 CHANGING HYDRAULIC FILTERS & OIL ............................................MA-35
5.21 CHANGING ENGINE FILTERS & OIL ...................................................MA-38
5.23 CHANGING GEARBOX OIL ON TRACKS ............................................MA-44
5.24 TRACK ADJUSTMENT .........................................................................MA-45
5.25 HYDRAULIC RAM MAINTENANCE ....................................................MA-48
5.26 RECOMMENDED LUBRICANTS .........................................................MA-49
5.27 REMOTE GREASING SCHEDULE ......................................................MA-51
5.28 MAINTENANCE SCHEDULES ............................................................MA-53
5.29 TIER 4 MAINTENANCE SCHEDULES ................................................MA-62
MA-2


amputated.




MA-3



DANGER 1. Nip Hazard.

Do not reach into an unguarded machine.


MA-4
WARNING

machine.

WARNING
running machinery.


Visibilty Vest.
MA-5
WARNING 1. Falling Rock Hazard. Do not walk near

material discharge areas. You are at risk of


crush points.

machinery.

supports provided.
MA-6


maintenance.

injured.

this machine.

above 2 metres(6-6”).
MA-7

MA-8
5.2 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 5.7-5.8 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
12. Wear safety goggles for eye protection. If fluid enters skin or eye, get immediate medical
attention. (See Hydraulic Safety for more detailed checklist).
MA-9
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.
16. NEVER make any modifications, additions or conversions which might affect safety without
the supplier’s approval.
WARNING
PRACTICE SAFE
MAINTENANCE READ AND
UNDERSTAND THE
OPERATORS MANUAL
BEFORE DOING ANY WORK
MA-10
5.3 HYDRAULIC SAFETY
1. Never disable or alter any hydraulic circuit or component without consulting with Terex®
MPE 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 Terex® MPE replacement hydraulic components are 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
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. 172 Bar (2500 PSI) conveyors; 245 bar (3500PSI) Tracks.
DANGER
HIGH PRESSURE
HYDRAULIC FLUID CAN
PENETRATE THE SKIN
CAUSING SERIOUS
INJURIES
MA-11
5.4 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 main terminals of a starter solenoid 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.
DANGER
ALL ELECTRICAL WORK
MUST BE CARRIED OUT BY
A QUALIFIED ELECTRICIAN
MA-12
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.
DANGER
ALL ELECTRICAL WORK
MUST BE CARRIED OUT BY
A QUALIFIED ELECTRICIAN
MA-13
5.5 HYDRAULIC SYSTEM
The Hydraulic system which is used in your

machine was chosen for its effectiveness
and resistance to climatic and operating
conditions.
This must be kept topped up with the

correct hydraulic fluid and regular checks
must be made to ensure this.
The filter element requires changing when

the indicator is in the red at operating
temperature.
The system should be checked for leaks

and the hydraulic oil analysed after 1500
hours and every 500 hours afterwards and
replaced if necessary.
WARNING
BEFORE MAINTENANCE
YOU MUST READ AND
UNDERSTAND
THE SAFETY SECTIONS IN
THIS MANUAL
MA-14
5.6 HYDRAULIC FLUIDS
Hydraulic fluids play an important part in Some adverse effects of incorrect viscosity
any hydraulic system. They have two main are:
functions. > Increased power consumption
> To transmit power > High oil temperatures
> To lubricate moving parts > Entrapment of air in oil,
> Increase pressure drop.
As a power transmitting medium the fluid > Excessive wear or even seizure under
must flow easily and be as incompressible heavy loads,
as possible. > poor pump performance.
In most hydraulic components, the fluid
provides internal lubrication only. For long
component life, fluids are available In addition to the qualities outlined earlier
containing additives that have high anti- the selected fluid should also:
wear properties. The fluids are known as
anti-wear type hydraulic oils, which are > Prevent rot
recommended for your machine. > Depress foaming
In most cases the fluid is the only oil seal > Prevent formation of sludge, gum and
present. For example, there are no sealing varnish
rings between the spool and the body of the > Retain its own stability, thereby
directional valve. As the sealing reducing fluid replacement.
characteristics of the fluid depend on its > Prevent corrosion and pitting.
retaining viscosity, it is important that the oil
selected is capable of maintaining the For best operating results it is strongly
minimum viscosity change over a wide recommended that the hydraulic fluid used
range of operating temperatures. is selected from the recommended range
listed in 5.26 “Recommended Lubricants”.
In the service it is recommended that the

hydraulic system is analysed every 500
WARNING
hours and the oil changed if necessary. The
hydraulic fluid should be changed after the
machine has stopped work. The drain plug
BEFORE MAINTENANCE for the hydraulic system is mounted
YOU MUST READ AND
underneath the tank. In the event of pump or
UNDERSTAND
THE SAFETY SECTIONS IN motor failure, both suction line and return
THIS MANUAL line filters must be changed.
MA-15
5.7 FILTRATION
DANGER
In order to maintain the hydraulic oil at its
peak performance, three different types of
filter are fitted to the hydraulic system,
HIGH PRESSURE HYDRAULIC
namely: FLUID CAN PENETRATE THE
SKIN CAUSING SERIOUS
(i) Air breather(Item A) INJURIES
(ii) Suction line filters(Item B)
(iii) Return line filters(Item C)
Air breather:
This combined unit, which also acts as a
filter cap, filters the displacement of air .
The filter is rated at 40 microns, and is of A

non-replacement type. This must not be left
off the machine at any time.
Air Breather
Air Breather
Suction Line Filter:

5x 125 microns filter, which are matched to
pump capacity, are fitted inside the
hydraulic tank where they are readily
accessible. (There are 3x 125 microns
filters on tier 4 machines.)
New filter element should be fitted at B
regular intervals (see routine maintenance
schedule for frequency).
Suction Line Filters
MA-16
Return Line Filter:
The 2 x 25 micron filters, which are fitted

on the tank, remove any tiny particles C
which can cause damage to the pumps
and motors etc. (There is 1 x 125 microns
filter on tier 4 machines.)
The filter element should be changed in
accordance with the routine maintenance
schedule.
Return Line Filters
Return Line Filter (Tier 4)
DANGER
HIGH PRESSURE
HYDRAULIC FLUID CAN
PENETRATE THE SKIN
CAUSING SERIOUS
INJURIES
MA-17
5.8 OILTANK, PIPES & FITTINGS
In order to prevent contamination, the Oil

Tank on your machine is of sealed
construction.
DANGER
Access to the tank, if required is via HIGH PRESSURE
inspection covers which are mounted on HYDRAULIC FLUID CAN
the top of the tank, underneath the filler PENETRATE THE SKIN
cap. CAUSING SERIOUS
INJURIES
The outside of the tank must be thoroughly
cleaned before the removal of any of these
covers.
It is very important that hydraulic pipes and
hoses are checked regularly for leaks,
scuffing and wear.
Loose fittings should be securely
tightened. Worn or leaking hoses should
be replaced.
Replacement hoses are available on
request.
MA-18
5.9 DIESEL ENGINE
The diesel engine is the heart of your

machine and a great deal of care and
thought has gone into its selection.
The engine has a max. fuel consumption of
20 Litres per hour.
In the interest of continued peak
performance from your machine the
engine must be maintained and cared for
with meticulous attention in accordance
with the manufacturers instructions as
DEUTZ Diesel Engine
detailed in the “Operators Handbook”, a
copy of which is included with this manual.
CAT 4.4 Diesel Engine
CAT 4.4 Tier 4 Engine
WARNING
SWITCH OFF AND
LOCKOUT BEFORE
EXIST
MA-19
5.10 SCREEN
Maintenance of your screen is minimal. How-

ever, we recommend the following guide to
increase its effectiveness and prolong its
lifespan.
After the initial 10 hours of operation;
A
(i) Visually check all the screen meshes
for clogging.
(ii) Check and tension the clamping bolts
(Item A) where necessary.
(iii) Check for wear and replace where
necessary. Screen Meshes
(iv) Screen Cloths should be re tensioned
after 2 hours, 8 hours,16 hours and
40 hours after replacement. WARNING
SWITCH OFF AND
To achieve an ideal screening condition the
LOCKOUT BEFORE
screen angle can be adjusted. WORKING AT A MACHINE
DANGEROUS
NIP POINTS EXIST
MA-20
5.11 BELT TRACKING
Oblique travel may cause fast deterioration of the belt. In order to assist you we have com-
piled some of the reasons for oblique travel with appropriate remedies.
Reasons for Oblique Remedies Examples of Oblique Travel
Travel
1. Insufficient aligning of a. Align all drums, carrying

drums and Idlers idlers and return idlers at right
angles to the travelling direction
of the belt.
Fig.1. Turning carrying idlers.
b. Check that all drums and

idlers are level to each other.
If a&b are as above then carry

out the following.
Adjustments are made as indi-
cated on Figs.1,2&3 by turning
drums and carrying idlers in Fig.2 Turn drums.
direction of arrow until the belt
is running straight and centred
on the conveyor.
Also return idlers may cause

oblique belt travel and there-
fore they must be aligned at
right angles to the travelling di-
rection of the belt and after that
adjustment can be made.
Fig.3. Turning both drum and
carrying idlers.
2. Misalignment of frame. Oblique travel can be reduced

by turning forward outer carry-
ing idlers 1-3 degrees in trav-
elling direction of the belt. See
Fig.4: if this does not correct
the oblique travel then align the
frame. Fig.4 Turning forward carry-
ing idlers.
3. Material built up on drums Clean idlers and drums. Check

and idlers. belt cleaners and replace if
necessary. Possibly change to
more efficient type.
MA-21
5.12 BELT TRACKING ON YOUR

MACHINE
Tracking is performed at the idler drum of

each conveyor. Both sides of the idler
drum are adjustable. A
(i) First determine which side requires

adjusting.
Oversize Idler Drum Adjuster
(ii) To adjust rotate the nut (Item.A) on
the idler drum adjuster. Use the 7/
8”spanner supplied in the toolbox.
A small movement in the adjuster i.e. less

than 10mm should be sufficient. A greater
movement will affect the tension of the belt.
Middle Grade Idler Drum Adjuster
DANGER FinesTransfer Idler Drum Adjuster

DO NOT REACH INTO A
MOVING MACHINE
EXIST
A
DO NOT CLIMB ONTO OR
ACROSS MOVING BELTS
FALL HAZARDS EXIST
Fines Idler Drum Adjuster
MA-22
5.13 BELT TENSIONING ON YOUR

MACHINE
Belt tensioning is performed at the idler

drum of each conveyor. Both sides of the
idler drum are adjustable.
A
By rotating the nut(Item A) on both idler
drum adjusters equally you can either
tighten or loosen the belt.
Use the 7/8”spanner-supplied in the
toolbox. Oversize Idler Drum Adjuster
The belt should be sufficiently tight to

prevent slippage at the drive drum.
If over tight the life of the belt will decrease.
Middle Grade Idler Drum Adjuster
DANGER
DO NOT REACH INTO A FinesTransfer Idler Drum Adjuster
MOVING MACHINE
EXIST
DO NOT CLIMB ONTO OR A

ACROSS MOVING BELTS
FALL HAZARDS EXIST
Fines Idler Drum Adjuster

MA-23
5.14 TENSIONING APRON FEEDER
If the Apron Feeder chain becomes slack it

occasionally needs to be tensioned. (See
maintenace schedule for details).
During operation the sprocket centres

vary. To ensure constant tension on the
chain, cone washers (Item A) are fitted. It
is important not to over tension the
adjuster,otherwise there will be no spring
in the cone washers, leading to excessive
strain on the chain.
Apronfeeder Idler Drum Adjuster
To tension:
(i) Loosen the securing nut (Item C).

A
(ii) Rotate the Nut (Item B) equally on
both sides of the Feeder. B
(iii) Tighten chain until compression

length (Min) of cone washers during C
Operation is 117mm.
(iv) Retighten the securing nut(Item C) to Min

prevent movement. Cone Washers
IMPORTANT
DO NOT OVERTIGHTEN MESHES.
THIS WILL CAUSE DIPS IN THE MESH
WHICH WILL EFFECT THE PERFORMANCE
OF THE MESH AND BRUSHES
MA-24
5.15 FASTENING APRON PANS ON APRON FEEDER
It is necessary to periodically check the

bolts(Item E) securing the Apron
Pans(Item D) in position (see
maintenance schedule for frequency).
The bolts should be tightened using a

D
torque wrench to the following settings:
Torque Value E
N•m 160 -188
lbf •ft 116-136
Apron Feeder Pans
IMPORTANT
DO NOT OVERTIGHTEN MESHES.
THIS WILL CAUSE DIPS IN THE MESH
WHICH WILL EFFECT THE PERFORMANCE
OF THE MESH AND BRUSHES
MA-25
5.16 CHANGING TOP DECK
5.16.1 Top Deck Punch Plate
(There are 4 punch plate sections on the

A
screen top deck.)
(i) Remove all the bolts (Item A) holding B

the clamping angles (Item B) on each
side of the top deck.
C
(ii) Remove the clamps (Item B) and Punch Plate fitted to Top Deck
replace the punch plate sections
(Item C).
MA-26
5.16.2 Top Deck Meshes
(There are 4 mesh sections on the screen

top deck.) D
(ii) Using a Hex Key loosen the Cam E

Adjusters (Item E). Next using a
24mm spanner remove all the Bolts F
(Item F) holding the mesh clamps
(Item G) in position. Remove the G
clamps.
(iii) Next Remove the mesh (Item D).

Top Deck Mesh & Mesh Clamps
(iv) Clean the screenbox down each side
where the mesh is clamped.Check
and ensure that the cushion rubbers
are in good repair. (Replace if
required).
(v) Fit the new mesh on the screen and

centralise it .This operation will H
require at least 2 operators.
(vi) Fit one of the clamps on the screen

and fix, starting with the bottom bolt
and nut (Item F) and finger tighten.
Mesh Securing Bolts
Now place the clamp on other side
and fix in position at (Item H). When
tightening move from one side to the
other following the letters in the dia
gram (Fig 1).
(vii) Start again at the bottom bolts and

nuts and re-tighten.
FIG 1
MA-27
5.16.3 Top Deck Cascades (Option)
To change an individual cascade tine:
(i) Remove the nut (Item B) holding the

Tine (Item A) in position. Remove the A
tine and replace with new tine.
B
To change cascade frame:
(i) Remove the bolts (Item C) on both

sides of the screen holding the Cascade Tines fitted to Top Deck
cascade frame (Item E). The frame
can now be removed and replaced.
5.16.4 Tightening tines C
Tines should be tightened regularly to ensure

optimum performance. Tighten to the follow-
ing torque settings:
Tine Bolt (Item B) 450 N • M
E
Cascade Frame
WARNING
SWITCH OFF AND
LOCKOUT BEFORE
EXIST
MA-28
5.17 BOTTOM DECK SCREEN CLOTH

A
To gain better access when changing

bottom deck meshes the screen can be
Raised.
To alter:
(i) Remove the pin (Item A) securing the

screenbox raise rams in the working
position, repeat for opposite side of Screenbox Working Position
the machine.
B
(ii) Operate the control (Item B) to raise
the screenbox, replace the pins (Item
C) on each side of the screen to hold
in position.
WARNING Screenbox Lift Ram Control Panel

USE A SUITABLE LIFTING
PLATFORM WHEN
WORKING ABOVE 2
METRES (6’- 6”).
FALL HAZARDS EXIST
C
IMPORTANT
THE SCREEN CANNOT BE RAISED TO THE Screenbox Lift ram
MAINTENANCE POSITION WHEN THE
APRON FEEDER IS IN THE TRANSPORT
POSITION. THIS WILL RESULT IN
DAMAGE TO YOUR MACHINE
Screenbox in Mainainance Position
MA-29
C
To change the bottom deck mesh:
(i) Loosen the Nut (Item C) on the

Tensioning devices on either side of
the screenbox. Turn the nut anti- D
clockwise using a 7/8” spanner
supplied in the toolbox.
(ii) Remove the holding pin (Item D)

which holds the cloth tensioning bar E
(Item E). The Tension bar can now be
Screenbox Bottom Deck Tensioner
moved forward leaving enough
space for the screen cloth to be
unhooked.
(iii) Remove the screen cloth. WARNING

(iv) Clean the screenbox down each side USE A SUITABLE LIFTING
of the clamping area. PLATFORM WHEN
WORKING ABOVE 2
METRES (6’- 6”).
(v) Hook the new screen cloth on the FALL HAZARDS EXIST
tension bar (Item E).
(vi) Place the tensioning bar (Item E)

back into position ensuring that the
tension bar hooks the top lip of the
screen cloth. Replace the holding pin
(Item D).
(vii) Tension the screen cloths by turning

the tensioner bolt (Item C) clockwise
on both sides. When tensioning
alternate between the tensioners on
both sides, this ensures the cloths
are tensioned evenly.
(viii) Check the tension of the screen

mesh by hand to ensure the mesh is
tight. The curved tension bar (Item E)
will become almost straight when the
bottom meshes are tightened.
MA-30
5.18 CHANGING BELTFEEDER GEARBOX OIL
(see Maintenance Schedule for

frequency) A
(i) Turn off the engine.
B
(ii) To drain the gearbox.
Remove the Fill plug (Item A) this will
allow air into the gearbox to allow it to
C
drain. (Use a 17mm socket or 7mm
allen key depending on which plug
has been fitted).
Gearbox
(iii) Remove the Drain plug (Item C) and

drain the oil to an external container
large enough to hold all the oil. (Use
a 17mm socket or 7mm allen key
depending on which plug has been
IMPORTANT
fitted). THE BELTFEEDER GEARBOX OIL MUST
BE CHANGED IN ACCORDANCE WITH THE
(iv) Replace the Drain Plug (Item C). MAINTENANCE SCHEDULES IN SECTION
5.29 OTHERWISE YOUR WARRANTY WILL
BE EFFECTED
(v) Remove the level indicating plug
(Item B).
(vi) Now refill the gearbox through the

Filler plug until the oil begins to flow
from the level indicating plug (Item
B). (See lubrication chart for correct
oil type).
DO NOT OVERFILL THE
GEARBOX
(vii) Replace the Filler plug (Item A).
MA-31
5.19 CHANGING FUEL FILTERS
STANDARD CAT ENGINE A

There are 2 fuel filters.
a) Secondary Fuel Filter (Item B).

b) Primary Fuel Filter (Item A) this is
also the water Seperator.
Refer to the Cat 4.4 engine manual for CAT Primary Fuel Filter
complete details on changing Filters.
To change the Secondary filter:

(i) Stop the engine and leave for 60
seconds to remove pressure from
system.
B
(ii) Place a suitable container under
the fuel filter in order to catch any fuel
that spills.
(iii) Clean the outside of the filter to

remove dirt. Remove the Filter CAT Secondary Fuel Filter
element (Item B).
(iv) Replace with new element, hand

tighten. Prime the system(see
engine manual)

C
(i) Unscrew the fuel filter (Item C) and
carefully dispose off.
DEUTZ Engine Fuel Filter
(ii) Fill the new filter with diesel and fit
into position.
CAUTION
(iii) Hand tighten the new filter.
AVOID NAKED FLAMES WHEN

WORKING ON THE FUEL SYSTEM.
DO NOT SMOKE
MA-32
5.20 WATERTRAP
STANDARD CAT ENGINE
5.20.1 Draining the Water Separator
(i) Place a container below the

seperator, place a tube onto the
drain and allow for the fluid to drain
(Item E).
(ii) Tighten the drain by hand

E
(iii) Remove the wiring harness from
the sensor on the bottom of the
glass bowl.
Watertrap Element Change
(iv) Use a 1U-8760 chain wrench to
Procedure
remove the canister and clean the
bowl.
(v) Install the new canister and tighten CAUTION

by hand. AVOID NAKED FLAMES WHEN WORKING
ON THE FUEL SYSTEM.
(vi) After discarding the old seals and DO NOT SMOKE.
canister, install the new o ring seal
onto the setscrew and into the
glass bowl.
(vii) Allign the glass bowl to the canister

and ensure the sensor (if
equipped) is in the correct position.
install the setscrew and tighten to a
torque of 5N.M (44 lb in).
(viii) If equiped, install the wiring

harness to the sensor.
(ix) Remove the container and dispose

of in a safe place.
NOTE: The secondary filter must be

replaced at the same time as the
primary filter. Refer to the CAT manual
for further instructions.
MA-33
5.20 WATERTRAP
OPTIONAL DEUTZ ENGINE D
5.20.2 Draining the Watertrap
(i) Loosen the draintap (Item F) on the

base of the watertrap.
E
(ii) Allow the water to drain off. Tighten the
draintap when all the excess water has
been drained off. F Watertrap
5.20.3 Changing Watertrap Filter
To change the watertrap filter element (Item

E) follow the procedure outlined.
(1) Stop the machine.

(2) Remove the bleed.
(3) Remove the filter& watertrapbowl.
(4) Remove the watertrap bowl from the
filter element.
(5) Oil the watertrap bowl as shown.
(6) Attach new element to watertrap bowl.
Watertrap Element Change
(7) Oil top of filter element.
Procedure
(8) Attach the filter element.
(9) Use the priming pump (Item D) to fill
the element and watertrap.
(10) Replace the bleed.
CAUTION
AVOID NAKED FLAMES WHEN WORKING
ON THE FUEL SYSTEM.
DO NOT SMOKE.
MA-34
5.21 CHANGING HYDRAULIC FILTERS & OIL
It is strongly recommended to change both

Suction filter and Return filter elements
when the Hydraulic oil is being changed.
A
5.21.1 Changing Return Filters
(i) Run the engine at full speed and
ensure all the hydraulic equipment is
operating.
(ii) Rotate open the hydraulic tank Hydraulic Tank Protection Cover
access covers(Item A) on the roof of
the engine compartment at the left
and right hand sides. B
(iii) Turn engine off and return all control
levers to the neutral position.
(iv) Open the Filler cap to release
pressure inside the tank. C
(v) Clean the area around the Return
filters to prevent dirt contaminating
the hydraulic oil when the filters are
removed. Return Line Filter
(vi) Loosen the bolts (Item B) on each fil-
ter. (Use a 13mm spanner).
B
(vii) Rotate the Top plate (Item.C) slightly
to remove.
(viii) Remove the Filter element by pulling
the removal handles. Dispose of the
C
old filters safely.
(ix) Insert new filter elements and replace
Top Plate (Item.C).
(x) Tighten the filter retaining bolts.
Return Line Filter
DANGER
SWITCH OFF AND LOCKOUT .
RELIEVE ALL HYDRAULIC
PRESSURE BEFORE WORKING
AT A MACHINE
HIGH PRESSURE HYDRAULIC

FLUID CAN PENETRATE THE
SKIN CAUSING SERIOUS
MA-35 INJURIES
5.21.2 Changing Suction Filters
(i) Turn engine off and return all control

A
(ii) Open the Filler cap (Item A) to relieve
any pressure inside the tank. B
C
(iii) Remove the bolts (Item B)(Use a
17mm spanner) securing the
inspection plate(Item C) in place.
Hydraulic Tank Inspection Plate & Filler Cap
(iv) The Suction filters are fitted to the

inside of the inspection cover. To D
remove them lift off the inspection
cover.
(v) Unscrew the Filters (Item D) from the

internal Suction pipes (Item E) and
replace with new filters. Hand tighten
the filters. E
(vi) Replace inspection covers and filler Internal Suction Filters

cap.
DANGER
SWITCH OFF AND
LOCKOUT . RELIEVE ALL
HYDRAULIC PRESSURE
BEFORE WORKING AT A
MACHINE
HIGH PRESSURE
HYDRAULIC FLUID CAN
PENETRATE THE SKIN
CAUSING SERIOUS
INJURIES
MA-36
5.21.3 Changing Hydraulic Oil
It is recommended that the machines

hydraulic oil is warm. This will enable the
oil to flow more easily.
A
(i) Return all Hydraulic Cylinders to their
closed position to return as much
hydraulic oil back to the tank as
possible.
Hydraulic Tank Inspection Plate

(ii) Turn engine off and return all control
(iii) Remove the drain plug (use a 27mm

spanner) at the base of the tank and
drain to an external container large B
enough to hold all the oil. (Hydraulic
Tank Capacity:=500 litres 132 UK
gallons 110 US Gallons).
(iv) Remove the inspection plate (Item A)

on the hydraulic tank and flush the Hydraulic Oil Level Guage
tank out with hydraulic oil to remove
dirt or other particles. Use a 17mm
spanner.
(v) Refill the tank until the oil is between

the Min. and Max. marks on the tank
DANGER
gauge (Item B). SWITCH OFF AND
LOCKOUT . RELIEVE ALL
HYDRAULIC PRESSURE
BEFORE WORKING AT A
(vi) Run the machine and operate MACHINE
hydraulic equipment to circulate oil.
HIGH PRESSURE
HYDRAULIC FLUID CAN
PENETRATE THE SKIN
(vii) Stop the machine and top up the CAUSING SERIOUS
hydraulic system. INJURIES
MA-37
5.22 CHANGING ENGINE FILTERS &

OIL STANDARD CATERPILLAR 4.4
(See the engine Operators Manual for
more detailed information regarding the
Engine)
5.22.1 Checking Engine Oil
(i) Turn off the engine. Open the Engine A

Inspection Doors (Item A).
(ii) Remove dipstick (Item C) from the

CAT Engine Filters Inspection Door
engine and clean.
Re-insert the dipstick fully.
(iii) Remove the dipstick again and

observe that the oil level is between
the min.and max.levels. If the level is
B
below the minimum mark oil has to be
added through the fillercap
(Item B). C
(iv) It is important the oil level is not above
the maximum level. If this happens
some oil must be removed. CAT Engine Oil Filler Cap
5.22.2 Changing Engine Oil & Filter

D
(i) Operate the eninge to ensure the oil
is warm, this enables the oil to flow
more easily, also when the oil is cool
waste particles settle on the bottom of
the oil pan and will not drain off.
(ii) Stop the engine and open the fillercap

(item B).
CAT Oil Filter
(iii) Remove the drain plug located
underneath the engine and drain the
oil to an external container large
enough to hold all the oil.
CAUTION
HOT SURFACES
(iv) When all the oil has drained off replace
the drain plug. Loosen the Filter (item BEWARE OF BURNS
D) and dispose off properly. Replace FROM HOT OIL
the new filter and hand tighten. Dip the
engine. See 5.22.1.
MA-38
5.22.3 Changing Air Filter Element

(For more details of Engine Air Filter
Maintenance view the Engine Operators A
Manual)
The Air filter requires cleaning/replacing if

the service indicator (item A) becomes red
on the control panel. When this happens
the machine must be stopped and the Filter
should be changed immediately.
Air Filter Service Indicator

(i) Turn off the engine and implement the
lockout and tagout procedure.
4
(ii) Unfasten the Filter Cover (Item 5) by
unclipping the holding clamps (Item
4). Remove the filter cover.
5
(iii) Carefully remove the outer Filter

element (Item 3). Remove the inner
filter element (Item 2). Clean inside Air Filter Housing
the filter. Insert a new filter elements.
1
(iv) Re-attach the filter cover and reclip
the holding clamps (Item 4). 2
Note:
If for any reason the Air Filter becomes 4
blocked the Air Filter Service Indicator will
automatically shut off the engine. To restart
the engine PRESS THE RESET button on 3
5
the front of the Service Indicator and follow
the engine start procedure.
CAT Engine Air Filter
MA-39
5.22 CHANGING ENGINE FILTERS & OIL
(See the engine Operators Manual for more de-

tailed information regarding the Engine)
5.22.1 Checking Engine Oil A
(i) Turn off the engine. Open the Engine

Inspection Doors (Item A).
DEUTZ Engine Filters Inspection
(ii) Remove dipstick (Item C) from the en- Door
gine and clean. Re-insert the dipstick
fully.
(iii) Remove the dipstick again and ob-serve

that the oil level is between the min. and
max. levels. If the level is below the mini- C
mum mark oil must be added through the
fillercap (Item B).
B
(iv) It is important the oil level is not above
the maximum level. If this happens D
some oil must be removed.
DEUTZ Engine Oil Filler Cap
CAUTION
HOT SURFACES
BEWARE OF BURNS
FROM HOT OIL
MA-40
5.22.2 Changing Engine Oil
(i) Operate the engine to ensure the oil

is warm, this enables the oil to flow
more easily.
C
(ii) Stop the engine and open the
fillercap. B
D
(iii) Remove the drain plug located
DEUTZ Engine Oil Filler Cap
underneath the engine and drain the
oil to an external container large
enough to hold all the oil.v(Approx Oil
capacity: 8.5litres-1.85gallons).
(iv) When all the oil has drained off

replace the drain plug and refill.
CAUTION
Check the oil level. See 5.22.1 HOT SURFACES
BEWARE OF BURNS FROM

HOT OIL
5.22.3 Changing Engine Oil Filter
It is recommended to change the Oil filter

when changing the oil.
(i) Loosen the Filter (Item D) and

dispose off properly.
(ii) Replace with new filter and tighten to

10 -12 N• M this corresponds to a
firm hand tightening.
MA-41
5.22.4 Changing Air Filter Element
(For more details of Engine Air Filter

Maintenance view the Engine Operators
Manual)
The Air filter will require changing if the Air Filter

light (Item A) illuminates on the starter Indicator
panel. When this happens the machine
must be stopped and the Filter should be
changed immediately.
Starter Panel
(i) Turn off the engine
(ii) Unfasten the Filter Cover (Item C) by

unclipping the holding clamps (Item
B). B
(iii) Carefully remove the Filter element.

Clean inside the filterhousing and C
insert a new filter element.
(iv) Re-attach the filter cover and reclip DEUTZ Air Filter Housing
the holding clamps (Item B).
MA-42
5.22.5 Engine Coolant Level
(For more details of Engine Coolant Level

Low coolant
view the Engine Operators Manual)
level
If the engine coolant level indicator illumi- Indicator
nates on the control panel the radiator must
be topped up.
5.22.6 Topping up coolant level A

Refer to Engine Manual for Fill and
Bleed procedures.
(ii) Carefully open the radiator cap through

the hole located on top of the power
unit.
Engine Inspection Doors
(iii) Fill the radiator with coolant.
(iv) Check the indicator on the control

panel to ensure the indicator is no
longer illuminated. WARNING
SWITCH OFF AND
LOCKOUT BEFORE
CAUTION
BEWARE OF SCALDS
FROM HOT WATER
UNDER PRESSURE
MA-43
5.23 CHANGING GEARBOX OIL ON TRACKS
(see Maintenance Schedule for

frequency)
A
More effective draining will take place if
the oil is hot.
(ii) To drain the gearbox clean the area B

around the gearbox plugs.
Position the Plugs (ItemsA&B) as Tracks Gearbox in Drain Position
shown in the photogragh ensuring the
plug(Item B) is at the bottom.
Remove the plug (Item A) this will C
allow air into the gearbox to allow it to
drain.(Use an 8mm allen key to
remove plug). D
(iii) Remove the Drain plug (Item B) (Use

an 8mm allen key to remove plug)
and drain the oil to an external
container large enough to hold all the
oil. Tracks Gearbox in Fill Position
DANGER
(iv) Start the engine and move the tracks
until the Gearbox is in the Fill
Position with the Plugs (Items C&D)
as shown in the photograph.
SWITCH OFF AND
(v) Now refill the gearbox through the LOCKOUT BEFORE
Filler plug (ItemC) until the oil begins
to flow from the level plug (Item D).
DO NOT OVERFILL THE
GEARBOX. DANGEROUS NIP POINTS
EXIST CLOSE GUARDS
(Approximate oil quantity 2.5 Litres
AFTER MAINTENANCE
per Gearbox)(For oil type see
Recommended Lubricants)
(vi) Replace the plugs (ItemC&D). IMPORTANT

THE GEARBOX OIL MUST BE CHANGED IN
(vii) After a short period of operation ACCORDANCE WITH THE MAINTENANCE
visually check the oil level. SCHEDULES IN SECTION 5.26
OTHERWISE YOUR WARRANTY WILL BE
EFFECTED
MA-44
5.24 TRACK ADJUSTMENT
As the track wears, they become

slack,and should be checked daily.
To establish if the tracks require
adjustment move the machine, a few
metres, backwards and forwards on level
ground, in a straight line.
This enables the track to adopt its natural
degree of tension. Measure the droop as
shown in Fig 1.
This measurement should not exceed Fig 1
25mm. (1.0”).
5.26.1 To Release Track Tension
(i) Remove the adjuster cover plate

(Item.A).(Use a 17mm Spanner.) A
(ii) Loosen the Grease fitting (Item B) on

the end of the track tensioning
cylinder by one half turn only.
(Use a 22mm Spanner)
Allow grease to leave the tension Track Adjustment Access Plate
cylinder therefore reducing the track
tension.
(iii) Retighten the Grease fitting (Item B)

and replace the cover plate (Item A). B
Track Adjustment Grease Fitting
MA-45
5.24.2 To Increase Track Tension
(i) Remove the adjuster cover plate

(Item A).
(Use a 17mm Spanner).
C
(ii) Using the special grease gun
adaptor (Item C) attach to a standard
grease gun and place over the
grease fitting (Item B).
(iii) Pump the track out to the correct Track Adjustment Greasegun Fitting
adjustment.
(iv) When the track droop appears to be

correct, move the machine
backwards and forwards, and
recheck the droop.
(v) Replace the cover plate (Item A).
MA-46
5.24.3 TRACK MAINTENANCE

TRACKS - OPERATING PRECAUTIONS
When travelling up a gradient, the tracks should be driven forward (i.e. idlers first, drive
sprocket to the rear). When travelling down a gradient, tracks should be driven sprocket
first.
ALWAYS:-
- Park the machine on flat, level ground. If it is necessary to park the machine on a gradi-
ent, 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 minimise
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.
MA-47
5.26 HYDRAULIC RAM MAINTENANCE
As part of the finish process in our chrome

rod manufacturing a natural lubricant is
rolled into the surface. A
To prolong the life of hydraulic cylinder we
recommend that any cylinder exposed (ie.
Item.A) for more than one week should
have the rod coated (i.e Item B) with a
good quality water resistant grease.
Exposed Hydraulic Ram Chrome Rod
DANGER B
SWITCH OFF AND
LOCKOUT. BEFORE
HIGH PRESSURE
HYDRAULIC FLUID CAN
PENETRATE THE SKIN
CAUSING Greased Chrome Rod
SERIOUS INJURIES
MA-48
5.26 RECOMMENDED LUBRICANTS
GREASE LUBRICATION
SPECIAL SCREEN SCREEN GREASE GENERAL PURPOSE

GREASE FOR HOT MATERIALS GREASE
B.P ENERGREASE LS- --- ENERGREASE L21M
EP2
TOTAL MULTIS EP2 --- MULTIS MS2
DUCKHAMS ADAMAX LEP2 --- ADAMAX LM2
CASTROL SPHEEROL EPL2 --- SPHEEROL AP3
SHELL ALVANIA EP2 LIPLEX EP2 ALVANIA R3
ESSO BECON EP2 UNIREX EP2 BECON Q2
TEXACO MULTIFAK EP2 --- MOLYTEX 2
CHEVRON DURALITH EP2 --- ---
GULF GULFCROWN EP2 SUPERCROWN EP2 ---
MOBIL MOBILUX EP2 MOBILGREASE HP2 MOBILGREASE MP
CENTURY REGULUSA2EP LUPLEX M2 REGULUS A3
F.A.G. ARCANOL L135 --- ARCANOL L71
ROCOL SAPPHIRE BG 151 ---
OPTIMOL LONGTIME PD --- ---
OMEGA --- 85 ---
Above are listed the recommended alternatives suitable for use with your
machine.
The above special screen greases are lithium base greases of Class 2 with
extreme pressure additives.
Hydraulic Oil Type

ISO VG 46 (Ambient temp. 0°C – 25°C)
ISO VG 68 (Ambient temp. 20°C - 40°C)
Anti- Freeze BS 6580
Beltfeeder Gearbox Oil: ISO VG 150 or SAE 80W/90
MA-49
5.26.1 RECOMMENDED LUBRICANTS FOR GEARBOX ON TRACKS & FEEDER
LUBRICANT -20°C + 5°c +5°C + 30°c 30°C + 50°c 30°C + 65°c

IV 95 min IV 95 min IV 95 min IV 95 min
ESSO Spartan Spartan Spartan Compressor oil LG
EP 100 EP 150 EP 320 150
AGIP Blasia Blasia Blasia Blasia
100 150 320 S 220
ARAL Degol Degol Degol Degol
BG 100 BG 150 BG 320 BS 220
BP MACH GR XP 100 GR XP 150 GR XP 320 SGR XP 200
CASTROL Alpha Alpha Alpha Alpha
SP100 SP150 SP 320 SN6
ELF Reduetell Reduetell Reduetell Oritis 125 MS
SP 100 SP 150 SP 320 Syntherma P30
CHEVRON Non leaded Gear Non leaded Gear Non leaded Gear
compound 100 compound 150 compound 320
GULF EP lubricant EP lubricant
HD 150 HD 320
I.P Mellana Mellana Mellana Telesia
100 150 320 oil 150
MOBIL Mobilgear Mobilgear Glycoyle 22/30
629 632 SHC 630
SHELL Omala Omala Omala Tivela
oil 100 oil 150 oil 320 oil SA
TOTAL Carter Carter Carter
EP 100N EP 150 EP 320N
KLUBER Lamora Lamora Lamora
100 150 320
ISO 3448 VG 100 VG 150 VG 320 VG 150-200
Machines are supplied with Mobilgear 629 Finlay Partcode 12.40.0629
MA-50
5.27 REMOTE GREASING SCHEDULE
The 883 has low level greasing to all

bearings. Grease pipes are returned from IMPORTANT
each bearing to low level where ALL BEARINGS MUST BE
maintenance can be performed with ease. LUBRICATED IN ACCORDANCE WITH
THE MAINTENANCE SCHEDULES IN
SECTION 5.28 OTHERWISE YOUR
WARRANTY WILL BE EFFECTED
11,12 15 25 5, 6 3,4 1, 2
17,18
19,20
21,22
23,24
9,10 26
15,16 13,14 7 8
MA-51
Item No. Hose No. Description Quantity Frequency

1 88324.01 OVERSIZE DRIVE DRUM (Left) 4 grams/2 pumps 50 Hours
2 88324.02 OVERSIZE DRIVE DRUM(Right) 4 grams/2 pumps 50 Hours
3 88324.03 OVERSIZE IDLER DRUM(Left) 4 grams/2 pumps 50 Hours
4 88324.04 OVERSIZE IDLER DRUM(Right) 4 grams/2 pumps 50 Hours
5 88312.01 M/GRADE DRIVE DRUM 4 grams/2 pumps 50 Hours
6 88312.02 M/GRADE DRIVE DRUM 4 grams/2 pumps 50 Hours
7 88324.07 MIDDLEGRADE IDLER DRUM 4 grams/2 pumps 50 Hours
8 88324.08 MIDDLEGRADE IDLER DRUM 4 grams/2 pumps 50 Hours
9 88312.03 FINES DRIVE DRUM 4 grams/2 pumps 50 Hours
10 88312.04 FINES DRIVE DRUM 4 grams/2 pumps 50 Hours
11 88324.11 FINES IDLER DRUM 4 grams/2 pumps 50 Hours
12 88324.12 FINES IDLER DRUM 4 grams/2 pumps 50 Hours
13 88324.13 TRANS IDLER DRUM 4 grams/2 pumps 50 Hours
14 88324.14 TRANS IDLER DRUM 4 grams/2 pumps 50 Hours
15 88324.15 TRANS DRIVE DRUM MOTOR SIDE 4 grams/2 pumps 50 Hours
16 88324.16 TRANS DRIVE DRUM 4 grams/2 pumps 50 Hours
17 88324.17 PANFEEDER DRIVE DRUM 4 grams/2 pumps 50 Hours
18 88324.18 PANFEEDER DRIVE DRUM 4 grams/2 pumps 50 Hours
19 88324.19 PANFEEDER IDLER DRUM 4 grams/2 pumps 50 Hours
20 88324.20 PANFEEDER IDLER DRUM 4 grams/2 pumps 50 Hours
21 88324.21 PANFEEDER UNDERSIDE BEARINGS 4 grams/2 pumps 50 Hours
25 88324.25 SCREENBOX BEARINGS (Use Screen Grease) 16 grams/8 pumps 50 Hours
26 88324.26 SCREENBOX BEARINGS (Use Screen Grease) 16 grams/8 pumps 50 Hours
IMPORTANT
ALL BEARINGS MUST BE
LUBRICATED IN ACCORDANCE WITH
THE MAINTENANCE SCHEDULES IN
SECTION 5.28 OTHERWISE YOUR
WARRANTY WILL BE EFFECTED
MA-52
5.28 MAINTENANCE SCHEDULES DATE
5.28.1 Daily Maintenance

(10Hour) Schedule
General Maintenance
Maintenance Task Notes Signature
Check For Material Bulid up Check/Remove

Check All Safety Guards are in Place Check/Replace
Check For Loose parts, missing nuts Tighten/Replace

& bolts
Check Hydraulic hoses, Rams & Tighten/Replace
pumps for leaks
(When tightening fittings use a
Torque wrench and follow the torque
setting on the following page)
Check Hydraulic oil level in site gauge Check/Top up

Check Diesel Level in fuel tank Check/Refill
Conveyor Maintenance
Check Conveyor belts for rips and Check/Repare

tears
Check Belt Tension Check/Tension
Check Belt Alignment Check/Align
Check All Rollers are free moving and Check/Free
free from obstruction
MA-53
Screen Maintenance
Check Mesh Securing bolts are tight Check/Tighten
Check Meshes for wear Check/Tghten
Check Tension of Tine Bolts(see 5.16.4)
Engine Maintenance (See Engine operators manual for more details)
Check Engine Oil Level Check/Top up
MA-54
DATE
5.28.2 Weekly Maintenance

(50Hour) Schedule
General Maintenance
Grease all bearing (see greasing Grease

Schedule)
Drain the Watertrap Drain
After first 50Hrs Replace Return Remove & Replace

Filters
Conveyor Maintenance
Check Tension of belt scrapers Check/Adjust/Replace
Check Tension of Belt Skirting Check/Adjust/Replace

Rubbers - No spillage
Check For Obstruction to drums Check/Remove
obstruction
Feeder Maintenance
Feeder Chains and Sprockets for Check/Adjust/Replace

Wear
Check Tension of Sprocket Chain Check/Tension
After first 50Hrs check Apron pan Check/Torque

bolts using torque wrench(5.15)
MA-55
After first 50Hrs carry out full engine Service

service
Air filter pre cleaner Clean up
Battery Acid Level Check/Top up
When tightening hydraulic fitting always use a torque wrench, as overtighting of fittings
can break internal seals. Please follow the torque settings in the table below
Thread Size Torque Torque Torque

Ft/Lb. Kg/m N/ m
¼” BSP 15 2.07 20.3
3/8" BSP 18 2.49 24.4
½” BSP 40 5.50 53.9
¾” BSP 60 8.30 81.3
1" BSP 85 11.75 115.2
1¼” BSP 110 15.20 149.0
1½” BSP 130 17.98 176.2
MA-56
DATE
5.28.3 Monthly Maintenance

(250 Hour) Schedule
General Maintenance
Maintenace Task Notes Signature
Drain the Watertrap Drain
After first 250Hrs change gearbox oil Change

in Apron feeder
Feeder Maintenance
Apron bolts using torque wrench (see Check/Tension

5.15)

Air Filter Elements Check/Replace
Track Maintenance
After first 250Hrs change gearbox oil Check

in tracks
MA-57
DATE
5.28.4 2 Monthly Maintenance

(500 Hour) Schedule
Check Engine Oil Drain & Refill
Change Engine Oil & Full Filters Remove & Replace
Change Air Filter Safety Element Remove & Replace
Adjust V Belt Tension Check/Adjust
Change Hydraulic Return Filters Remove & Replace
MA-58
DATE

(1000Hour) Schedule
General Maintenance
Maintenace Task Notes Signature
Hydraulic Oil Analysis Oil and change

if required**
Suction Filters Remove & Replace
** Your local oil supplier will be able to analysis your hydraulic oil.
MA-59
DATE

(2000Hour) Schedule
Alternator and Starter Motor Check
MA-60
DATE
5.28.6 Yearly Maintenance

(2500Hour) Schedule
Feeder Maintenance
Change the Feeder Gearbox Oil Drain/Refill
Track Maintenance
Change the Track Gearbox Oil Drain/Refill
MA-61
5.29 Tier 4 Maintenance Schedules

5.29.1 When Required
Object Job Remarks Sign
Battery Replace
Battery or battery cable Disconnect
Engine Clean
Engine air cleaner element (Dual element) Clean/replace
Engine air cleaner element (single element) Inspect/Replace
Engine air cleaner element (single element) Replace
Fuel System Prime
Severe service application Check
5.29.2 Daily Schedule

Coolant system coolant level Check
Engine air cleaner service indicator Inspect
Engine air precleaner Check/Clean
Engine oil level Check
Fuel system primary filter / water separator Drain
Walk around inspection
5.29.3 Weekly
Hoses and clamps Inspect/Replace
5.29.4 Every 50 Service Hours or Monthly

Fuel tank water and sediment Drain
5.29.5 Every 250 Service Hours

Coolant system coolant sample (Level 1) Obtain
Engine oil sample Obtain
Engine Oil and Filter Change*
*Due to the severe environment that most crushers and screeners operate in the engine oil and filter
change should be every 250 hours of service. However if oil sampling and analysis is carried out it is
possible to increase the engine oil and filter change to every 500 hours of service.
MA-62

Belt Inspect
Engine oil and filter Change
Fan clearance Check
5.29.7 Every 500 Service Hours or 1 Year

Battery electrolyte Level Check
Cooling System Supplemental Coolant
Additive (SCA) Test/Add
Engine air cleaner element (Dual Element) Clean/Replace
Engine air cleaner element (Single
Element) Inspect/Replace
Engine air cleaner element (Single
Element) Replace
Fuel system primary filter (water separator)
element Replace
Fuel system secondary filter Replace
Radiator Clean

W ater pump Inspect

Engine crankcase breather element Replace

Aftercooler Core Inspect
Engine Mounts Inspect
Starting Motor Inspect
Turbocharger Inspect
MA-63

Alternator Inspect
Alternator and Fan Belts Replace
Belt Tensioner Inspect
Radiator Pressure Cap Clean/Replace
5.29.12 Every 3000 Service Hours or 2 years

Cooling system coolant (DEAC) Change

Aftercooler core Clean/Test
5.29.14 Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) Add
5.29.15 Every 12000 Service Hours or 6 Years

Cooling System Coolant (ELC) Change
MA-64
SECTION 6: TRANSPORT ENG
Contents
6.1 SAFETY INTRODUCTION .......................................................................... TR - 2
6.2 SAFETY BEFORE AND DURING TRANSPORT ........................................ TR - 5
6.3 STOPPING THE MACHINE ........................................................................ TR - 7
6.4 PREPARING FOR TRANSPORT ................................................................ TR - 8
6.5 LoWERING THE HOPPER EXTENSION FLAPS ....................................... TR - 9
6.6 LOWERING SCREENBOX TO TRANSPORT POSITION ........................ TR - 10
6.7 LOCATING APRON FEEDER IN TRANSPORT POSITION ..................... TR - 11
6.8 FOLDING THE FINES CONVEYOR ......................................................... TR - 12
6.9 FOLDING THE MIDDLE GRADE CONVEYOR ........................................ TR - 13
6.10 FOLDING THE OVERSIZE CONVEYOR .................................................. TR - 15
6.11 REMOVING CATWALK ACCESS STEPS ................................................ TR - 16
6.12 PLACING SCREEN CATWALK IN TRANSPORT POSITION................... TR - 17
6.13 RAISING SUPPORT LEGS ....................................................................... TR - 18
6.14 READY FOR TRANSPORT ...................................................................... TR - 19
6.15 PRIOR TO HAULAGE ............................................................................... TR - 20
TR-1


amputated.

WARNING

machine.

TR-2

injured.

this machine.

above 2 metres (6-6”).
WARNING 1. Explosive separation of a tyre and rim

parts can cause serious injury or death.
2. Do not inflate the tyres above the

recommended pressure (See
maintenance section).
3. When inflating tyres use a clip-on chuck

and extension hose long enough to allow
you to stand to one side and not in front.
Use a safety cage if available.
TR-3
WARNING
running machinery.


Glooves, Steel Toed Boots and a High
Visibilty Vest.

crush points.

machinery.
3. Always use pins and/of mechanical

supports provided.
TR-4
6.2 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 the Safety Sign fitted at the towbar
end of the machine as seen here.
CAUTION
PRIOR TO TRANSPORT
(1) Check tyre pressures
(2) Check wheel nut torque
(3) Connect and check braking

system
(4) Recheck wheel torque every

150 miles(200km)
Refer to Operator manual for

correct tyre pressures and torque
values.
3. Before transportation on public roads, ensure the machine has been properly secured with
no loose material left in or on the machine. (See Section 6 – Transport).
4. Ensure wheel nuts are torqued between 500 to 550 ft.lb (69 to 76 kg.m) prior to transport.
5. The site drawbar is for site use only. It is not permitted for use on public roads.
6. Check your tyres for:

- correct pressure
- cuts or bulges
- nails or spikes
- uneven or excessive wear
- missing valve caps
7. Check your wheels for:

- damaged rims
- missing or loose wheel nuts or bolts
- obvious misalignment
TR-5
8. Have cuts or punctures repaired by authorised personnel before adding air.

Beware an over-inflated tyre can explode and cause serious injury or death.
9. Extreme caution is required when transporting machinery on site. Soft or uneven ground
may cause accidents.
10. When transporting a machine on a truck or trailer, know the overall height to avoid
contacting overhead obstructions such as bridges, power lines etc.
11. Machines fitted with braked axles must have the drain tap on their air tank released before
the machine can be moved on site.
TR-6
WARNING
6.3 STOPPING THE MACHINE
The sequence to stop the machine is 6.3.1 BEFORE MAINTENANCE

to 6.3.5. YOU MUST READ AND
Before stopping any parts off this machine UNDERSTAND
THE SAFETY SECTIONS IN
ensure all material has been processed THIS MANUAL
through the machine.
6.3.1 Stop the feeder, by operating the A

B
6.3.2 Stop the Screenbox, by operating the
control lever (Item A). C
6.3.3 Stop the Oversize and Middlegrade
conveyor by operating the control
lever (Item C). D
CAT Main Hydraulic Control Panel
6.3.4 Stop the Fines Conveyor by
operating the control lever (ItemD).
6.3.5 Gradually decrease the engine A

speed to minimum using the throttle
or engine speed switch on the control
panel. Do not stop the Engine. B
D DEUTZ Main Hydraulic Control Panel
ED
C
B
A
Tier 4 Main Hydraulic Control Panel
TR-7
6.4 PREPARING FOR TRANSPORT
Inspect the feeder, Hopper, Screen and

conveyor to ensure that the machine is
clear of all material.
WARNING
The machine should be washed to remove HAZARDOUS NIP AND
all debris. CRUSH POINTS IN THIS
AREA
It is advisable to have an operator on the
opposite side of the machine to ensure
areas around machine are clear of ENSURE ALL PERSONNEL ARE CLEAR
personnel as serious crush points exist. BEFORE PUTTING MACHINE INTO THE
TRANSPORT POSITION
CRUSH POINTS EXIST
TR-8
6.5 LOWERING THE HOPPER EXTENSION FLAPS
To meet height regulations the Hopper A

extensions are lowered during Transport.
To lower:
(i) Lower the extensions (Item A) and

place in the transport position
(Item B).
Hopper Extensions in working position
WARNING
B
HAZARDOUS NIP AND

AREA
Hopper Extensions in Transport position
TR-9
6.6 LOWERING SCREENBOX TO TRANSPORT POSITION
Prior to folding all the conveyors the

screenbox must be lowered to the
transport position.
To lower:
(i) Remove the Securing pin (Item A) on

A
both sides of the machine.
(ii) Lower the screenbox using control

lever (Item B) until the screenbox is in Screenbox Raised position
transport position (12° hole).
(iii) Secure in the transport position by

inserting the securing pin (Item C).
B
Screenbox height Control
WARNING
HAZARDOUS NIP AND
AREA C
Screenbox in Transport position
TR-10
6.7 LOCATING APRON FEEDER IN TRANSPORT POSITION
To allow the fines conveyor to fold into the

transport position the apron feeder must A
be moved forward for transport (Item A).
To place Apron Feeder in the transport

position: B
(i) Remove the pin (Item B) securing the
apron feeder in the working position.
(repeat on opposite side of the
machine).
Apron Feeder in the WorkingPosition
(ii) Operate the control bank (Item C) to
move the apron feeder to the
transport position.
(iii) Place securing pin (Item E) to hold in

the transport position (Item D). C
Apron Feeder Control Panel
WARNING
D
HAZARDOUS NIP AND
AREA
Apron Feeder in the Transport Position
TR-11
6.8 FOLDING THE FINES CONVEYOR
To put the conveyor into the transport

position.
(i) Remove the feedboot extensions

(Item A). A
(ii) (Optional Extendable conveyor).
Remove the securing pins from (Item
Feedboot Extensions
B) on both sides of the conveyor.
Operate the control lever (Item C) to
retract the conveyor and replace the
B
holding pin.
(iii) Operate the control lever (Item F) this

will fold the complete conveyor up
and inwards.
(iv) To fold the top and middle sections of

the conveyor operate the control lever
(Item E). This will fold the conveyor
across the machine. C
D
(v) Operate the control (Item D) to fold
the top Section (Item G) down into E
the transport position.
IMPORTANT F
USE THE CONTROL LEVERS IN A

SMOOTH AND CONTROLLED MANNER. Conveyor Control Bank
THIS WILL DAMAGE THE CONVEYOR.
G
WARNING
HAZARDOUS NIP AND
AREA
TR-12
6.9 FOLDING THE MIDDLE GRADE

CONVEYOR
To fold the conveyor into the transport

position:
(i) Remove the feedboot Extensions

(Item A). A
(ii) Operate the control lever (Item C) to

raise the feedboot (Item B). Feedboot Extensions
(iii) Secure in the transport position by

placing the pin (Item D) into position.
IMPORTANT
SMOOTH AND CONTROLLED MANNER. Conveyor Feedboot in lowered position
DO NOT RUSH OR JERK THE CONTROLS. C
WARNING
HAZARDOUS NIP AND
AREA
Control Panel
Middle Grade Feedboot Transport pin
TR-13

move the securing pins from (Item E)
E
on both sides of the conveyor. Oper-
ate the control lever (Item G) to retract
the conveyor and replace the holding
pin.
(v) Operate the control lever (Item J) this

will fold the complete conveyor up and
inwards.
(vi) To fold the top and middle sections of

the conveyor operate the control lever F
(Item I). This will fold the conveyor
across the machine.
(vii) Operate the control (Item H) to fold

the top Section (Item K) down into
the transport position.
Middle Grade In Working Position

G
H
I
Conveyor Control Bank
TR-14
6.10 FOLDING THE OVERSIZE CONVEYOR
A
To fold the Oversize conveyor to the
transport position:
(i) Remove the pins (Item A) securing

the Oversize Conveyor in the working
position.
Oversize Conveyor Securing Pin
(ii) Operate control lever (Item B) to fold B
the Oversize conveyor into the
transport position (Item D).
(iii) Secure at each side using pins (Item

C).
Oversize Conveyor Controls
IMPORTANT
SMOOTH AND CONTROLLED MANNER.
Oversize Securing Pins
WARNING
HAZARDOUS NIP AND
AREA D
Oversize Conveyor Transport Position
TR-15
6.11 REMOVING CATWALK ACCESS STEPS
A
To rerove the Access steps:
(i) Remove the bolts (Item A) holding

the steps (Item B) in position.
B
(ii) Repeat for the catwalk at the
opposite side of the machine.
(iii) Place the access steps (Item D) in

the apron Feeder where they are
stored for transport.
Access steps in Working Position
DANGER Access step Support

SWITCH OFF AND
LOCKOUT BEFORE
D
WARNING
DO NOT CLIMB INTO
WORKING OR
MOVING MACHINERY
FALL HAZARDS EXIST
Access steps
TR-16
6.12 PLACING SCREEN CATWALK IN

TRANSPORT POSITION
A
To put the Catwalk into the transport
position.
(i) Remove the handrail (Item A).
(ii) Lift the mesh sections (Item B) and

tie in the transport position.
Catwalk in Working Position
(iii) Remove the bolts (Item D) along the
side of each catwalk.
(iv) Raise the Catwalk extension (Item F) B

and secure in transport position
using bolts (Item G).
C
(v) Rotate the Catwalk frame (Item C) to
the transport position(Item H).
Replace the bolts (Item D) to secure D
in the transport position.
Catwalk holding Bolts
(vi) Repeat for the catwalk on the
opposite site of machine.
DANGER
G
SWITCH OFF AND

LOCKOUT BEFORE
WORKING AT A MACHINE Catwalk Extension
WARNING
DO NOT CLIMB INTO
WORKING OR H
MOVING MACHINERY
FALL HAZARDS EXIST
Catwalk in Transport Position
TR-17
6.13 RAISING SUPPORT LEGS
A
The Rear support legs (Item B) have to be
raised before the machine can be moved.
To Raise the Rear support legs use the

control lever (Item A) located at the main
hydraulic control panel.
DEUTZ Control Panel
Rear Jack Leg In working Position CAT 4.4 Tier 4 Control Panel
B Support Legs in Raised Position
WARNING
HAZARDOUS NIP AND
AREA
TR-18
6.14 READY FOR TRANSPORT
The machine should now be ready for

transport.
WARNING
NOTE: Before tracking the machine BEFORE TRANSPORTING
ensure the engine speed is idle. THIS MACHINE YOU MUST
READ AND UNDERSTAND
Using the Radio control handset or THE SAFETY SECTIONS IN
THIS MANUAL
Wander lead handset to load the machine
onto the trailer.
Secure machine with Chain shackles to

the Lowloader.
Use securing eyes (Item A) fitted on the

machine undercarriage on either side.
IMPORTANT
DO NOT TRANSPORT THIS MACHINE
WITHOUT IT BEING PROPERLY SECURED
ONTO THE LOW LOADER
Machine on Lowloader
Tracks Secured on Lowloader
TR-19
6.15 PRIOR TO HAULAGE
(i) Recheck for loose parts or debris on

the machine.
WARNING
(ii) Ensure all pins are secured with ‘R’ BEFORE TRANSPORTING
pins and Split pins. THIS MACHINE YOU MUST
READ AND UNDERSTAND
(iii) Raise the support legs fully. THE SAFETY SECTIONS IN
THIS MANUAL
(iv) Ensure wheel nuts are torqued

between 500 to 550 Ft.lb (69 to 76
kg.m) prior to transport.
(v) Ensure persons transporting the

machine adhere to all safety signs
and procedures.
TR-20
SECTION 7: FAULT FINDING ENG
Contents
7.1 NO RESPONSE FROM ANY HYDRAULIC SYSTEM ............................ FA-2
7.2 MACHINE OPERATING SLOWLY. NO EXTERNAL OIL LEAKS ............. FA-3
7.3 EXCESSIVE NOISE FROM HYDRAULIC PUMP ................................... FA-4
7.4 SCREEN NOT WOKING .......................................................................... FA-4
7.5 FEEDER NOT WORKING WHEN MAIN CONVEYOR RUNNING .......... FA-5
7.6 SCHREECHING NOISE WHEN CONVEYOR IS RUNNING ................... FA-5
7.7 CONVEYOR BELT NOT RUNNING ......................................................... FA-6
7.8 CONVEYOR BELT TENDS TO RUN BACK IF STOPPED
WITH A LOAD ON THE BELT .................................................................. FA-6
7.9 MESHES BREAKING PREMATURELY .................................................. FA-7
7.10 SCREEN BEARINGS FAIL PREMATURELY .......................................... FA-7
7.11 ENGINE FAILS TO START ...................................................................... FA-8
7.12 BELT STOPS UNDERLOAD.................................................................... FA-8
7.13 ENGINE STOPS....................................................................................... FA-9
7.14 CONVEYOR BELTS RUNNING OUT OF LINE ....................................... FA-9
The following guide is intended to describe basic procedures to remedy some problems
that may arise.
NOTE: Repair and maintenance work.

It is recommended that repair and maintenance work of an intricate nature such as the
electrical and hydraulic systems which contain safety components is referred to qualified
personnel in the field.
Never alter any equipment or parts of equipment without consulting with Terex® MPE.
DANGER WARNING
SWITCH OFF AND PRACTICE SAFE
LOCKOUT BEFORE MAINTENANCE READ AND
WORKING AT A MACHINE. UNDERSTAND THE
DANGEROUS NIP POINTS OPERATORS MANUAL
EXIST BEFORE DOING ANY WORK
FA-1
7.1 NO RESPONSE FROM ANY HYDRAULIC SYSTEM
POSSIBLE FAULT REMEDY
Low oil level Top up hydraulic system with correct fluid
Choked suction line filter Fit new element
Hydraulic pump shaft broken Replace relevant hydraulic pump
Coupling damaged or broken Replace coupling
Pressure relief valve stuck in open position Repair or replace valve cartridge
Restricted or broken suction line Check restriction on tank

Replace if broken
Override button not functioning Check wires, fuses
Loose Suction line Tighten Suction Line
Motor Not Turning /Ram not moving Check wires, fuses
FA-2
7.2 MACHINE OPERATING SLOWLY. NO EXTERNAL OIL LEAKS
Low oil level Top up hydraulic system with correct fluid
Drain tank and replace with correct fluid

Incorrect hydraulic fluid
Replace filter element
Choked suction line filter
Leaking relief valve Repair or replace relief valve
Worn control valve spool Replace control valve
Worn hydraulic pump Replace relevant hydraulic pump
Engine performance not to standard Consult engine manual fault finding section
Loose Suction line Tighten Suction Line
Hydraulic Oil Leaking Through Motor Check or replace motor
Engine Running slow Set Throttle Cable
Engine slowing down under normal load Change Air Filter and Fuel Filters
Detent loose on control valve Tighten Detent
Spool loose Tighten Spool
FA-3
7.3 EXCESSIVE NOISE FROM HYDRAULIC PUMP
Choked suction line filter Fit new element
Damaged hydraulic pump coupling Replace hydraulic pump coupling
Worn hydraulic pump Replace hydraulic pump
Low oil level pump cavitating Top up hydraulic tank
Loose connections in suction line Tighten all joints
Flexible suction hose worn Replace hose
7.4 SCREEN NOT WOKING
When machine is new grease may have Use Proper Grease

settled in the bearing
Screen bearing seized Replace bearing
Hydraulic motor coupling broken Replace bearing
Flow control valve incorrectly set Reset flow control valve
FA-4
7.5 FEEDER NOT WORKING WHEN MAIN CONVEYOR RUNNING
Drive chain loose or broken Adjust or repair as necessary
Faulty control valve Replace or adjust
Flow control valve incorrectly set Reset flow control valve
7.6 SCHREECHING NOISE WHEN CONVEYOR IS RUNNING
Lack of bearing lubrication Grease all bearings
Conveyor belt wedged or rubbing against Clear obstruction, adjust and track conveyor
fixed parts belt
Top end drum belt scraper too tight Ease pressure at scraper
Roller Seized Replace relevant roller
Rubbers over tight Readjust rubbers
Faulty flow control Replace flow control
Idler drum jammed Free idler drum
FA-5
7.7 CONVEYOR BELT NOT RUNNING
Belt drive coupling broken or loose Replace or tighten coupling
Bearing collapsed or seized Replace bearing
Debris obstructing end drum Remove obstruction
Skirting Rubber too tight Adjust skirting rubber
Material Build up around return rollers Clean build-up of material
Belt Stopped with too much load Clear material of belt and restart.
7.8 CONVEYOR BELT TENDS TO RUN BACK IF STOPPED WITH A LOAD

ON THE BELT
Non return valve worn Replace non return valve(Refer problem to

your Finlay Dealer)
Non- Return valve stuck in open position Test oil & change filters change oil if
due to soiled hydraulic fluid required. Clean/Replace Valve
FA-6
7.9 MESHES BREAKING PREMATURELY
Meshes not tightened up evenly Tighten meshes evenlyy
Meshes are not supported by the cushion Change Cushion Rubber. Retension the
rubbery meshes
Mesh is not made from a large enough Fit a heavier grade of mesh
grade of wire
Heavy material landing on one spot of the Move the impact spot or hang rubber over
mesh the mesh
Mesh Pegging Lower screen angle/add weight

segments(same both sides)(Consult Finlay
Dealer). Reverse screen rotation to through
forward. Clean meshes regularly
7.10 SCREEN BEARINGS FAIL PREMATURELY
Wrong Grease is being used Use Proper Grease
Too much grease is being used Use 4-6 gms of grease per bearing every
50Hrs.
The screen is low on one side Fit a heavier grade of mesh
Not enough grease Grease every 50 working Hrs
FA-7
7.11 ENGINE FAILS TO START
Start delay is faulty Replace start delay
Starter relay faulty Replace starter relay
Diesel Hose drawing air Repair diesel hose
Main fuse blown Check glow plugs or for a electrical short
Heater plugs are faulty Replace heater plugs
7.12 BELT STOPS UNDERLOAD
Skirting rubbers too tight Adjust Skirting Rubber
Plough Scraper too tight Adjust Plough Scraper
Material build up under the belt Clean away all obstructions around the belt
(switch off and lockout before clearing)
Idler drum is jammed Clear Obstruction(seesection 5)
Bearing has seized Replace Bearing
Drum coupling has failed Repair or replace coupling
Pressure relief valve set to low Set pressure relief valve
Motor check valve stuck open Clean motor check valve
FA-8
7.13 ENGINE STOPS
Engine Overheats Check fan belt. Check water level. Clean

engine (See Engine Manual)
Stop Button pressed Reset stop button
Intermittent Signal from switches Check each circuit independantly, an

intermitent fault will stop the engine without
showing up on the starter panel. Check
water level, for air in the water, for faulty -
temperature switch/oil pressure switch/fan
belt switch/stop buttons/electrical short.
7.14 CONVEYOR BELTS RUNNING OUT OF LINE
Belt Running off the Idler Drum Adjust Idler Drum (See 5.11)
Belt Running off the Drive Drum Adjust Drive Drum (see 5.11)
Belt wanders under load If the belt wanders to the right underload,
push the right handside of the centre rollers
forward or the left hand side back. (Switch
off machine and lockout before carrying out
any repairs.
FA-9
SECTION 9: APPENDIX ENG
RECEIVER PROGRAMMING
Each transmitter has a unique operating code and if a transmitter or receiver is replaced
the receiver has to be programmed to recognize the transmitter.
If a transmitter is taken from one system and used to operate another system by
reprogramming the second system the original system should be disabled by removing the
2 amp fuse on the receiver circuit board and labelling the receiver with instructions to
reprogram the receiver before putting it into service. Otherwise the situation could arise
that one transmitter will operate 2 different systems.
To program a receiver to recognize a transmitter proceed as follows:

Remove the cover from the receiver unit casing by unscrewing the 4 fixing screws.
Ensure that “LED1” is turned on. This led indicates that the receiver is supplied with
power.
Locate the “Prog I D” switch, the “Program ID” push button, the “Prog led” and the “Valid
Signal led”. (See Figure 1)
Set the “prog I D” switch to programming position by moving the switch lever to the left
position.
Press and release the “Program I D” push button. The “Prog led” will turn on.
If the transmitter is turned off press the “ON” button twice within 2 seconds to turn the
transmitter on. The transmitter led will flash to indicate that the transmitter is active. With the
transmitter turned on press any transmitter-operating button (Except the ON button). The
“Prog led” will turn off and the “Valid Signal led” will turn on while the transmitter button is
being pressed. Release the transmitter button.
FIGURE 1
AP - 1
SECTION 9: APPENDIX ENG
Set the “Prog I D” switch to the operating position by moving the switch lever to the right
position. The programming is now complete.
Replace the lid on the control unit casing and secure with the 4 screws.
NOTE: When programming do not hold the transmitter to close to the receiver. The
transmitter should be held at least 500mm away from the receiver.
FIGURE 1
AP - 2
SECTION 9: APPENDIX EN
7LHU Engine Fault Codes

If there is an engine fault the engine fault screen will be shown on the display (Figure D.1) when the
alarm button (item 2, Figure D.2) is pressed.
Figure D.1 - Engine Fault Screen
2 4
3
DUN00084
Figure D.2 - Control Panel Display
The engine fault screen displays the following information:

• The SPN number identifies the specific component which has a fault.
• The number of hours specifies the engine run hours when the fault occurred.
• The FMI number indicates the type of failure that is associated with the component.
• The OC number specifies how many times that particular fault has occurred.
Table D.1 gives a list of the fault codes and descriptions of the faults corresponding to the combination
of codes from the engine fault screen. Table D.1 can be used to determine what the active fault is.
AP - 3
Example:
Table D.1 gives a list of the engine fault codes aong with a description of the fault.
The J1939 code is made up of two numbers separated by a dash. The first number is the SPN number.
The second number is the FMI number.
The engine fault screen in Figure D.1 is shown on the display screen. The SPN number is 111 and
the FMI number is 1. The corresponding numbers in Table D.1 indicate that the engine coolant level
is low.
Extract from table:
J1939
Code Description Refer to Procedure
111-1 Engine Coolant Level : Low - most severe (3) Coolant Level is Low
The engine fault screen also shows that this fault has occurred twice and the last time it occurred
was when the engine run hours was 6 hours. The yellow warning symbol at the right hand side of
the screen indicates that the fault is currently active.
AP - 4
Table D.1 - Engine Fault Codes and Descriptions
J1939
27-3 Engine Exhaust Gas Recirculation Valve Position Valve Position Sensor - Test
Sensor : Voltage Above Normal
27-4 Engine Exhaust Gas Recirculation Valve Position Valve Position Sensor - Test
Sensor : Voltage Below Normal
29-2 Accelerator Pedal Position 2 : Erratic, Throttle Switch Circuit - Test
Intermittent, or Incorrect (Engines equipped with
a throttle switch)
29-2 Accelerator Pedal Position 2 : Erratic, Intermittent Analog Throttle Position
or Incorrect (Engines equipped with an analog Sensor Circuit - Test
throttle)
29-3 Accelerator Pedal Position 2 : Voltage Above Analog Throttle Position
Normal (Engines equipped with an analog Sensor Circuit - Test
throttle)
29-3 Accelerator Pedal Position 2 : Voltage Above Digital Throttle Position Sensor
Normal (Engines equipped with a digital throttle) Circuit - Test
29-4 Accelerator Pedal Position 2 : Voltage Below Analog Throttle Position
throttle)
29-4 Accelerator Pedal Position 2 : Voltage Below Digital Throttle Position Sensor
29-8 Accelerator Pedal Position 2 : Abnormal Digital Throttle Position Sensor
Frequency, Pulse Width or Period Circuit - Test
51-3 Engine Throttle Position : Voltage Above Normal Valve Position Sensor - Test
51-4 Engine Throttle Position : Voltage Below Normal Valve Position Sensor - Test
91-2 Accelerator Pedal Position 1 : Erratic, Throttle Switch Circuit - Test
Intermittent, or Incorrect (Engines equipped with
a throttle switch)
91-2 Accelerator Pedal Position 1 : Erratic, Intermittent Analog Throttle Position
or Incorrect (Engines equipped with an analog Sensor Circuit - Test
throttle)
91-3 Accelerator Pedal Position 1 : Voltage Above Analog Throttle Position
throttle)
91-3 Accelerator Pedal Position 1 : Voltage Above Digital Throttle Position Sensor
91-4 Accelerator Pedal Position 1 : Voltage Below Analog Throttle Position
throttle)
91-4 Accelerator Pedal Position 1 : Voltage Below Digital Throttle Position Sensor
91-8 Accelerator Pedal Position 1 : Abnormal Digital Throttle Position Sensor
Frequency, Pulse Width or Period Circuit - Test
97-3 Water In Fuel Indicator : Voltage Above Normal Water in Fuel Sensor - Test
97-15 Water In Fuel Indicator : High - least severe (1) Fuel Contains Water
AP - 5
J1939
97-16 Water In Fuel Indicator : High - moderate severity Fuel Contains Water
(2)
100-1 Engine Oil Pressure : Low - most severe (3) Oil Pressure Is Low
100-3 Engine Oil Pressure : Voltage Above Normal Engine Pressure Sensor Open
or Short Circuit - Test
100-4 Engine Oil Pressure : Voltage Below Normal Engine Pressure Sensor Open
100-17 Engine Oil Pressure : Low - least severe (1) Oil Pressure Is Low
100-21 Engine Oil Pressure : Data Drifted Low 5 Volt Sensor Supply Circuit -
Test
102-16 Engine Intake Manifold #1 Pressure : High - Intake Manifold Air Pressure Is
moderate severity (2) High
102-18 Engine Intake Manifold #1 Pressure : Low - Intake Manifold Air Pressure Is
moderate severity (2) Low
105-3 Engine Intake Manifold #1 Temperature : Voltage Engine Temperature Sensor
Above Normal Open or Short Circuit - Test
(Passive Sensors)
105-4 Engine Intake Manifold #1 Temperature : Voltage Engine Temperature Sensor
Below Normal Open or Short Circuit - Test
(Passive Sensors)
105-15 Engine Intake Manifold #1 Temperature : High - Intake Manifold Air
least severe (1) Temperature Is High
105-16 Engine Intake Manifold #1 Temperature : High - Intake Manifold Air
moderate severity (2) Temperature Is High
107-15 Engine Air Filter 1 Differential Pressure : High - Inlet Air Is Restricted
least severe (1)
108-3 Barometric Pressure : Voltage Above Normal Engine Pressure Sensor Open
108-4 Barometric Pressure : Voltage Below Normal Engine Pressure Sensor Open
108-13 Barometric Pressure : Calibration Required Sensor Calibration Required -
Test
108-21 Barometric Pressure : Data Drifted Low 5 Volt Sensor Supply Circuit -
Test
110-0 Engine Coolant Temperature : High - most Coolant Temperature Is High
severe (3)
110-3 Engine Coolant Temperature : Voltage Above Engine Temperature Sensor
Normal Open or Short Circuit - Test
(Passive Sensors)
110-4 Engine Coolant Temperature : Voltage Below Engine Temperature Sensor
(Passive Sensors)
110-15 Engine Coolant Temperature : High - least Coolant Temperature Is High
severe (1)
110-16 Engine Coolant Temperature : High - moderate Coolant Temperature Is High
severity (2)
AP - 6
J1939
111-1 Engine Coolant Level : Low - most severe (3) Coolant Level is Low
157-3 Engine Injector Metering Rail #1 Pressure : Engine Pressure Sensor Open
Voltage Above Normal or Short Circuit - Test
157-4 Engine Injector Metering Rail #1 Pressure : Engine Pressure Sensor Open
Voltage Below Normal or Short Circuit - Test
157-16 Engine Injector Metering Rail #1 Pressure : High Fuel Rail Pressure Problem
- moderate severity (2)
157-18 Engine Injector Metering Rail #1 Pressure : Low - Fuel Rail Pressure Problem
moderate severity (2)
158-2 Keyswitch Battery Potential : Erratic, Intermittent Ignition Keyswitch Circuit and
or Incorrect Battery Supply Circuit - Test
168-2 Battery Potential / Power Input 1 : Erratic, Ignition Keyswitch Circuit and
Intermittent or Incorrect Battery Supply Circuit - Test
168-3 Battery Potential / Power Input 1 : Voltage Above Ignition Keyswitch Circuit and
Normal Battery Supply Circuit - Test
168-4 Battery Potential / Power Input 1 : Voltage Below Ignition Keyswitch Circuit and
Normal Battery Supply Circuit - Test
172-3 Engine Air Inlet Temperature : Voltage Above Engine Temperature Sensor
(Passive Sensors)
172-4 Engine Air Inlet Temperature : Voltage Below Engine Temperature Sensor
(Passive Sensors)
174-3 Engine Fuel Temperature 1 : Voltage Above Engine Temperature Sensor
(Passive Sensors)
174-4 Engine Fuel Temperature 1 : Voltage Below Engine Temperature Sensor
(Passive Sensors)
174-15 Engine Fuel Temperature 1 : High - least severe Fuel Temperature Is High
(1)
174-16 Engine Fuel Temperature 1 : High - moderate Fuel Temperature Is High
severity (2)
190-8 Engine Speed : Abnormal Frequency, Pulse Engine Speed/Timing Sensor
Width or Period Circuit - Test
190-15 Engine Speed : High - least severe (1) Engine Overspeeds
411-3 Engine Exhaust Gas Recirculation Differential Engine Pressure Sensor Open
Pressure Sensor : Voltage Above Normal or Short Circuit - Test
411-4 Engine Exhaust Gas Recirculation Differential Engine Pressure Sensor Open
Pressure Sensor : Voltage Below Normal or Short Circuit - Test
411-13 Engine Exhaust Gas Recirculation Differential Sensor Calibration Required -
Pressure Sensor : Calibration Required Test
412-3 Engine Exhaust Gas Recirculation Temperature: Engine Temperature Sensor
Voltage Above Normal Open or Short Circuit - Test
(Passive Sensors)
AP - 7
J1939
412-4 Engine Exhaust Gas Recirculation Temperature: Engine Temperature Sensor
Voltage Below Normal Open or Short Circuit - Test
(Passive Sensors)
412-15 Engine Exhaust Gas Recirculation Temperature : NRS Exhaust Gas
High - least severe (1) Temperature Is High
412-16 Engine Exhaust Gas Recirculation Temperature : NRS Exhaust Gas
High - moderate severity (2) Temperature Is High
558-2 Accelerator Pedal 1 Low Idle Switch : Erratic, Idle Validation Switch Circuit -
Intermittent or Incorrect Test
626-5 Engine Start Enable Device 1 : Current Below Ether Starting Aid - Test
Normal
626-6 Engine Start Enable Device 1 : Current Above Ether Starting Aid - Test
Normal
630-2 Calibration Memory : Erratic, Intermittent or Flash Programming
Incorrect
631-2 Calibration Module : Erratic, Intermittent or ECM Memory - Test
Incorrect
637-11 Engine Timing Sensor : Other Failure Mode Engine Speed/Timing Sensor
Circuit - Test
651-2 Engine Injector Cylinder #01 : Data Incorrect Injector Data Incorrect- Test
651-5 Engine Injector Cylinder #01 : Current Below Injector Solenoid Circuit - Test
Normal
651-6 Engine Injector Cylinder #01 : Current Above Injector Solenoid Circuit - Test
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
AP - 8
J1939
Normal
Normal
676-6 Engine Glow Plug Relay : Current Above Normal Starting Aid (Glow Plug) Relay
Circuit - Test
678-3 ECU 8 Volts DC Supply : Voltage Above Normal Digital Throttle Position Sensor
Circuit - Test
678-4 ECU 8 Volts DC Supply : Voltage Below Normal Digital Throttle Position Sensor
Circuit - Test
723-8 Engine Speed Sensor #2 : Abnormal Frequency, Engine Speed/Timing Sensor
Pulse Width or Period Circuit - Test
1075-5 Engine Electric Lift Pump for Engine Fuel Supply Fuel Pump Relay Circuit - Test
: Current Below Normal
1075-6 Engine Electric Lift Pump for Engine Fuel Supply Fuel Pump Relay Circuit - Test
: Current Above Normal
1076-5 Engine Fuel Injection Pump Fuel Control Valve : Solenoid Valve - Test
Current Below Normal
1076-6 Engine Fuel Injection Pump Fuel Control Valve : Solenoid Valve - Test
Current Above Normal
1188-5 Engine Turbocharger 1 Wastegate Drive : Solenoid Valve - Test
1188-6 Engine Turbocharger 1 Wastegate Drive : Solenoid Valve - Test
1196-9 Anti-theft Component Status States : Abnormal Data Link Circuit - Test
Update Rate
1239-0 Engine Fuel Leakage 1: High - most severe (3) Fuel Rail Pressure Problem
2659-7 Engine Exhaust Gas Recirculation (EGR) Mass NRS Mass Flow Rate Problem
Flow Rate : Not Responding
2791-5 Engine Exhaust Gas Recirculation (EGR) Valve Motorized Valve - Test
Control : Current Below Normal
Control : Current Above Normal
Control : Not Responding Properly
2882-2 Engine Alternate Rating Select : Erratic, Mode Selection Circuit - Test
Intermittent, or Incorrect
2970-2 Accelerator Pedal 2 Low Idle Switch : Erratic, Idle Validation Switch Circuit -
Intermittent, or Incorrect Test
3241-3 Exhaust Gas Temperature 1 : Voltage Above Engine Temperature Sensor
(Active Sensors)
3241-4 Exhaust Gas Temperature 1 : Voltage Below Engine Temperature Sensor
(Active Sensors)
AP - 9
J1939
3242-3 Particulate Trap Intake Gas Temperature : Engine Temperature Sensor
Voltage Above Normal Open or Short Circuit - Test
(Active Sensors)
3242-4 Particulate Trap Intake Gas Temperature : Engine Temperature Sensor
Voltage Below Normal Open or Short Circuit - Test
(Active Sensors)
3242-15 Particulate Trap Intake Gas Temperature : High - Diesel Particulate Filter
least severe (1) Temperature Is High
3242-16 Particulate Trap Intake Gas Temperature : High - Diesel Particulate Filter
moderate severity (2) Temperature Is High
3242-18 Particulate Trap Intake Gas Temperature : Low - Diesel Particulate Filter
moderate severity (2) Temperature Is Low
3251-3 Particulate Trap Differential Pressure : Voltage Engine Pressure Sensor Open
Above Normal or Short Circuit - Test
3251-4 Particulate Trap Differential Pressure : Voltage Engine Pressure Sensor Open
Below Normal or Short Circuit - Test
3251-13 Particulate Trap Differential Pressure : Sensor Calibration Required -
Calibration Required Test
3358-3 Engine Exhaust Gas Recirculation Inlet Engine Pressure Sensor Open
Pressure: Voltage Above Normal or Short Circuit - Test
3358-4 Engine Exhaust Gas Recirculation Inlet Engine Pressure Sensor Open
Pressure: Voltage Below Normal or Short Circuit - Test
3358-13 Engine Exhaust Gas Recirculation Inlet Pressure Sensor Calibration Required -
: Calibration Required Test
3358-21 Engine Exhaust Gas Recirculation Inlet Pressure 5 Volt Sensor Supply Circuit -
: Data Drifted Low Test
3464-5 Engine Throttle Actuator 1 Control Command : Motorized Valve - Test
Not Responding Properly
3473-31 Aftertreatment #1 Failed to Ignite Diesel Particulate Filter
Collects Excessive Soot or
ARD Failed to Ignite
3474-14 Aftertreatment #1 Loss of Combustion : Special ARD Loss of Combustion
Instruction
3474-31 Aftertreatment #1 Loss of Combustion Diesel Particulate Filter
Collects Excessive Soot or
ARD Loss of Combustion
3479-5 Aftertreatment #1 Fuel Pressure Control : Solenoid Valve - Test
3479-6 Aftertreatment #1 Fuel Pressure Control : Solenoid Valve - Test
3480-3 Aftertreatment #1 Fuel Pressure #1 : Voltage Engine Pressure Sensor Open
Above Normal or Short Circuit - Test
AP - 10
J1939
3480-4 Aftertreatment #1 Fuel Pressure #1 : Voltage Engine Pressure Sensor Open
Below Normal or Short Circuit - Test
3480-15 Aftertreatment #1 Fuel Pressure #1 : High - least ARD Pilot Fuel Pressure Is
severe (1) High
3480-16 Aftertreatment #1 Fuel Pressure #1 : High - ARD Pilot Fuel Pressure Is
moderate severity (2) High
3480-17 Aftertreatment #1 Fuel Pressure #1 : Low - least ARD Pilot Fuel Pressure Is
severe (1) Low
3480-18 Aftertreatment #1 Fuel Pressure #1 : Low - ARD Pilot Fuel Pressure Is
moderate severity (2) Low
3483-11 Aftertreatment #1 Regeneration Status : Other Diesel Particulate Filter
Failure Mode Requires Initial Regeneration
3484-5 Aftertreatment #1 Ignition : Current Below ARD Ignition - Test
Normal
3484-6 Aftertreatment #1 Ignition : Current Above ARD Ignition - Test
Normal
3487-5 Aftertreatment #1 Air Pressure Control : Current Motorized Valve - Test
Below Normal
3487-6 Aftertreatment #1 Air Pressure Control : Current Motorized Valve - Test
Above Normal
3487-7 Aftertreatment #1 Air Pressure Control : Not Motorized Valve - Test
Responding Properly
3488-3 Aftertreatment #1 Air Pressure Actuator Position : Valve Position Sensor - Test
Voltage Above Normal
3488-4 Aftertreatment #1 Air Pressure Actuator Position : Valve Position Sensor - Test
Voltage Below Normal
3509-3 Sensor Supply Voltage 1 : Voltage Above Normal 5 Volt Sensor Supply Circuit -
Test
3509-4 Sensor Supply Voltage 1 : Voltage Below Normal 5 Volt Sensor Supply Circuit -
Test
3510-3 Sensor Supply Voltage 2 : Voltage Above Normal 5 Volt Sensor Supply Circuit -
Test
3510-4 Sensor Supply Voltage 2 : Voltage Below Normal 5 Volt Sensor Supply Circuit -
Test
3556-7 Aftertreatment Fuel Injector #1 : Not Responding ARD Nozzle - Test
Properly
3563-3 Engine Intake Manifold #1 Absolute Pressure : Engine Pressure Sensor Open
Voltage Above Normal or Short
3563-4 Engine Intake Manifold #1 Absolute Pressure : Engine Pressure Sensor Open
Voltage Below Normal or Short
3563-13 Engine Intake Manifold #1 Absolute Pressure : Sensor Calibration Required -
3563-21 Engine Intake Manifold #1 Absolute Pressure : 5 Volt Sensor Supply Circuit -
Data Drifted Low Test
3609-3 Diesel Particulate Filter Intake Pressure 1 : Engine Pressure Sensor Open
Voltage Above Normal or Short
AP - 11
J1939
3609-4 Diesel Particulate Filter Intake Pressure 1 : Engine Pressure Sensor Open
3609-13 Diesel Particulate Filter Intake Pressure 1 : Sensor Calibration Required -
3609-15 Diesel Particulate Filter Intake Pressure 1 : High Diesel Particulate Filter Has
Least Severe High Inlet Pressure
3609-17 Diesel Particulate Filter Intake Pressure 1 : Low Diesel Particulate Filter Has
Moderate Severity Low Inlet Pressure
3609-21 Diesel Particulate Filter Intake Pressure 1 : Data 5 Volt Sensor Supply Circuit -
Drifted Low Test
3703-31 Particulate Trap Active Regeneration Inhibited Diesel Particulate Filter
Due to Inhibit Switch Collects Excessive Soot or
ARD Is Disabled
Due to Low Exhaust Gas Temperature Collects Excessive Soot or
ARD Temperature Is Low
Due to Temporary System Lockout Collects Excessive Soot
Due to Permanent System Lockout Collects Excessive Soot
3719-0 Particulate Trap #1 Soot Load Percent : High - Diesel Particulate Filter
most severe (3) Collects Excessive Soot
3719-16 Particulate Trap #1 Soot Load Percent : High - Diesel Particulate Filter
moderate severity (2) Collects Excessive Soot
3720-15 Particulate Trap #1 Ash Load Percent : High - Diesel Particulate Filter Has
least severe (1) High Ash Load
3720-16 Particulate Trap #1 Ash Load Percent : High - Diesel Particulate Filter Has
moderate severity (2) High Ash Load
3750-31 Diesel Particulate Filter 1 Conditions Not Met for Diesel Particulate Filter
Active Regeneration Collects Excessive Soot or
ARD Is Disabled
3837-3 Aftertreatment 1 Secondary Air Pressure : Engine Pressure Sensor Open
Voltage Above Normal or Short Circuit - Test
3837-4 Aftertreatment 1 Secondary Air Pressure : Engine Pressure Sensor Open
3837-13 Aftertreatment 1 Secondary Air Pressure : Sensor Calibration Required -
3837-17 Aftertreatment 1 Secondary Air Pressure : Low - ARD Combustion Supply Air
least severe Pressure Is Low
3837-21 Aftertreatment 1 Secondary Air Pressure : Data 5 Volt Sensor Supply Circuit -
Drifted Low Test
4265-5 Aftertreatment #1 Transformer Secondary Output ARD Ignition - Test
4265-6 Aftertreatment #1 Transformer Secondary Output ARD Ignition - Test
AP - 12
J1939
4301-5 Aftertreatment #1 Fuel Injector #1 Heater Control ARD Nozzle Heater - Test
4301-6 Aftertreatment #1 Fuel Injector #1 Heater Control ARD Nozzle Heater - Test
4783-2 DPF #1 Mean Soot Signal : Erratic, Intermittent, Soot Sensor - Test
or Incorrect
4783-3 DPF #1 Mean Soot Signal : Voltage Above Soot Sensor - Test
Normal
4783-4 DPF #1 Mean Soot Signal : Voltage Below Soot Sensor - Test
Normal
4783-9 DPF #1 Mean Soot Signal : Abnormal Update Soot Sensor - Test
Rate
4783-12 DPF #1 Mean Soot Signal : Failure Soot Sensor - Test
4783-13 DPF #1 Mean Soot Signal : Out of Calibration Soot Sensor - Test
4783-21 DPF #1 Mean Soot Signal : Data Drifted Low Soot Sensor - Test
5423-5 Aftertreatment Regeneration Device Fuel Pump ARD Fuel Supply - Test
Relay : Current Below Normal
5423-6 Aftertreatment Regeneration Device Fuel Pump ARD Fuel Supply - Test
Relay : Current Above Normal
5571-0 High Pressure Common Rail Fuel Pressure Fuel Rail Pressure Problem
Relief Valve : High - most severe (3)
5576-2 Aftertreatment #1 Identification Number Module : Diesel Particulate Filter
Erratic, Intermittent, or Incorrect Identification Signal - Test
Abnormal Frequency, Pulse Width, or Period Identification Signal - Test
Special Instruction Identification Signal - Test
AP - 13
Intentionally Left Blank
AP - 14
Tier 3 Electrical Schematics

Work on the electrical system or equipment may only be carried out by a skilled and qualified electrician or
by specially instructed personnel under the control and supervision of such an electrician and in accordance
with applicable electrical engineering rules and regulations.
AP - 15
AP - 16
M
Tier 4 Electrical Schematics

Work on the electrical system or equipment may only be carried out by a skilled and qualified electrician or
by specially instructed personnel under the control and supervision of such an electrician and in accordance
with applicable electrical engineering rules and regulations.
AP - 17
AP - 18
F
B
E
A
For this document and the object represented in that we reserve all rights according to DIN 34.
Duplication announcement onto third party or utilization of his contents are without forbidden to our.
1
1
-X1
Battery Cable 70mm-B 1/2 Battery Cable 70mm-R
2/2
-X1
JUMP START
CONNECTOR
2
2
-X2
1/1
30A
-LF1
-X5 -X3
1/1 AUTO 6mm-R 1/1 AUTO 6mm-R -X115:1 #126
1/1
/11.A5
1
-X4
3
3
only in
the E3!
drawing
Changing
80A
-LF2
-X8 -X6
1 1/1 Battery Cable 16mm-R 1/1 Battery Cable 16mm-R #148
0
2
3
/2.A1
2
1
Revision
1/1 1/1
-X9 -X10 -X7
12V
1/1
ECO
1/1
-X11
50A
-LF3
-X17 -X15
30
87
1/1 AUTO 6mm-N 1/1 AUTO 6mm-N AUTO 6mm-N

1/1 1/1 1/1
1
1/1 1/1
2
ENGINE
-X16 -X12
4
-X18 -X14 -X13
Revision text
4
PREHEAT
-K1
PRODUCTION
Battery Cable 70mm-B
-X20
1/1 Battery Cable 70mm-R
-X19
1/1
300A
FUSE ADDED OIL COOLER

14
-K1
-1 -X22 -X21
AUTO 0.75mm-W 1/1 1/1 AUTO 1mm-N
13
85
86
-X25 -X23
1/1 1/1
Date
Battery Cable 70mm-B
M
23.1.12
30.1.12
1/1 -X148
-X24
5
5
1/1
-X27
1/1 Battery Cable 35mm-B
1/1
1/1
1/1
CD
CD
Name
#PREHEAT_RELAY
#ECU_ACTUATOR_RTN
1/1
-X30
-X29
-X28
-X26
/11.B8
/11.B8
Battery Cable 25mm-R
User
Proved
Date
AUTO 3mm-B
AUTO 3mm-B
AUTO 3mm-G
6
6
-X149
#138 1/1
Name
#-VE_ECU
#-VE_SPLICE
#-VE
/2.F6
/2.F1
/11.A4
7
7
Type
M.-Nr.: CAT C4.4 T4
8
8
POWER UNIT
60552235
Description: Electrical Kit
Drawing number
9
9
No.
Location
Sheet 1
Assignment
16 Sh.
F
B
E
A
F
B
E
A
/1.F6
/1.B3
#-VE
#148
1
1
-S1
10A
-X32 -X31
-F1
-3 -2
-S7
-S6
2/5 1/4 AUTO 1mm-R 2/5 1/4 AUTO 1mm-R AUTO 1mm-R
1
1
2
1
1/5 1/5
39
2/4 2/4
30
-W4 2BU
-W4 BN
-W3 2BU
-W3 BN
-3 -X32 -2 -X31
ON 15 START
44
AUTO 1mm-R
2
2
38
50
247
ESTOP
ESTOP
-5 -4
CHASSIS
CHASSIS
1/4 1/4
46
AUTO 1mm-R
37
2/4 2/4
-5 -4
AUTO 1mm-R
AUTO 1mm-R
AUTO 1mm-R
3
3
36
#START_REQ
only in
the E3!
drawing
Changing
ESTOP
ESTOP
1
0
2
3
-7 -6
CHASSIS
CHASSIS
Revision
1/4 1/4
/6.D6
AUTO 1mm-R
35
2/4 2/4
ECO
-7 -6 Battery Cable 16mm-R
AUTO 1mm-R
4
Revision text
4
#IGN_ON
34
PRODUCTION
/3.A1
-K2
/2.F5
-X38 -X37
30
1/1 1/1
85
86
-K2
/2.E4
Date
87 /2.C5
23.1.12
30.1.12
30A
-F2
5
87
30
5
AUTO,AUTO 6mm-R,6mm-R AUTO 6mm-R

/3.A1
2
1
#MP_FEED-F7:1
33
1/1 1/1
CD
CD
Name
-X40 -X39
49,161
-K2
/2.F5
User
Proved
Date
30A
-F3
-X43
6
30
87
6
/1.F6
STARTER SOLENOID 1/1 AUTO 3mm-RW AUTO 3mm-RW
2
1
1/1 1/1
48
167
CONNECTION
Name
-X42 -X41
32,264
-K4
/7.F2
AUTO 3mm-B
#-VE_SPLICE
15A
-F5
-X48
Splice-2.5
-X49
30
87
1/2
AUTO 3mm-RW
HYD OIL
2
1
28
2/2 COOLER 1/1 1/1
AUTO 2mm-P
-X48 -X47 -X46
7
FAN No.1
-K6
7
AUTO,AUTO 3mm-B,1mm-B /7.F4
Type
AUTO 3mm-P
15A
-F6
-X151
HYD OIL 1/2
2
1
2/2 COOLER
261
263
AUTO 2mm-P
-X151 FAN No.2
-X55:2
M.-Nr.: CAT C4.4 T4

#-VE_SPLICE
8
8
/3.E1
POWER UNIT
5A
-F4
30
87
IGNITION ON /11.B8 AUTO 0.75mm-Y
2
1
60552235
#IGN_ON_TO_ECU
29
31
TO ECU 1/11/1
-X45 -X44
-K5
/7.F3
Drawing number
#-VE
9
9
No.
/4.A1
Location
Assignment
Sheet 2
16 Sh.
F
B
E
A
1 2 3 4 5 6 7 8 9
#MP_FEED-X40:1 #MP_FEED
/2.D5 /4.A1
AUTO 6mm-R
#IGN_ON #IGN_ON
/2.C4 /4.A1
AUTO 1mm-R
A A
1 1
-F7 -F8
15A 10A
2 2
51
62
B B
AUTO 2mm-P
1
-S4
AUTO 3mm-P
2
-X50
1/1
-X53
1/1
/8.B1 30
TRACKS /3.D4
SUPPLY -K3 86
87 -K3
/3.D4
1/1
85
-X51
C 50 C
AUTO 1mm-GW
1/1
-X54
52 53
#ELP
AUTO 2mm-P
/11.B8
AUTO 0.75mm-NK
-X55
1/2
-K3
/3.C4 1
-X52
30
1/2
87 /3.C3
ECU CONTROLLED -H1
FUEL LIFT PUMP
D 2 D
2/2
SUPPLY
-X55
FUEL PUMP
2/2
-X52
E E
#-VE_SPLICE 167 #-VE_SPLICE
/2.F8 /7.E5
POWER UNIT
LIGHT
F F
3 Date Name Type Description: Electrical Kit Assignment

Changing
2 M.-Nr.: CAT C4.4 T4 POWER UNIT Location
drawing
1 FUSE ADDED OIL COOLER 30.1.12 CD User
only in Drawing number Sheet 3
0 PRODUCTION 23.1.12 CD
the E3! Proved 60552235 No. 16 Sh.
Revision ECO Revision text Date Name
1 2 3 4 5 6 7 8 9
F
B
E
A
/3.A9
/2.F9
/3.A9
#-VE
1
1
#IGN_ON
#MP_FEED
AUTO 1mm-S
CAN_L
4
AUTO 1mm-Y
CAN_H
3
AUTO 1mm-B
GND
2
AUTO 1mm-R
2
2
8...32 V DC
1
N.C
-P1
CR0451
3
3
only in
the E3!
drawing
Changing
-A1
1
0
2
3
Revision
CR0403
ifm
ECO
A CR0403
1 VBBs N 1/1
IN0 1 -X56 AUTO 1mm-R
/5.E2 2 ESTOP HEALTHY VBBs
IN1
1/1 -X57 AUTO 1mm-B
/8.A1 3 TRACK REQUEST GND 2
4
Revision text
4
1/1 -X58 AUTO,AUTO 0.75mm-GY,0.75mm-GY
PRODUCTION
4 GND CAN2_H 3
1/1 -X59
5 GND CAN2_L 4
IN2
/5.E5 6 LOW SPEED

IN3
/5.E6 7 INTER SPEED
8 VBBs
-R3
B
1 VBBs
1W
IN4
120 Ω
/5.E8 2 HIGH SPEED

#CAN2_L
#CAN2_H
Date
/5.E9 IN5
3
23.1.12
30.1.12
CONV1 ST REQ
4 GND
5
5
5 GND
CD
CD
IN6
/11.A8
/11.A8
/6.E2 6
Name
/6.E3 IN7
7
8 VBBs P/N1 1/1 -X60 AUTO 1mm-R
VBBs 1
1/1 -X61 AUTO 3mm-R
C VBB1 2
1/1 -X62 AUTO 3mm-R
1 VBBs VBB2 3
1/1
User
IN8 -X63 AUTO 1mm-B
GND 4
Proved
/6.E5 2 AIR FILTER RESTRICT
IN9 1/1 -X64 AUTO,AUTO 1mm-Y,1mm-Y
/6.E6 3 ENG START REQ CAN1_H 5
Date
1/1 -X65 AUTO,AUTO 1mm-S,1mm-S
4 GND CAN1_L 6
5 GND
6
6
IN10
/8.A8 6 MACHINE STOP
IN11
/6.E9 7 HOL
Name
8 VBBs
D
49
46
55
58
167
OUT0
/7.A1 1 ENG CRANK
2 GND
OUT1 -8
/7.A2 3 FUEL SYSTEM
1/5 AUTO 1mm-R
4 GND
OUT2
2/5 AUTO,AUTO 3mm-R,1mm-R
/7.A3 5 HYD OIL FANS 3/5 AUTO 1mm-B
6 GND
4/5 AUTO,AUTO 1mm-Y,1mm-Y
7
OUT3
7
/7.A5 7 SIREN/BEACON
SOCKET
5/5 AUTO,AUTO 1mm-S,1mm-S

8 GND
EXPANSION NODE
#MP_FEED
#-VE
#IGN_ON
Type
E OUT4
/8.A2 1 TRACKS ENABLE
2 GND
/5.A1
/5.A1
/5.D1
OUT5
/9.A1 3 SPARE
4 GND
/9.A2 5 OUT6
SPARE
M.-Nr.: CAT C4.4 T4

6 GND
OUT7
/9.A3 7 SPARE
8
8
8 GND
-R1
F
1W
OUT8
5/5
4/5
-X66
-X66
120 Ω
/9.A5 1 SPARE
POWER UNIT
2 GND
OUT9
/9.A6 3 SPARE
4 GND
60552235
/9.A7 5 OUT10
CONV 1 RUN
6 GND SOCKET
Drawing number
OUT11
/9.A8 7 SPARE
8 GND
PROGRAMMING
9
9
No.
Location
Assignment
Sheet 4
16 Sh.
F
B
E
A
1 2 3 4 5 6 7 8 9
#IGN_ON #IGN_ON
/4.A7 /6.A1
#-VE #-VE
/4.A7 /6.A1
AUTO 3mm-B
A A
AUTO,AUTO 1mm-R,1mm-R
B -B1 -X72 B
IFS208 1 1/5 AUTO 1mm-R #IGN_ON
/6.B1
2 -X72
1 1 1 3 3/5 AUTO,AUTO 1mm-B,1mm-B
#-VE
/6.B1
-S5 -X72
4 4/5
2 2 2 CONVEYOR START
DELAY SENSOR
C
-X74
23/31 AUTO 1mm-BW
C
23/31
-X73
66
67
246
#MP_FEED 46
/4.A7
70
D D
AUTO 1mm-R
-X67
-X68
-X69
-X70
-X75
1/1
1/1
1/1
1/1
1/1
2 6 7 2 3
IN0 IN2 IN3 IN4 IN5
E /4.E4 /4.E4 /4.E4 /4.E5 /4.E5
E
ESTOP HEALTHY LOW SPEED INTER SPEED HIGH SPEED CONV1 ST REQ
-A1 -A1 -A1 -A1 -A1
Input Input Input Input Input
F F

Changing
drawing
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
#IGN_ON #IGN_ON
/5.A9 /8.B7
A A
#-VE #-VE
/5.A9 /7.F1
AUTO 1mm-GR
13/31 13/31
-X73 -X74
AUTO 1mm-B
14/31 14/31
-X73 -X74
#IGN_ON
/5.B9
AUTO 1mm-R
B B
#-VE
/5.B9
-X76
1/2
HYD OIL LEVEL
-X77
SENSOR
#IGN_ON 1/2
188
C 3/4 3 C
AFR SWITCH
(BY OTHERS) 2/4 2
1/4 1
-X82 -B2
320428
#28
/2.C3
AUTO 1mm-NW
2/2
-X77
2/2
#START_REQ
-X76
D 192 247 D
25/31
-X74
25/31
AUTO 1mm-R
-X73
AUTO 1mm-BR
AUTO 1mm-NW
-X78
-X79
-X81
1/1
1/1
1/1
E E
6 7 2 3 7
IN6 IN7 IN8 IN9 IN11
/4.E5 /4.E5 AIR FILTER RESTRICT /4.E6 ENG START REQ /4.E6 HOL /4.E6
-A1 -A1 -A1 -A1 -A1
Input Input Input Input Input
F F

Changing
drawing
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
A A
Output Output Output Output
-A1 -A1 -A1 -A1
ENG CRANK FUEL SYSTEM HYD OIL FANS SIREN/BEACON
/4.E6 /4.E7 /4.E7 /4.E7
OUT0 OUT1 OUT2 OUT3
1 3 5 7
1/1
1/1
1/1
1/1
-X92
-X83
-X86
-X89
B B
76,77
73
74
75
-X93
-X95
1/2
1/2
C C
-X84
-X87
-X90
1/1
1/1
1/1
1/2
-X96
86 86 86
-K4 -K5 -K6
/7.F2 /7.F3 /7.F4
-W2 BN
85 85 85
MACHINE
BEACON
1/1
1/1
1/1
1
-X91
-X85
-X88
-H3
2
D D
-W2 BU
2/2
-X96
2/2
2/2
-X93
-X95
#-VE_SPLICE
E /3.E9 E
AUTO 1mm-B
AUTO 1mm-B
AUTO,AUTO 1mm-B,1mm-B
AUTO,AUTO 1mm-B,1mm-B
#-VE
/6.A9
-K4 -K5 -K6
/7.C1 /7.C3 /7.C4
30 87 /2.C6 30 87 /2.C9 30 87 /2.C7
F F

Changing
drawing
1 2 3 4 5 6 7 8 9
F
B
E
A
/3.C2
#-VE
1
1
/4.E4
-A1
#+VE_TRACKS
TRACKS ON SW
-X74 -X98 -X73 -X97
2/31 AUTO 1mm-B 10/16 AUTO 0.75mm-RU 10/31 AUTO 0.75mm-RU 1/1
IN1
Input
10/31
3
2/31 2/16
-X73 -X98 -X74
TRACK REQUEST
2
2
62
-X98 -X73
4/16 AUTO 1mm-P 4/31
4/31
/4.E7
-A1
-X74
LTF
-K7
/8.F3
24
12
14
-X74
22
-X98 -X73 -X99

5/31 AUTO 0.75mm-UO 3/16 AUTO 0.75mm-RW 3/31 AUTO 0.75mm-RW 1/1
OUT4
-K7
/8.F3
1
5/31 5/16 3/31

A2
A1
Output
21
-X73 -X98 -X74

TRACKS ENABLE
3
3
0.75mm-UO AUTO
11/10.C3
only in
the E3!
drawing
Changing
AUTO 3mm-R
1
0
2
3
Revision
#+VE_TRACKS
ECO
LTR
-K8
/8.F4
24
14
22
12
-X74
8/31 AUTO 0.75mm-UY
/10.A1
-K8
/8.F4
8/31 8/16
A2
A1
21
4
-X73 -X98
Revision text
4
PRODUCTION
0.75mm-UY AUTO
11/10.C4

RTF
-K9
/8.F5
Date
24
14
22
12
-X74
23.1.12
30.1.12
6/31 AUTO 0.75mm-NS
-K9
/8.F5
5
5
6/31 6/16
A2
A1
21
-X73 -X98
CD
CD
0.75mm-NS AUTO
Name
11 /10.C5
TRACKING UMBILICAL
User
Proved
Date
RTR
-K10
/8.F6
22
24
12
14
-X74
6
6
9/31 AUTO 0.75mm-NY
/8.F6
-K10
9/31 9/16
A2
A1
Name
21
-X73 -X98
0.75mm-NY AUTO
11 /10.C7
/6.A9
#IGN_ON
FAST AUTO,AUTO 1mm-R,1mm-R
/8.F7
-K11
7
24
12
14
-X74
7
22
1/31 AUTO 0.75mm-GY
/8.F7
-K11
1/31 1/16
A2
A1
11
21
-X73 -X98
Type
0.75mm-GY AUTO
-X74 RADIO TRACK -X98 -X73
15/31 AUTO 0.75mm-BP STOP LINK 16/16 AUTO 0.75mm-GY 16/31
15/31 15/16 16/31
-X73 -X98 -X74
/4.E6
-A1
AUTO 1mm-B
M.-Nr.: CAT C4.4 T4

MACHINE REMOTE
8
STOP
8
-X74 -X98 -X73 -X100

7/31 AUTO 0.75mm-BY 12/16 AUTO 0.75mm-WR 12/31 AUTO 0.75mm-WR 1/1
IN10
12/31
6
Input
7/31 7/16
MACHINE STOP
-X73 -X98 -X74
POWER UNIT
60552235
#-VE
-X114:1 #IGN_ON
Drawing number
/9.F1
9
9
/11.D3
No.
Location
Assignment
Sheet 8
16 Sh.
F
B
E
A
1 2 3 4 5 6 7 8 9
Output Output Output Output Output Output Output

A -A1 -A1 -A1 -A1 -A1 -A1 -A1 A
SPARE SPARE SPARE SPARE SPARE CONV 1 RUN SPARE
/4.E8 /4.E8 /4.E8 /4.E8 /4.E8 /4.E9 /4.E9
OUT5 OUT6 OUT7 OUT8 OUT9 OUT10 OUT11
3 5 7 1 3 5 7
1/1
-X101
B B
82
AUTO 1mm-R
-X73
30/31
C C
30/31
-X74
AUTO 1mm-GN
-X102
1/4
D D
2/4
-X102
AUTO 1mm-B
31/31
-X74
E E
31/31
-X73
#-VE #-VE
/8.F9 /10.F1
F F

Changing
drawing
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
#+VE_TRACKS 62 -X73:26
#+VE_TRACKS
/8.B3 /11.A1
A A
AUTO 1mm-P
AUTO 1mm-P
AUTO 1mm-P
AUTO 1mm-P
B B
12 14 12 14 12 14 12 14
-K7 -K8 -K9 -K10

/8.F3 /8.F4 /8.F5 /8.F6
C 11 11 11 11 C
-X73
-X73
-X73
-X73
20/31 AUTO 1mm-GO
17/31 AUTO 1mm-RY

18/31 AUTO 1mm-BO
19/31 AUTO 1mm-GK
20/31
17/31
18/31
19/31
-X74
-X74
-X74
-X74
D D
AUTO 1mm-RY
AUTO 1mm-BO
AUTO 1mm-GK
AUTO 1mm-GO
-X103
-X105
-X106
-X107
1/4
1/4
1/4
1/4
LEFT TRACK LEFT TRACK RIGHT TRACK RIGHT TRACK
FORWARD SOL. REVERSE SOL. FORWARD SOL. REVERSE SOL.
2/4
2/4
2/4
2/4
E E
-X103
-X105
-X106
-X107
-X104 #-VE
21/31 21/31 Splice-2.5
-X73 -X74
#-VE #-VE
/9.F9 /11.E1
F F

Changing
drawing
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
ENGINE
ECU
#+VE_TRACKS
/10.A1
/10.A9
-X117
/1.F6
/1.B3
50/70
A #CAN2_H /4.B5 A
48/70
AUTO 0.75mm-GY
-X117
#126
-X117
34/70
#-VE_ECU
#CAN2_L /4.B5
52/70
AUTO 0.75mm-U
-X117
-X73
26/31
-X117
21/70
#ELP /3.C5
53/70
AUTO 1mm-R
AUTO 0.75mm-NK
-X117
26/31
-X117
-X74
70/70
#IGN_ON_TO_ECU /2.D9
-X115 55/70
AUTO 1mm-R
AUTO 0.75mm-W
Splice-2.5 -X117
B -X117 B
-X116 20/70
#PREHEAT_RELAY
/1.A5
Splice-2.5 57/70
AUTO 1mm-N
-X117
-X117
59/70
#ECU_ACTUATOR_RTN /1.C5
AUTO 0.75mm-W
61/70 -X117
-X117 5/70 -X119
-X108
1/4
Splice-2.5 B/3
AUTO 1mm-RS
-X122
-X117
AUTO 1mm-B
63/70 4/70
-X117 A/3
AUTO 1mm-BO
SENSOR
C -X122 C
-X117
RADIO CONTROLLED TIPPING GRID -X112 49/70
COOLANT LEVEL
RECIEVER (TELERADIO) Splice-2.5 65/70 C/3

AUTO 1mm-WO
-X117 -X122
-X117
35/70
1/3
AUTO 1mm-GU
-X123
67/70 -X120 #94
AUTO 1mm-B
2/4
-X117 Splice-2.5 2/3
FUEL
-X123
CONTAM.
-X108
AUTO 1mm-B
-X113 3/3
D D
AUTO 1mm-WO
Splice-2.5 69/70 -X123

-X117
-X117
17/70
27/31
-X74
#IGN_ON /8.B7 37/70 1/2
AUTO 1mm-G
/8.B9 -X117 -X124

-X117
3/70
AIR INLET
-X121
27/31
-X73
TEMP SENSOR
38/70 Splice-2.5 2/2

AUTO 1mm-O
-X117 -X124
-X117
2/70 -X118
AUTO 1mm-WY
Splice-2.5 1/4
AUTO 1mm-GP
-X125
-X117
AUTO 1mm-NO
E 26/70
E
#-VE 2/4
/10.F9
DPF AIR
-X125
-X117
AUTO 1mm-B
TEMP SENSOR
14/70
3/4
AUTO 1mm-P
-X125
-X111
-X111
-X114
-X114
-X114
4/6
-X114
2/2
2/6
5/6
1/2
1/6
1/6
1/2
2/2
DPF SOOT SENSOR -X126
-X150
-X150
F CAN C 3/6 F
DPF ID
AUTO 1mm-K
MODULE
TERMINATION -X126
CONNECTOR
1W
120 Ω
6/6
AUTO 1mm-RS
-X126
-R2

Changing
drawing
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
2400MM
A A
-U64 Part No. 60552225/6 -X2#2
-X1#2 -X1#1 1 70.00 mm² Red -X1:1
1/2 1/1
1 70.00 mm² Red -X2:1 -X2#1
2/2
2 70.00 mm² Black -X9:1 -U65 -X9#2
1 70.00 mm² Black -X1:2
1/1
-X9#1
ENGINE JUMP START CONNECTION
TO BATTERY
-X10#1
-X11#1
1/1
1/1
2100MM
B B
480MM
-X19#2 -X19#1 -U59 Part No. 60552223 -X18#2

1/1
1 70.00 mm² Black -X18:1 1 70.00 mm² Black -X19:1
1/1
-X18#1
-VE BATTERY TO MAIN ISOLATOR
C C
1400MM
-X20#2 -X20#1 -U60 Part No. 60552221 -X23#2

1/1
1 70.00 mm² Red -X23:1 1 70.00 mm² Red -X20:1
1/1
-X23#1
+VE BATTERY TO STARTER +VE STUD
D D
1400MM
-X24#2 -X24#1 -U61 Part No. 60552224 -X25#2

1/1
1/1
-X25#1
MAIN ISOLATOR TO STARTER -VE STUD
E E
300MM
-X26#2 -X26#1 -U62 Part No. 60552222 -X27#2

1/1
1/1
-X27#1
STARTER -VE STUD TO CHASSIS GROUND
600MM
F -X148#2 -X148#1 -U63 Part No. 60552227 -X149#2 F

1/1
1 25.00 mm² Red -X149:1 1 25.00 mm² Red -X148:1
1/1
-X149#1
STARTER +VE STUD TO ALTERNATOR CHARGE TERMINAL

Changing
drawing
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9 10 11 12
-X108#2
1 1.00 mm² Green-Red -X74:26
2 1.00 mm²,1.00 mm² Black, Black /11.E1, -X74:27
3
4
1 2
-X108#1
REMOTE TIPPING GRID *4/4
A RECIEVER CONNECTION
A
FRONT
-X74#2 VIEW
1 0.75 mm² Green-Yellow -X98:1
2 1.00 mm² Black -X98:2
3 4
3 0.75 mm² Red-White -X98:3
4 1.00 mm² Purple -X98:4
5 0.75 mm² Blue-Orange -X98:5
6 0.75 mm² Brown-Grey -X98:6
7 0.75 mm² Black-Yellow -X98:7
8 0.75 mm² Blue-Yellow -X98:8
9 0.75 mm² Brown-Yellow -X98:9
10 0.75 mm² Red-Blue -X98:10
11
12 0.75 mm² White-Red -X98:12
13 1.00 mm²,1.00 mm² Green-Red,Red -X82:1, /6.B1
14 1.00 mm²,1.00 mm² Black, Black -X82:2, -X72:3
15 0.75 mm² Black-Purple -X98:15
17 1.00 mm² Red-Yellow -X103:1
18 1.00 mm² Black-Orange -X105:1
19 1.00 mm² Green-Pink -X106:1
20 1.00 mm² Green-Orange -X107:1
21 1.00 mm² Black -X104:1
200mm
22
B 1.00 mm² Black- White -X72:4
B
23
24
25 1.00 mm² Brown-White -X82:3
26 1.00 mm² Green-Red -X108:1
27 1.00 mm² Black -X108:2 Part No. 60552326 -X103#2
28 1 1.00 mm² Red-Yellow -X74:17
29 LTF SOLENOID 1.00 mm²,1.00 mm²,1.002 mm²,1.00 mm²,1.00 mm² Black,Bl ack,Bla ck,B lack,Bl ack-X104:1,-X105:2
30 1.00 mm² Green-Brown -X102:1 3
31 1.00 mm² Black -X102:2 PE
*4/4
-X103#1
1050mm 600mm 50mm 2600MM 200mm
-X105#2
1 1.00 mm² Black-Orange -X74:18
LTR SOLENOID 1.00 mm²,1.002 mm²,1.00 mm²,1.00 mm² Black,Bl ack, Black,Bl ack -X106:2, -X103:2, -X104:1
-U1 -U3
-U7 3
PE
*4/4
-X105#1
-X106#2
1 1.00 mm² Green-Pink -X74:19
RTF SOLENOID 2 1.00 mm²,1.00 mm² Black, Black -X105:2,-X107:2
-X74#1 -U 4 3
*31/31
*4/4
PE
C -X106#1 C
-X107#2
1 1.00 mm² Green-Orange -X74:20
RTR SOLENOID 1.002 mm²,1.00 mm²,1.00 mm² Black,Bla ck,B lack -X106:2, /10.E8, :(X1)
3
PE
*4/4
-X107#1
450mm
400mm
D D
-U2
TRACKING -X98#1
UMBILICAL CONNECTION *16/16
-X98#2
2 1.00 mm² Black -X74:2
3 0.75 mm² Red-White -X74:3
4 1.00 mm² Purple -X74:4
300mm
5 0.75 mm² Blue-Orange -X74:5
6 0.75 mm² Brown-Grey -X74:6
7 0.75 mm² Black-Yellow -X74:7
100mm
1000mm
8 0.75 mm² Blue-Yellow -X74:8

E E
9 0.75 mm² Brown-Yellow -X74:9
10 0.75 mm² Red-Blue -X74:10
11
12 0.75 mm² White-Red -X74:12
13
14
15 0.75 mm² Black-Purple -X74:15
CONVEYOR DELAY 16 0.75 mm² Green-Yellow -X74:16
SENSOR
*5/5
-B1#1
-X72#1
-X72#2
1 1.00 mm² Red /5.B9
2
3 1.00 mm²,1.00 mm² Black, Black -X74:14, /5.B9 FEED CONVEY OR
4 1.00 mm² Black- White -X74:23
SOLENOID
5
*4/4
-X102#1
-X102#2
1 1.00 mm² Green-Brown -X74:30
F 2 1.00 mm² Black -X74:31 F
3
PE
G G
HYD. OIL LEVEL

SENSOR
*4/4
-X82#1
-X82#2
1 1.00 mm² Green-Red -X74:13
2 1.00 mm² Black -X74:14
3 1.00 mm² Brown-White -X74:25
H 4 H

Changing
2 POWER Location
drawing M.-Nr.: CAT C4.4 T4UNIT
the E3! Proved No. 16 Sh.
1 2 3 4 5 6 1 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
100mm 50MM 250MM 1000mm 300mm
-U8 -U11 -U 54 -U15 -U22 -U33 -U35 -U37
A A
-U10
-U9
300mm
600mm
100MM
100mm
-X117#2
1
2 1.00 mm²,1.00 mm² Green-Pink,G reen-Pink -X125:1, -X118:1
450mm
B 1.00 mm² Orange -X121:1
B
3
4 1.00 mm² Black-Orange -X122:A
5 1.00 mm² Red-Grey -X119:1
6
7
8
9
-U12
-U55
-U38
400mm
10
11
-U16
-U 34
12 W2S -X93#1
*2/2
13
14 1.00 mm² Pink -X126:3 BEACON
15 CONNECTION
16
17 1.00 mm² Green -X124:1
18 -X93#2 60505024
-U56
19 1 1.00 mm² Red -X92:1
*2/2
POWER UNIT 20 1.00 mm² Brown -X21:1 2 1.00 mm²,1.00 mm² Black, Black -X151:2, -X95:2
LIGHT 200mm 100mm 100mm 21 0.75 mm² Brown-Pink -X54:1 STARTER
-X55#1
22 SOLENOID
-X55#2 23
1/1
-U 24 -U27
1 1.00 mm² Green-White -S4:2 -U23 -U26 -U31 24
-X43#1
2 1.00 mm² Black -X49:1 25
-X117#1 26 1.00 mm² Purple -X125:3
*70/70
-U17
27 -X43#2
28 1 3.00 mm² Red-White -X42:1
C C
29
30
-U40
31
ENGINE ECU 32
CONNECTOR 33
34 0.75 mm² Blue -X59:1
800MM
35 1.00 mm² Green-Blue -X123:1
36
37 1.00 mm²,1.00 mm² White-Yellow,White-Yellow -X111:1,-X114:5
38 1.00 mm²,1.00 mm² Brown-Orange,Brown-Orange-X111:2,-X114:4
39 HYD OIL COOLER -X48#1
*2/2
800MM
40 FA N N o. 1 400mm
41
42
43 -X48#2
44 1 2.00 mm²,3.00 mm² Purple,Purple -F5:2, -X151:1 -U36
45 3.00 mm²,3.002 mm²,3.00 mm²,3.00 mm² Black,Bl ack, Black,Bl ack -X49:1, /2.F8
-U 57
46
-U41
47
400mm
48 1.00 mm² Red -X117:52 -X151#1
*2/2
-U18
700mm
49 1.00 mm²,1.00 mm² White-Orange,White-Orange-X122:C, -X123:3
50 0.75 mm² Green-Yellow -X58:1 HYD OIL COOLER
-U58
51 FAN No.2
AIR INLET 52 1.00 mm²,1.00 mm² Red,Red -X117:48,-X115:1 -X151#2
*2/2
TEMP SENSOR 53 1.00 mm² Red -X117:55 1 3.00 mm²,2.00 mm² Purple,Purple -X48:1, -F6:2
54 2 3.00 mm²,1.00 mm² Black, Black -X49:1, -X93:2
-X124#1
D D
-X124#2 55 1.00 mm²,1.00 mm² Red,Red -X117:53,-X117:57
1 1.00 mm² Green -X117:17 56
2 1.00 mm² Orange -X121:1 57 1.00 mm²,1.00 mm² Red,Red -X117:55,-X116:1 W2S -X95#1
58 *2/2 2 1
59 0.75 mm² White -X22:1 -LF1 -LF1#1
AIR FILTER 60 SIREN 1 2
*2/2
RESTRICTION 61 1.00 mm² Black -X117:63
CONNECTION
150mm
62
-X76#1
-U25
-U28
-X76#2 63 1.00 mm²,1.00 mm² Black, Black -X117:61,-X117:65 -X95#2 60505024
1 1.00 mm² Red /6.A1 64 1 1.00 mm² Red -X92:1
2 1.00 mm² Black-Red -X78:1 65 1.00 mm²,1.00 mm² Black, Black -X117:63,-X112:1 2 1.00 mm² Black -X93:2 2 1
66 -LF2#1 -LF2#1
-X123#1 W2S -X52#1 67 1.00 mm² Black -X117:69 1 2
1700mm
*3/3 *2/2 68
1.0069mm²,1.00 mm²,1.00 mm² Black,Bla ck,B lack -X117:67, -X112:1, -X113:1
FU E L 70 0.75 mm² White -X45:1 2 1
CONTAMINATION -LF3 -LF3#1
-U42
SENSOR 1 2
Fuel Pump Supply
-U29
-X123#2 -X52#2 60505024
1 1.00 mm² Green-Blue -X117:35 1 2.00 mm² Purple -X51:1
2 1.00 mm² Red-Grey -X119:1 2 1.00 mm² Black /3.E1
3 1.00 mm² White-Orange -X117:49
E E
-U43
100mm
500mm
DP F A I R
TEMP. SENSOR
-X125#2
-X125#1 1 1.00 mm²,1.00 mm² Green-Pink,G reen-Pink -X117:2, -X118:1
-U 32
*4/4 2 1.00 mm² Orange -X121:1
3 1.00 mm² Purple -X117:26
400mm
100mm
-U30
DPF ID
-U19
F -X126#2 MODULE F
-X126#1 1 1.00 mm² Green-Pink -X118:1
*6/6 2
3 1.00 mm² Pink -X117:14
-U 44
4
ENGINE 5
PREHEAT 6 1.00 mm² Red-Grey -X120:1
1/1
TERMINAL
-X12#1
-U 39
-X12#2
-U20
1 6.00 mm² Brown -X13:1
1/1
1/1
1/1
-X28#1
-X29#1
-X30#1
1/1
1/1
1/1
-X8#1
-X5#1
-X17#1
150mm
G G
/1.F6
-X112:1
-X49:1
300MM
-X4:1
-X7:1
-X16:1
3.00 mm² Green

3.00 mm² Black
3.00 mm² Black
-U 14
6.00 mm² Red
6.00 mm² Brown
16.00 mm² Red
-X28#2
1
-X29#2
1
-X30#2
1
-X122#1
*3/3 COOLANT LEVEL
-X5#2
1
-X8#2
1
-X17#2
1
-U21
SENSOR
-X122#2
A 1.00 mm² Black-Orange -X117:4 -X114#1
B 1.00 mm²,1.00 mm² Red-Grey,Red-Grey -X119:1 *6/6
C 1.00 mm² White-Orange -X117:49
-X111#1
*2/2
DPF SOOT
H SENSOR CAN C H
-X114#2 TERMINATION RESISTOR
1 1.00 mm² Red /8.B7 -X111#2
2 1.00 mm² Black -X73:27 1 1.00 mm² White-Yellow -X117:37
3 2 1.00 mm² Brown-Orange -X117:38
4 1.00 mm² Brown-Orange -X117:38
5 1.00 mm² White-Yellow -X117:37
6
W2 P
-X150#1
*2/2
-X150#2
1 -R2.X2:1
2 -R2.X1:1 Changing
2 POWER Location
drawing M.-Nr.: CAT C4.4 T4UNIT
DT04-2P 0 PRODUCTION 23.1.12 CD
the E3! Proved No. 16 Sh.
1 2 3 4 5 6 1 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9
A A
500MM
Part No. 60552028 2

1
-X96#1
-X96#2
1 1.00 mm² Brown -H3:1 -W2
2 1.00 mm² Blue -H3:2 -W2
-H3#1
B B
-S7#1
-U48
5500MM
C E11506 C
Part No. 60552247

ESTOP POWER UNIT *5/5
OFF SIDE -X32#1
-X32#2
1 1.00 mm² Brown -S7:1 -W4
2 1.00 mm² Blue -S7:2 -W4
3
4
5
D D
-S6#1
-U51
2000MM
E11506
E E
Part No. 60552265
ESTOP POWER UNIT *5/5
NEAR SIDE -X31#1
-X31#2
1 1.00 mm² Brown -S6:1 -W3
2 1.00 mm² Blue -S6:2 -W3
3
4
F 5
F

Changing
drawing
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
A A
B B
DURITE
12 volt 120 amp
-P1
-K1
30 85 86 87
1 2
DURITE
5
-A1
12 volt 120 amp -P1 4 3
-K2
30 85 86 87
LED
30
86 85
3 4 3 4 3 4 3 4 3 4
85
OK
30
RELAY
-K4
0- 727- 16
40A 12V
-X144
6 6 6 6 6
86
DURITE
5 5 5 5 5
87 87a
87
7 8 7 8 7 8 7 8 7 8 -X127-X133 -X132 -X131 -X130 -X137 -X134
30
86 85
14 12
21 24
14 12
21 24
14 12
21 24
14 12
21 24
14 12
21 24
85
1
1 1
1 1
1 1
1 1 1 1
1 N2
1 1
22
22
22
22
22
RELAY
A1
A1
A1
A1
A1
-K6
0- 727- 16
30
40A 12V
-X145
86
DURITE
VBBs 1
-F1 -F2 -F3 2 -F4 -F5 -F7 -F8
G ND 2
-K7 -K8 -K9 -K10 -K11 2 2 2 2 2 2
87
CAN2_H 3
87 87a
11
A2
11
A2
11
A2
11
A2
11
A2
4
CAN2_L
30
-X142 -X141 -X140 -X139 -X138
86 85
85
A B C D E F P/N1 O I LOW IN T HI GH -S1
1 1
RELAY
1
-K5
0- 727- 16
A VBBs 1 1 C VBBs
30
40A 12V
1 B VBBs
1 2 1 2 1 2 1 2 1 2 1
VBBs
-X146
86
DURITE
2 2
2
2 D G ND 2 E G ND FG ND
2
2
3 3 VBB1
3 3 3 1
3
VBB2 3
1 1 1
87
4 4
87 87a
A G ND B G ND C G ND 4 D G ND 4 E G ND 4 FG ND
4
G ND 4
5 5 -S1
A G ND 5 B G ND 5 C G ND 5 30 15 50
5 -S4
CAN1_H 5
6 6 -S5 -S5
6
6 D G ND 6 E G ND FG ND
6
CAN1_L 6 -S5 -S5 -S4
7 7 NC
7 7 7
7 NO NO NO
C
RELAY
-K3
25A 12V
0- 727- 13
8 D G ND
8
A VBBs
8 B VBBs 8 C VBBs 8 E G ND 8 FG ND
C
DURITE
2
-X147
2 2 2
87 86 85 30
85 86 30 87a 87
-2 -7
1 2 1 2
4 3 4 3
X73
-8
-3 -6
3
4 2 1 2 1 2
5 1 4 3 4 3
D -4 -5
D
1 2 1 2
U9
4 3 4 3
E E
F F

Changing
drawing
1 2 3 4 5 6 7 8 9
SECTION 10: WARRANTY ENG
SECTION 10 : WARRANTY
10. WARRANTY
All conditions and warranties expressed or implied by any statute common law, trade usage or
otherwise are hereby excluded. No liability is accepted by Terex® MPE for any loss, damage
or injury to property or persons arising directly or indirectly from any failure or defect in the
machinery supplied. The materials employed by Terex® MPE in the manufacture of their
machinery, to the best of their knowledge, are the highest available quality of their respective
kinds. Terex® MPE undertake to replace or repair free of cost any part supplied to them direct
to the customer of which they shall receive notice and which shall be proved to the satisfaction
of Terex® MPE within a period of six months of delivery to be defective in workmanship or
materials provided:
A:- The written note of complaint is given within seven days of the discovery of the defect
B:- That the part is returned carriage paid to Terex® MPE and shall, in the event of replacement
become their property.
C:- That Terex® MPE shall not be liable for the cost of removal of the defective part or the cost
of fitting a new part.
D:- That the defect has not been caused by carelessness or improper or inadequate lubrication.
E:- That the guarantee period shall be proportionally reduced if the machinery is run for more
than one eight hour shift per day.
No unauthorised alternation or modification has been made to the plant or machine or component
the subject of the claim.
The new part will be delivered by Terex® MPE, carriage paid to the customers nearest station
in the UK or F.A.S. port of exportation.
In case of parts or components not manufactured by Terex® MPE the customer will be entitled
to the benefits in so far as it may be transmitted to the customer, of any guarantees given by the
manufacturer in respect thereof and Terex® MPE liability in respect of such goods is limited to
making the benefits of the manufacturers guarantees available to the customer to the extent
aforesaid.
This understanding is in lieu of and excludes any other conditions guarantees, or warranties
expressed or implied, statuary or otherwise. In no event shall Terex® MPE be liable (except to
the extent if any of its undertaking as foresaid) for any loss injury or damage howsoever caused
or arising.
The guarantee contained aforesaid hereof is personal to Terex® MPE customer and may not be
assigned.
WA - 1
www.terex.com
Terex, Drumquin Road, Omagh, Co. Tyrone, BT78 5PN, Northern Ireland,
Tel: +44 (0) 2882 418700, Fax: +44 (0) 2882 418700, E-mail: sales@terex.com
Printed in the UK

883mkii Operation English +090312-09

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Operations Manual (ENG)

OPERATION MANUAL MUST BE WITH THE MACHINE AT ALL TIMES

1. Comply with EC,OSHA, Federal, State, and Local Regulations.

3. Use Good, Safe Work Practices in a common sense way.

4. Only have trained operators — directed by informed and knowledgeable

1.1 SAFETY INTRODUCTION ..................................................................... SA - 2

1.2 SAFETY SIGNS ON YOUR MACHINE ................................................. SA-19

1.3 WORK AREA SAFETY .......................................................................... SA-24

1.4 HYDRAULIC SAFETY .......................................................................... SA-25

1.5 ELECTRICAL AND ENGINE SAFETY .................................................. SA-26

1.6 SAFETY BEFORE AND DURING OPERATION ................................... SA-27

1.7 SAFETY BEFORE AND DURING MAINTENANCE ............................. SA-28

1.8 SAFETY BEFORE AND DURING TRANSPORT ................................. SA-30

1.9 INFORMATION SIGNS ......................................................................... SA-31

1.10 REMOTE STOPS ON YOUR MACHINE .............................................. SA-37

1.11 SAFETY GUARDS ON YOUR MACHINE ............................................ SA-38

1.12 NOISE LEVELS AROUND YOUR MACHINE ....................................... SA-39

2.1 FAMILIARISATION ................................................................................. TE - 2

2.2 KEY COMPONENTS ............................................................................. TE - 3

2.3 OPTIONS ............................................................................................... TE - 6

2.4 TECHNICAL DATA................................................................................. TE - 7

2.5 TRANSPORT DIMENSIONS ................................................................. TE - 9

2.6 WORKING POSITION DIMENSIONS .................................................. TE-10

2.5 TRANSPORT DIMENSIONS (LONG CONVEYOR) .............................. TE-11

2.6 WORKING POSITION DIMENSIONS (LONG CONVEYOR) ................ TE-12

2.7 CORRECT USE OF MACHINE ............................................................ TE-13

3.1 SAFETY INTRODUCTION ...................................................................... IN - 2

3.2 STARTING ENGINE (STANDARD CAT ENGINE) .................................. IN - 8

3.3 STARTING ENGINE (OPTIONAL DEUTZ ENGINE) ...............................IN-12

3.4 STARTING ENGINE (TIER 4 MCU300 ENGINE) ...................................IN-15

3.5 MACHINE SETTINGS .............................................................................IN-22

3.6 TRACKING THE MACHINE ....................................................................IN-23

3.7 TRACKING OPTIONS .............................................................................IN-25

3.8 LOWERING SUPPORT LEGS ................................................................IN-31

3.9 LEVELLING .............................................................................................IN-34

3.10 FITTING SCREEN CATWALK ................................................................IN-35

3.11 FITTING CATWALK ACCESS STEPS ....................................................IN-37

3.12 UNFOLDING THE OVERSIZE CONVEYOR ..........................................IN-38

3.13 UNFOLDING THE MIDDLE GRADE CONVEYOR .................................IN-39

3.14 UNFOLDING THE FINES CONVEYOR ..................................................IN-41

3.15 LOCATING APRON FEEDER IN WORKING POSITION ........................IN-42

3.16 RAISING SCREENBOX TO WORKING POSITION ................................IN-43

3.17 SCREENBOX SPILLAGE RUBBER .......................................................IN-44

3.18 RAISING THE HOPPER EXTENSION FLAPS .......................................IN-45

4.1 SAFETY INTRODUCTION .................................................................... OP - 2

4.2 SAFETY BEFORE AND DURING OPERATION ................................... OP - 8

4.3 OPERATING MACHINE (STANDARD CAT ENGINE) .......................... OP - 9

OPERATING MACHINE (OPTONAL DEUTZ ENGINE) ....................... OP-10

OPERATING MACHINE (TIER 4 CAT ENGINE) ................................... OP-11

4.4 SCREENING ......................................................................................... OP-12

4.5 APRONFEEDER SPEED CONTROL ................................................... OP-13

4.6 CONVEYORS SPEED CONTROLS ..................................................... OP-13

4.7 FEEDER START/SOP & ENGINE STOP (OPTION) ............................. OP-14

4.8 REMOTE FEEDER START/STOP (OPTION) ....................................... OP-17

5.2 SAFETY BEFORE AND DURING MAINTENANCE ............................. MA - 9

5.3 HYDRAULIC SAFETY .......................................................................... MA-11

5.4 ELECTRICAL AND ENGINE SAFETY ..................................................MA-12

5.5 HYDRAULIC SYSTEM .........................................................................MA-14

5.6 HYDRAULIC FLUIDS ...........................................................................MA-15

5.7 FILTRATION ..........................................................................................MA-16

5.8 OILTANK, PIPES & FITTINGS...............................................................MA-18

5.9 DIESEL ENGINE ...................................................................................MA-19

5.10 SCREEN ...............................................................................................MA-20